OMAC PackML Implementation Guide

Transcription

OMAC (P&G)PackML
Implementation Guide
• Procter & Gamble
• Rob Aleksa
Copyright © 2010 OMAC. All rights reserved.
P&G Business
•
•
•
•
Sales: $80B ’09, Net Earnings:
g ~$13.5B ’09
~54+% Sales Outside US
300+ of Worlds Best Known Brands
23 - $1B Brands
Agenda
•
•
•
•
•
Challenge
Standards for Better Software Design
Industry PackML Perspective
PackML & S88 Concepts
p
OMAC Implementation Guide
–
–
–
–
–
–
Recommendations
St
Steps
for
f Success
S
Equipment Decomposition & PackML
Event Management
HMI Template
Key Features
• Expectations
• Summary
3
PackML: Changing The World
4
4
Typical Packaging System
Enterprise Systems
Including MES
M2M
MES
Code
Code
Filler
Programming
PC
M2M
MES
Code
Code
Capper
Line
Interface
M2M
MES
Code
Code
Labeler
MES
M2M
Code
Code
Casepacker
PackML: ((ISA TR088.05)
Un-Holding
Un-Hold
SC
Held
SC
Idle
• Standard Operational Structure
Start
Starting
SC
Hold
Execute
SC
SC
Resetting
Un-Suspending
Un-Suspend
Holding
SC
Completing
SC
Complete
SC
Aborting
Suspend
Suspended
SC
Suspending
Clear
Aborted
Reset
Reset
Stop
Business Units Desire
• Well Executed PackML Code
Stopped
SC
• Structured
St t d M
Modular
d l S
Software
ft
Stopping
Abort
Clearing
State Model
• Standard Equipment Decomposition
S88: Make2Pack
Industry PackML Perspective
` Understanding PackML
◦ Standards
St d d document
d
t 100+
100 pages
◦ More options than most OEMs need
◦ Lots of Tags
` Past
P t PackML
P kML implementation
i l
t ti solutions
l ti
◦ OEM Implements PackML themselves (sometimes not robust or too complex)
◦ Control vendor templates (sometimes not robust or too complex)
◦ Issues
I
x Confusing, complex code
x Complexity impacts scan time
x Hung
H
states
t t
◦ Conclusion
x Inconsistent implementations defeats purpose of PackML
x PackML getting a bad rap!
7
OMAC (P&G) PackML Design Strategy
• Start simple…add functionality as needs arise
• Intuitive (code and communications)
– No dead code
– No work-arounds to make something functional
• Only use needed PackTags for MES interface
• Robust
– AOI’s thoroughly tested
– Overall template easily modified without breaking
• Follow standards (S88, only PackML worldwide)
8
Why is P&G Sharing Our Design?
•
•
•
•
•
Expand
p
PackML usage
g w/end-Users & OEMs
Drive industry consistency
Make it easier for OEM’s to implement
Reduce OEM interface effort by end-users
Reduce everyone’s software management effort
9
PackML Concepts
• Modes & States
– 17 available States
– Transition, Action, Defined State paths
• PackTags
– Command Tags
– Machine interface parameters
p
– Status Tags
– Machine state/mode & line control information
– Administration Tags
– Higher level information system information
10
S88: Make2Pack Definitions
• Enterprise:
p
Company
p y that owns facility
y
• Site: Location of single facility
• Production Line: Collection of machines linked together to
produce a product
• Machine / Unit: Collection of related modules carrying out one
or more p
processing
g activities
• Equipment Module: Function group of modules carrying out a
finite number of activities
• Control Module: Lowest
L
t llevell off control
t l where
h
a single
i l ffunction
ti
is executed
11
OMAC PackML Guide
• Free ((Request
q
donation))
• What’s available for download
– PackML Implementation Guide
– Intended
I t d d to
t be
b control
t l hardware
h d
agnostic
ti
– Software
–
–
–
–
PackML AOI (add-on instruction, encapsulated code)
Event AOI (alarm manager)
PackML HMI screen templates
Help files
• Expect other control suppliers to post
• When to use
12
Approach Recommendation
• PackTags
g Only
y Approach
pp
–
–
–
–
Existing Software
Why? Minimize impact on existing software
Force fitting PackML State Model can cause issues
Map PackTags into existing machine software
• Full PackML & Modularity Compliant
–
–
–
–
New or existing
