verticale

Il nuovo ruolo dell’automazione nell’Industria 4.0

(in lingua inglese)

GEA –“engineering for a better world”
Application
Preventive Maintenance
Standard CMMS vsGEMS

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mcT Alimentare - Verona ottobre 2017 Industria alimentare verso il 4.0: tecnologie avanzate, prestazioni e sicurezza per l’efficienza produttiva

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da Benedetta Rampini
mcT Alimentare - Verona 2017Segui aziendaSegui




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Veronafiere 19 ottobre 2017 Gli atti dei convegni e pi di 8.000 contenuti su www.verticale.net GEA Service ' I4.0: The new role of Automation GIORGIO CAVATORTA - VERONA, OCTOBER 19TH 2017 GEA is one of the largest suppliers of process
technology for the food industry and a wide range of
other industries. The international technology group focuses on process
technology and components for sophisticated
production processes in various end-user markets. The company is listed on the German MDAX stock
index and included in the STOXX Europe 600 Index.
In addition, the company is listed in selected MSCI
Global Sustainability Indices. GEA ' 'engineering for a better world' Order intake (EUR) 4,674 million Employees (FTEs) 16,937 Operating EBITDA (EUR) 566 million Operating EBITDA margin 12.6% Revenue (EUR) 4,491 million Earnings per share (EUR) 1.48 2 GEA Service ' I4.0: The new role of Automation Our ambition ' be your no. 1 choice We strive to be the
world's leading global
technology group in
supplying smart solutions
for sophisticated process
industries. Our goal is to
be the customer's
preferred partner in the
industries we serve. 3 GEA Service ' I4.0: The new role of Automation Our applications ' in touch with GEA every day Approx. one quarter of processed milk comes from GEA production systems Around every third process line for instant coffee was installed by GEA Every third chicken nugget is produced by GEA technology Approx. every second liter of beer is brewed with the aid of systems and process solutions from GEA Every second
container ship
in the
world sails with GEA
marine equipment on
board Each industry we serve
utilizes GEA's industrial
refrigeration technologies Every fourth liter of
human blood
is
handled by GEA
equipment More than one third
of all polymer
producers
are using
GEA Drying
technology Dairy Farming
and Processing Food Beverages Pharma Chemical Utilities Marine 4 GEA Service ' I4.0: The new role of Automation What is PMP (Preventive Maintenance
Program)'
' A maintenance policy which aims to execute maintenance work of a 'revision'
'substitution' or 'repair' before the
component might occur in a failure. ' It means planning the maintenance intervention wel in advance in order to be
able to decide when to stop the plant with
minimal impact to production needs. Benefits
' Avoid unwanted downtime due to the equipment failure. ' Optimizing maintenance costs, decreasing intervention timings. ' Decrease timing for management and supply of spare parts. ' Increase the overhaul efficiency of the line. GEMS ' Preventive Maintenance 5 GEA Service ' I4.0: The new role of Automation Preventive Maintenance: Why' Preventive Maintenance in practice No Preventive
Maintenance
Scheduled downtime Unscheduled downtime Preventive
Maintenance
Average bottling plant performace in Europe OEE = 52% * Target reached by Solving Efeso company applying the criteria of TPM (Total Productive Maintenance) to some Final Customers in Europe. Possible target for bottling plant Performace OEE = 61%* OEE = Overal
Equipment Efficiency 6 GEA Service ' I4.0: The new role of Automation DEVICE LIFETIME - CUSTOMER EXPERIENCE - DEVICE LIFETIME GEMS GEMS COCKPIT GEA SYNET SERVER GEMS ' Standard CMMS vs GEMS Computerized Maintenance Management System GEA Embedded Maintenance System WORKSTATION PRINTER / FAX DEVICE DATABASE - DEVICE ORDER CODE - DEVICE FEATURES DEVICE LIFETIME - CUSTOMER EXPERIENCE - DEVICE LIFETIME GEMS SYSTEM ASEPTIC BLOC SCADA ASEPTIC BLOC PLC - PRODUCTION DATA ONLINE MONITORING
PROACTIVE SUPPORT
- COMPONENT LIST SUPPLIER - SPARE PARTS QUOTATION ' Standard CMMS DEVICE DATABASE - DEVICE ORDER CODE - DEVICE FEATURES 7 GEA Service ' I4.0: The new role of Automation ' GEMS is not just a physical device, it is a system that involves al areas of GEA Procomac GEMS ' A structured system 'it involves R&D area
in devices analysis' 3) R&D DEVICES ANALISYS 4) CUSTOMER FEEDBACK GEMS System begins
at the mechanical design stage' 1) PROCESS DESIGN 2) MECHANICAL DESIGN 'it involves After Sales Department and IT Department. 7) IT DEPARTMENT 8) AFTER SALES / SERVICE 'it involves Automation Dept. for data acquisition and user interface design' 5) PLC SOFTWARE DESIGN 6) SCADA SOFTWARE DESIGN 8 GEA Service ' I4.0: The new role of Automation INTERNET via OpenVPN ' GEMS system is continously evolving. The chance to record, by means of a black box, the plant's statistical data has opened new horizons for a system's further development. ' Local GEMS server can estabilish a connection to a centralized server (Cockpit Server) instal ed by GEA Procomac headquarters, through a secure internet access (OpenVPN), sharing the devices
worn out data and production statistical data. GEMS is evolving Customer Plant PLC SCADA GEMS ROUTER Sterilizer Rinser Fil er Capper GEMS Cockpit 9 GEA Service ' I4.0: The new role of Automation Customer Plant PLC SCADA GEMS ROUTER Sterilizer Rinser Fil er Capper GEMS IN A GLOBAL VIRTUAL NETWORK ' Data col ected on GEMS Cockpit wil be accessible to al the users according to their clearance level. GEMS ' SERVER Network GEA & CUSTOMER Users GEMS Local Servers INTERNET OpenVPN 10 GEA Service ' I4.0: The new role of Automation PREVENTIVE MAINTENANCE
What can do I4.0 for help us for a brownfield instal ations'
' I4.0 is a new frontier, the machines are producing a lot of data but only a smal part of those are used, al of us know we don't have alternatives, but nobody
have an idea about which are the real opportunity and limits with the instal ed
equipment. ' With our customers the starting point should be the critical analysis, understand what is real y needs, and after working together, it should try to
create a new efficiency roadmap, fixing and sharing the goals. Digital Box for Service activities' 11 GEA Service ' I4.0: The new role of Automation Which are our roadmap and goals' ' Machine Data acquisition OEE ' Predictive Maintenance (ticketing) ' Energy report consumption ' Tweet status & unexpected stops FINISH START Critical Analysis ' H.M. interaction AR sensors CLOUD 12 To improve the performance of a process
you need to col ect data from the machines
and to know the current performance Benefits
' High reduction equipment related losses
' Important reduction unplanned downtime and increase OEE ' Improve a quality of product
' Energy saving, environment respect and reduction cost of utilities / product ' Alarm and status message - Notify situations that require actions ' Support for problem solving and emergency situations management ' Definition of performances and warranties Which are the benefits' 13 GEA Service ' I4.0: The new role of Automation GEMS Overview 14 GEA Service ' I4.0: The new role of Automation gea.com


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