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krones Information Technology KIT
IT Solutions for Optimizing Production
Keeping a Clear Overview
Today, the role of management in the beverages industry is driven by extensive requirements. Fast and accurate decisions are required on a daily basis at different levels of production. These decisions have to be perfectly aligned with corporate strategies, ensure the best possible efﬁciency and maximize full potential for development.
However, the increasing diversity of products and variation in equipment conﬁguration has resulted in a trend towards ever smaller batch sizes – something which has certainly not helped to make the job of decision makers any easier. Furthermore, increased deadline and cost pressures and reduced proﬁt margins have made it essential to optimize the highly engineered production and bottling concept:
■ Identiﬁcation of savings potential ■ Automatic consolidation of pro-
duction data, thus delivering transparency throughout the company ■ Coordination of individual production orders in the most cost-effective sequence without the need for extensive machine setups ■ Use of standardized facts & ﬁgures
2 | krones KIT
krones it – the Tool for Decision Makers
ERP enterprise resource planning
Production planning Real-time reports History analysis Quality management QualiKIT Malfunction analysis DownalyseKIT Large text display Production data acquisition LDS
Maintenance management SIPS
Central information system Raw materials, consumable and purchased materials
Order management LMS Network technology NetKIT Production Bottling and Warehouse
Technical reporting ReportKIT
As a system supplier, krones offer a one-stop solution for machine and plant engineering, including information technology. This ensures that the data ﬂow within the plant and the human-machine dialog are standardized and simpliﬁed. krones information technology offers added value for users. With the Manufacturing Execution System from krones, a bottling plant receives a comprehensive, standardized platform which links both the individual machines at ﬁeld level and the modules at Enterprise Resource Planning System (ERP).
The Beneﬁts at a Glance: ■ Industry-speciﬁc solution for the beverages and food industry ■ Target-oriented and holistic analyses of the complete plant ■ Provision of data across different sites as the basis for operational optimization ■ Provision of industry oriented ﬁgures for overall production (e.g. Overall Equipment Effectiveness, OEE) ■ Comprehensive and consistent modular solution in accordance with individual customer requirements
■ Coordinated hardware and soft■ Standardized and highly available
ware from a single source network infrastructure
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Coordinating and Organizing – krones LMS
By incorporating material lists and bill of material for all products in the ERP system or the production planning, the LMS order system coordinates the complete line on the basis of the individual production batches. The Line Management System takes
the strain off the user by providing up-to-the-minute production information at the individual touchscreens of the machines. Production data are fed back to the higher level system in order to increase the ﬂow of information and close the information loop.
4 | krones KIT
Five Reasons for Using the Line Management System (LMS) ■ Increased plant availability ■ Coordination of the line as a complete plant with full integration of all individual machines ■ Fast and simple batch changes ■ Deﬁned order processing sequence ■ Tracking & tracing of batches (TraceKIT)
Features of the Line Management System ■ Automatic recipe and batch based order processing ■ Production is speciﬁed to bottle or tank level in order to maximize cost-effectiveness in terms of raw materials, auxiliary materials and other resources. ■ Information about the current batch and subsequent batches on the individual machine monitors on the line ■ Provision of required raw materials, auxiliary materials and other resources in just-in-time
■ Evaluation of currently running
articles by batch numbers and start/end times ■ Interactive human-machine dialog for fast and effective line operation ■ “Flying-changeover” as the basis for simultaneous processing of multiple bottling tasks on the line ■ Automatic, recipe based adjustment of printing and inspection devices
Contiform Filler ERP Line management system LMS Labeller Packer Palletiser 0%
Order Y Order Y Order preparation Order Y Order X completed Order X 100 %
Recipe and order system
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Gathering Data – Monitoring Processes krones LDS
krones Line Documentation
System LDS In times of increasing cost pressures, data recording and analysis are essential tools for assessing line efﬁciency. The krones LDS performs this role of automatic data acquisition.
Real-time visualisation Data Monitor
Five Reasons for Using the LDS as a Data Acquisition System ■ Securing cost-effectiveness of the plant through transparency of production data ■ Central storage of operational data ■ Real-time and historical appraisal of production performance with standardized visualization and trend displays ■ Acquisition of consumption data for energy and media ■ Documentation of production data required for tracking and tracing
LDS reporting Data Report
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Features of the Line Documentation System (LDS) ■ Acquisition of line data for calculation of the OEE and the technical efﬁciency according to DIN standards ■ Acquisition of disturbance data, counters and analog values ■ Secured long-term documentation DownalyseKIT downtime management module: ■ Provides a quick and reliable representation of the complex interaction of the machines within the line as a complete system ■ Is used for fast identiﬁcation of potential weaknesses in the line so that speciﬁc measures can be implemented in order to improve performance ■ Automatic resolution of all production downtime in relation to the leading machine in accordance with the fault-cause principle ■ Top-down analysis including ABC assessment on the basis of key performance indicators
Besides line key ﬁgures, the downtime management module indicates which machines cause leading machine downtimes to what extent.
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Securing Product Quality – krones QualiKIT
Sampling Barcode printing
Sample planning Barcode scanning
krones Laboratory an Management
System QualiKIT Production-oriented IT solutions must be capable of documenting the quality of a batch and presenting it in a manner which can be evaluated, this is the only way to ensure that the stringent requirements in the beverages and food industry can be met. krones QualiKIT is the laboratory information and management system which delivers all the information required for quality control and quality assurance.