Why? Gains all benefits
Use PackML Mode & State Manager
Use S88: Make2Pack modular structure method
13
PackTags Only Approach
Advantages
Disadvantages
Common interface to the machine Does not follow the PackML state
for line integration
and mode model
Does not require as detailed
knowledge of the original code
Loose common look and feel
across machines since PackML
mode and state model are not
controlling the machine
PackML status tags may report the
wrongg information (if not all
programming conditions were accounted
for)
Inconsistent machine
programming
p
g
g mayy p
potentiallyy
increase MTTR
Ability to easily reapply code
across machines may be lost
14
Fully PackML & Modularly Compliant
Advantages
Disadvantages
Common interface to the
machine for line integration
Requires
q
detailed workingg
knowledge of the machine and
existing code
More programming time for
migrating existing machines than
the PackTags only approach
Follows the PackML state and
mode model
Consistent look and feel to the
programmers and operators
Consistent and easier integration
with MES systems
15
Steps for Success
1. Decompose machine using S88: Make2Pack physical
hierarchy
2. Define PackML modes & states
3. Define Unit Machine, Equipment Module, & Control
Module action during each mode & state
4. Define PackTags needed for line integration and MES
functionality
5. Define alarms (conditions that issue stop and abort commands)
6. Program
g
the machine
16
Equipment Decomposition
Machine:
Form-Fill-Sealer
Equipment Module: Weigh
Scale
Control
Module:
Infeed Gate
Control
Module:
Scale
Control
Module:
Dump Gate
Equipment Module: Bag
Forming
Control
Module: Axis
Left
Control
Module: Axis
Right
h
Equipment Module:
Sealer/Cutter
Control
Module:
Heater
Equipment Module: Feed
Rollers
Control
Module: Axis
Sealer
Control
Module:
Servo 1
Control
Module:
Servo 2
17
Defining Actions per State
Real Example
Mode Transition
Un-Holding
Idle
Starting
Stopped
Execute
UnSuspending
Resetting
Stopping
Holding
Held
Completing
Suspending
Suspended
Clearing
Complete
Aborted
Aborting
Producing
Idle
Starting
UnSuspending
Resetting
Stopped
Execute
Stopping
Suspending
Suspended
Clearing
Aborted
Aborting
Semi-Auto
Idle
Starting
Execute
Resetting
Stopped
Stopping
Clearing
Aborted
Aborting
Setup
19
PackML AOI Instruction
20
Data Flow
21
Data Flow Detail
22
Event AOIs
• CM Event AOI
– Captures CM alarm events and categorizes
• Event Manager AOI
– Creates one list of events for EM
• Event Summation AOI
– Summarizes data from EM
• Event Sort Filter
– Sort by category, time, category group
23
Event AOIs
24
Programming
25
Event Data Flow
26
PackML HMI Template
27
Key Features
• Defined 6 step
p development
p
p
process
• Easy to troubleshoot
–
–
–
–
Control Module code driven directly by State Model
Minimize unused code
1 rung shows all states a servo is enabled
Servo axes defined in 1 Control Module
– All info of axis in 1 routine
– Recipe, setpoint calculations, alarms warnings, motion cmds, etc
– Cross-referencing
g simplified
p
• Saves energy
– Only enable servos in needed states
• Modular, reusable code
28
Summary
• What’s important
p
– Implement PackML State Model & S88: Make2Pack modular
structure (2nd option in guide)
– Code doesn
doesn’tt have to be identical
• OMAC Implementation
p
Guide
– Good starting point if no other option
– Easy to deploy
– Easy to troubleshoot
29
Expectations
• OMAC
– “MES Definitions Team” defines base set of PackTags
• Control Vendors
– Adopt OMAC’s
OMAC s PackML design strategy
• OEMs
– Adopt OMAC’s PackML implementation method
– Include in their machine design by default
– Advertise this an advantage to end-users!!!
• End-Users
– Ask for it
– Include PackML in specifications
30
Have you had enough?
32
32
Questions
33

OMAC PackML Implementation Guide

Transcription

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