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L’evoluzione della manutenzione in Coca-Cola HBC

(in lingua inglese)

Statistical process control tool
The purpose of SPC TOOL is to ensure that the measurements data from on-line and laboratory equipment are collected and SPC KBIs (CpK, PpK, Cp, Pp, PDPM) for key quality attributes (BRIX, Carbonation, Torque, Net Content) are calculated using the standardized statistical methodology with further on line process statistic visualization and with historical statistical reports generation.
SPC TOOLIn real time SPC Tool show data and KBI.
Key Value Stakeholders.

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Atti di convegni o presentazioni contenenti case history
MCM ottobre 2018 La digitalizzazione della manutenzione: la sfida per la Manutenzione 4.0

Pubblicato
da Benedetta Rampini
MCM 2018Segui aziendaSegui




Settori: 


Estratto del testo
Veronafiere 17-18 ottobre 2018 Vi aspettiamo a mcT Petrolchimico Milano, 29 novembre 2018 Cogenerazione Termotecnica Industriale Pompe di Calore 27 ottobre Cogenerazione Termotecnica Industriale Pompe di Calore Alimentare Alimentare Petrolchimico Alimentare 28 ottobre Alimentare Petrolchimico Alimentare Alimentare Petrolchimico Visione e Tracciabilit 28 ottobre Luce Energia Domotica LED Luce Energia Domotica LED Petrolchimico Alimentare Petrolchimico Petr L'evoluzione della manutenzione in Coca-Cola HBC NOGARA PLANT THE COCA-COLA SYSTEM WORLDWIDE ' Operate on the territory
' Buy the concentrate from TCCC
' Produce and sell the products
' B2B marketing activities BOTTLER PARTNERS ' Owns the patent for the concentrate
' Posseses the licence of the trademarks
' B2C marketing activities 2 BOTTLER IN TERMS OF SALES VOLUME 600 MILLION CONSUMERS 55 PLANTS COCA-COLA HELLENIC BOTTLING COMPANY 28 COUNTRIES COCA-COLA HBC ITALIA Coca-Cola HBC Italia is the main manufacturer and distributor of The Coca-Cola Company brand products in Italy. PRODUCTIO
N
BOTTLING DISTRIBUTION DEVELOPMENT OF SALES CHANNELS 4 PLANTS 22 PRODUCTION LINES 2,000 EMPLOYEES 17,000 CUSTOMERS IN MODERN TRADE 14,000 CUSTOMERS IN HORECA 95% presence in Italy NOGARA PLANT ' 1975: building start for the first can line
' 1978: first expansion for the second can line ' 1996: blowing introduction, Pet, Bib, glass and drum lines installation ' 2005: aragoN project - new aseptic line, new high-speed PET line. Construction of the warehouse (35.000 m2) ' 2008: automatic High Bay warehouse
' 2010: CHP ' Combined Heat and Power generation
' 2014: aragoN 2.0 Project, new high-speed PET line
' 2015-16: GLASS Strategy and Fanta Slider
' 2017: CANS OBPPC ' Fuze Tea
' 2018: RGM Pet (0,45-0,66-1,35) and Cans (250-150 slim) WATER = 1,260 mio m3 Electricity = 39'000 MW CO2 = 9'500 tons Surface = 137'000 sqm Production volumes
129 mio unit cases
, 732 mio L soft drink, more than 1 billion
primary pack , 176 sku's Production lines
10: 3 PET, 1 Aseptic, 2 Can, 1 Glass, 1 Premix, 2 Postmix NOGARA PLANT Primary pack formats: 25 Shift pattern:
6/7 low season
7/7 High season STATISTICAL
PROCESS
CONTROL tool
Q1 2018 PLANT
MONITORING
SYSTEM
Q2 2018 AUGMENTED
REALITY
ON GOING NOGARA ROADMAP TO THE DIGITALIZATION STATISTICAL PROCESS CONTROL tool Q1 2018 ROADMAP TO THE DIGITALIZATION SPC TOOL The purpose of SPC TOOL is to ensure that the measurements data from on-line and laboratory equipment are collected
and SPC KBIs (CpK, PpK, Cp, Pp, PDPM) for key quality attributes (BRIX, Carbonation, Torque, Net Content) are calculated
using the standardized statistical methodology with further on line process statistic visualization and with historical
statistical reports generation. SPC TOOL In real time SPC Tool show data and KBI PLANT MONITORING SYSTEM Q2 2018 ROADMAP TO THE DIGITALIZATION Server (TREX SW) Interactive Operational Panel (taking input from operator) ' connected to the machine sensors! 1 - Blower
2 ' Filler
3 - Labeller
4 - Packer
5 - Palletizer FOR OPERATOR:
- DTs recording;
- Targets;
- On-line SLE
- On-line quantity related to PO (planned &
produced) FOR PLANT
MAINTENANCE:
- Automatic maintenance
notification ; - DTs statistic FOR PLANT
MANAGEMENT:
- DTs statistic;
- On-line manufacturing
performance and
statistic; FOR
REGION/GROUP
MANAGEMENT:
- On-line plant performance and
