JANUAR Y/FEBRU
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The Food & Beverage Industry Tough challenges ahead
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Contents
Contents
JANUAR Y/FEBRU
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2 Editor’s notes Wonderware in the Food and
3 Beverage industry
Wonderware industry solutions
7 for the Food and Beverage
Woodlands Dairy chooses Wonderware for its Dairy 46 Production Monitoring and Control System SAB manages the big picture with
51 help from Wonderware Intelligence
industry
Imana Foods get HACCP
IntelaTrac in the food and
55 accreditation with help from
ArchestrA Workflow in the Food
59 Internal Benchmarking
21 CFR Part 11 at a glance – introduction and what’s in it
62 Southern Africa gets ISO 9001
12 beverage industry
16 and Beverage industry
Wonderware
Invensys Operation Management
18
21 CFR Part 11 at a glance
22 – scope and summary of requirements
The Consumer Packaged Goods
27 (CPG) industry and solution providers
29
Wonderware solutions at work in the South African Food & Beverage industry
30
Coca-Cola Swaziland uses Wonderware solutions to optimise energy usage and reduce costs Orley Foods’ Oompa-Loompas
34 maintain world-class standards with help from Wonderware
Protocol Magazine Owner and Publisher: Invensys Operations Management Southern Africa
39
TSB’s Komati Mill consolidates SCADA and industrial IT with help from Wonderware
Certification
Invensys Operations
63 Management SA wins prestigious Frost & Sullivan award
Food and Beverage industry
66 dictionary
68 Events: X-CHANGE 2013 72 Invensys Sentinel Services 74 Customer FIRST 2012/2013 Training Schedule
75 (Johannesburg)
Use Protocol Magazine to
76 generate business opportunities 78 On the lighter side 80 Protocol crossword # 58
Marketing Manager: Jaco Markwat jaco.markwat@invensys.co.za
Editor: Denis du Buisson, GMT Services ddb@iafrica.com
Advertising Sales: Heather Simpkins, The Marketing Suite heather@marketingsuite.co.za
Distribution: Nikita Wagner nikita.wagner@invensys.co.za
Contributors Many thanks to the following for their contributions to this issue of the magazine: • Roberto Zerbi, Global Industries Solutions - Life Sciences, Invensys Operations Management for the article on the basics of 21 CFR Part 11 • Karen Ashworth of Karen Ashworth Consulting Ltd. for the article on the scope and summary requirements of 21 CFR Part 11
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Wonderware Southern Africa WonderwareSA WonderwareSA
www.protocolmag.co.za
• Jay R. Jeffreys, PE; Director, Wonderware Solution Provider Programmes for the article on Consumer Packaged Goods • Dr. Kobus van der Merwe of Industrial Management Enhancement for the article on internal benchmarking
January/February 2013 | 1
Editor’s Notes
We may be able to do without a new TV but food isn’t an option. So, if you wanted to get into a business today that promises no dip in demand for ever more, you could do a lot worse than venture into the food and beverage industry. This may come as a shock to some but food production is South Africa’s largest manufacturing sector. South Africa’s food and beverage industry is a strongly competitive sector, producing high quality products for local and international niche markets. Consumers in the middle to upper income brackets demand healthy, convenient, quality foods with strong emphasis on meat and meat products, while
Figure 1: U.N. estimates of world population
the poorer sections of the population need
growth
staple foods at low prices. are on the supermarket shelves. Major South Africa produces a wide variety of crops
South African companies such as Pioneer
and has a substantial number of secondary
Foods, Tiger Foods, Distell, Capespan,
food processing industries. Fresh fruit is the
Clover, Ceres Fruit Juices and SAB Miller are
largest export followed by sugar, processed
important world-class food processors.
vegetables and fruit, fish products, alcoholic products, cereals and grain.