Features of the QualiKIT Laboratory Information and Management System ■ Veriﬁcation of production conditions in accordance with HACCP criteria ■ Supports the laboratory manager in the organization of the laboratory and the laboratory workﬂow ■ Traceability and archiving of quality related data from laboratory and production, on either a batch or time basis ■ Identiﬁcation of batches for quarantine measures ■ Automatic information about required batch blocks and registration of release activities
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Increasing Plant Availability – krones SIPS
Message in SIPS Order in SIPS Feedback in SIPS
krones Maintenance Management
System SIPS Maintenance also plays a key role in the cost-effectiveness of the plant. Preventative maintenance is enhanced by carefully incorporating speciﬁc service intervals in the program according to a schedule based on a recommended number of operating hours. Production planning can be made even more efﬁcient with the aid of krones SIPS, a module for preventative maintenance and servicing of all individual machines which ensures high plant availability.
Features of the SIPS Maintenance and Service Module ■ Increased line efﬁciency and plant service life, thus resulting in lower total cost of ownership ■ Automatically generated schedules and requirements for maintenance and service measures in accordance with pre-set parameters (ﬁlled system) ■ Open system offering integration of maintenance data for krones machines and third party machines ■ Additional Spare Part Management System module: management and administration system for spare parts in the spare parts storage warehouse with analysis options for warehouse optimization
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Compact Data for Technical Reporting krones ReportKIT
Internet based access to identical information formats across factories and sites and standardized evaluation tools require the use of a structured and standardized reporting system. The krones ReportKIT utilizes the data from the MES modules to generate current, user-oriented reports.
Five Reasons for Using ReportKIT ■ Time-saving evaluation options for production, line and batch data ■ User-speciﬁc representation of the data ■ Uniform, standardized deﬁnition of key parameters and their calculation for all users ■ Multi-dimensional linking of data (e.g. shift, product, area or site related) with long-term evaluation ■ Document management for central administration of documents
Features of the ReportKIT ■ Fast analyses over long time horizons ■ Representation of relevant, industry-oriented indicators like OEE, efﬁciency, degree of utilization, quality etc. for deﬁned user groups ■ Decision-oriented gathering and processing of data from the production process ■ Industry-speciﬁc pre-conﬁgured dashboards, reports and analyses
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Taking the Network as its Basis – krones NetKIT
Internet-Portal WEB-server eGate
Firewall Firewall Router Statistics/ Report APO Manufactoring execution system LDS LVS LIMS MOSIS SIPS Internet World Wide Web
Business Network KRONES Service Phone Phone Operational Network Service station & Networkmanagement system WareMaintenance house
Modem Modem ProBrew- duction LaborShift foreman master manager atory
Router Control Network HMI CR HMI CR HMI CR HMI CR HMI CR HMI CR HMI CR HMI CR Access Point MFR Commis- NVE sioning Labelling Access Point
HMI CR HMI CR HMI CR HMI CR HMI CR HMI CR HMI CR HMI CR
Stacker truck terminal
Filling & Packaging
Industrial Ethernet transports the data: from ﬁeld level and process/ production level to management level. Ethernet LAN and Wireless LAN offer high-availability access and reliable communications between the plant and the MES solution.
Virtual Private Network (VPN) offers secure data exchange and access to both various customer sites and – if enabled – between the customer and the machine manufacturer. This enables the implementation of costsaving teleservice facilities, or alternatively also networking and crossfunctional visualization of lines and sites.
Mobile solutions like handhelds or PDAs (Personal Digital Assistant) allow the reports from the krones IT modules to be called up and controlled from any location. Integrated SMS services allow production relevant data to be forwarded to deﬁned users – regardless of their location.
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Office net Mail Server
Böhmerwaldstraße 5 93073 Neutraubling Germany Phone: +49 9401 70-0 Fax: +49 9401 70-2488 E-mail: email@example.com Internet: www.krones.com
Subject to technical changes · Printed in Germany · 0 900 22 885 0 · Erhardi Druck GmbH · 500e · 10/06
The Expert View – IT-Consulting Consultancy and individual reviews are a key element of krones information technology. This is because the analysis of existing bottling and packaging plants and IT systems is the necessary basis on which the machine information can be utilized. This allows the data from the machines and any already existing IT systems to be forwarded to or integrated in the MES system. Elements of this consultancy service include: ■ Analysis of the current situation with a review of plant components and a determination of the current IT landscape, also potentially across different sites ■ Appraisal of the results of the assessment of the plant and IT structure ■ Development of suitable solution scenarios for best-possible process optimization, taking into account the integration of existing IT systems and the constraints of remaining within the investment budget ■ Realization of the jointly developed solution
Overview of krones IT Solutions: ■ Assistance for the plant operator in order to achieve high plant availability and a reduction of production costs ■ Industry-oriented IT solution for a Manufacturing Execution System (MES) ■ Implementation of the MES solution according standard ISA S95 ■ Modules for planning, controlling, documenting, analyzing and servicing the production operation ■ Connecting link between the enterprise resource planning system (ERP) and the plant level (vertical integration of the systems)