statistic (cockpit
view) Data exchange Data exchange BETTER CONTROL, FAST REACTION, BETTER PERFORMANCE/ENGAGENENT FAST REACTION TIME, BETTER UNDERSTANDING OF DTs RC AND FOCUS AREAS ON-lINE PEROFRMANCE VIEW, BETTER UNDERSTANDING OF FOCUS AREAS AND ISSUES RC ON-LINE PERFRORMANCE VIEW, FAST FOCUS ON OPPORTUNITIES Key Value Stakeholders FOR OPERATORS ' Better process control and transparency ' Less Manual records ' Faster reaction for non- conformance
situations ' Better engagement and awareness FOR PLANT MAINTENANCE TEAM ' Fast reaction for breakage situations ' Better understanding of DTs root causes and
critical areas FOR PLANT MANAGEMENT ' Real-time manufacturing performance visibility ' Fast analysis of problems root causes ' More effective line maintenance ' reduction
of line breakages and
stoppages ' Higher awareness of operators FOR REGION/GROUP MANAGEMENT ' Real-time Manufacturing performance transparency ' Better understanding of gaps and opportunities PLANT MONITORING SYSTEM PLANT MONITORING SYSTEM ' OPERATOR'S PANEL OPERATOR PANEL IS THE KEY TOUCHSCREEN TERMINAL
FOR COMMUNICATION OF OPERATOR WITH THE PLANT
MONITORING SYSTEM!
PANELS ARE INSTALLED IN ALL KEY MACHINES OF THE LINE
' BLOWER, FILLER, LABELER, PACKER, PALLETIZER! PANEL IS GIVING TO OPERATOR THE NEXT CAPABILITIES: ' TO SEE LINE TARGETS (SLE, ME)
' TO SEE RT LINE PERFORMANCE (SLE, ME)
' TO SEE RT PRODUCTION ACCURACY PER PO/SHIFT (ACTUAL PRODUCTION VS PLAN) ' TO SEE RT DTs PER MACHINE
' TO LOAD THE DT (EPL & OPL) CODES DT START/END TIME TO THE SYSTEM IMMEDIATELY IN CASE OF
MACHINE STOPPAGE
Screen of Operator's panel VISUALIZATION:
' LINE TARGETS (SLE, ME)
' RT LINE PERFORMANCE (SLE, ME)
' RT PRODUCTION ACCURACY PER PO/SHIFT
' RT DTs PER MACHINE ABILITY TO LOAD:
' DT (EPL & OPL) CODES DT START/END TIME TO THE SYSTEM IMMEDIATELY IN CASE OF MACHINE STOPPAGE Screen saver mode Operational mode Screens in production area ' one screen per line! Plant Monitoring Screens hierarchy CCH MAP COUNTRY SCREEN PLANT/LINE SCREENS INDIVIDUAL MACHINE SCREEN Screens are equipped with 'Reports' button
To access the screen for the filtering required reports! REPORTS DT PARETO SLE WATERFALL STOPPAGES STATISTIC ' TOP 20 REASONS SPEED LOSS LINE STATUS Benefits of Plant Monitoring BEFORE AFTER Can not see Online Productions Online-Realtime Monitoring (Better Follow Up) Manual record to SAP for more than 15 Minutes
Stoppages
100% Accurate Stopage / Eff. Analysis
(Up to 1 second Stoppage)
Can not see Slow Speed Loss Can Follow Up Slow Speed Loss Excell Sheet Daily Reporting Automatic Daily Reporting (E-Mail) Operators Awareness(Eff.) was Lower Higher Awareness for Operators San. / CO Standardisation was
More Difficult
Capable to Follow Up San.&CO
Stoppages
AUGMENTED REALITY ON GOING ROADMAP TO THE DIGITALIZATION FROM BDM TO CBM Maintenance activities split in Nogara Preventive 40% Manutenzion
e correttiva + guasti 60% Maintenance cost split in Nogara Service 52% Spare Parts 48% of which more
then 15% with
just one OEM
supplier
FROM BDM TO CBM Maintenance cost split in Nogara Service 52% Spare Parts 48% of which more
then 15% with
just one OEM
supplier
Maintenance activities split in Nogara Preventive 40% AIMS
- Optimize cost and time of services for TBM
- reduce downtime due to Breakdown
- moving to CBM Manutenzion
e correttiva + guasti 60% FROM BDM TO CBM AUGMENTED REALITY This project covers a pilot for a 'See-What-I-See' use for remote inspections and allow remote subject-matter-experts
to assist in field service and maintenance work. Smartglasses implementation for Augmented Reality AIMS
- Optimize cost and time of services for TBM
- reduce downtime due to Breakdown (MTTR reduction)
- moving to CBM AUGMENTED REALITY While using Skylight 'on-the-field' workers can engage with the four key user experience types shown below: 1. In-View Work Instructions
Get daily work orders, service tickets,
and maintenance tasks in a flexible workflow system. 2. Immediate Access to Help
Share your live view on video calls to remote experts. 3. Live Data Feeds Connect your workforce to big data, smart tools, and smart environments. 4. Capture & Share Media Document work for compliance and after-the-fact analysis. AUGMENTED REALITY Thank you


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