The Food and Beverage industry – tough challenges ahead
For many decades, these companies have kept up with demand through careful management
South Africa’s food processing industry is
and the adoption of the latest technologies
generally technically advanced and able
and there’s no reason to believe that they will
to compete with major food processing
not continue to do so in the foreseeable future
The world’s enormous population has led to
companies internationally. Major
– even though things are getting increasingly
huge increases in industrial output which,
international companies such as Nestlé,
more challenging for them.
in turn, is making a significant contribution
Unilever, Dole, Parmalat and McCain have
to pollution and global warming – which
local companies or links with South African
Until next time,
has led to unpredictable weather patterns
companies. This means that brands such as
Denis du Buisson
of excessive droughts and floods – which is
Kellogg, Marmite, Maggi, Coke and Pepsi
ddb@iafrica.com
affecting food production worldwide – which means that it is becoming increasingly difficult to feed the population that started it all in the first place (figure 1). There is no evidence that this cycle will change because there is no talk about changing it. While people are up-in-arms about global warming, sustainable green energy and anything prefaced by “eco”, there is no talk about addressing the real problem of too many people making yet more people – ad infinitum. There’s probably never been a bigger elephant in the room. Well, we’re certainly not going to fix the problem here but this serves to highlight the role of the world-wide food and beverage industry that shoulders the responsibility for feeding the Earth’s billions.
2 | www.protocolmag.co.za
Figure 2: Income from F&B industry
Wonderware in the Food and Beverage industry
January/February 2013 | 3
Introduction
seriously impacted financial markets as well
management systems based on the ISO
as everyone involved in the animal feeds and
9000 standard since they will insist on
Since the advent of ArchestrA technology
meat-producing industries. This led to the
the proper documentation of production
in 2003, it’s been categorically proven that
imposition of enforceable audit trails that
processes. Wonderware solutions allow for
simply throwing more applications and
stretch from feed producers to consumers.
the “playback” of cause-and-effect scenarios in order to pinpoint the source of errors
money at a problem doesn’t necessarily make it disappear. What production
The information that health officials have is
and to maintain quality and production
personnel and managers were looking for
only as valid as the accuracy of the source
parameters. Complete and comprehensive
was a flexible infrastructure or framework
data. Through the application of batch
production databases ensure that full
that would unify disparate solutions, protect
tracking solutions, real-time database
product genealogy is available at any time.
their investments, help define standards and
principles as well as web enablement and
provide the necessary flexibility to grow and
analysis methods, Wonderware solutions are
change to meet their company’s evolving
helping animal feed producers and others
business needs.
store and disseminate information in a way
Because taste is such a personal thing, any
that is most useful to those who need to
inconsistency of product quality can result in
use it.
the loss of customers and their trust. In order
While this sounds as if it could apply to any industry, it’s particularly true for the food
Consistent product quality
to maintain product quality, it’s important
and beverage industry with its need for
In 2005, Control Engineering magazine
to integrate LIMS-based raw material and
consistent quality, regulatory compliance
selected the Wonderware eCompliance
final product sampling with tightly controlled
and working with increasingly tighter
Solution for its 2005 “Editors’ Choice
process parameters. Ready access to the
budgets in a highly competitive field.
Award.”
graphical reporting of real-time trends can help operators and managers alike forestall
Today, Wonderware is a leading supplier of industrial automation and Manufacturing
“Complying with U.S. Food and Drug
problems and bring processes back on track.
Execution System (MES) solutions to the
Administration requirements will continue
Today, food and beverage manufacturers
food and beverage industry worldwide
to be an important issue in coming years for
have access to all the necessary functionality
through the supply of software and
food-processing companies,” said David
to sustain the quality standards that are the
hardware products that help companies
Greenfield, Control Engineering editorial
hallmarks of their products.
in that industry overcome their challenges
director. “Wonderware’s eCompliance
profitably.
Solution was recognised for features that
Reduced operating costs
enable customers to address regulations In what follows, we have largely stayed away
issued by the FDA, which are designed
To do this, it’s necessary to optimise the
from product names (except in the case
to deal with any emergency involving the
efficiency of processes, minimise waste and
studies) since they are unimportant. You are
nation’s food supply by keeping current,
get the most from expensive production
probably much more interested in how your
accurate records of every ingredient or
equipment.
operational and business needs can be met
component that goes into processed food
by open solutions that won’t “box you in”
products,” said Greenfield.
Advanced Process Control, Statistical Process Control, a tighter control of
and that will protect your investment while improving plant performance and, ultimately,
The Wonderware eCompliance Solution
production parameters and wide access
your bottom line in the short, medium and
enables food companies to meet the
to real-time “dashboard-like” information
long term.
reporting and record-keeping rules
with drill-down facilities go a long way
required by the FDA and offers food-
to improving the efficiency of processes
processing companies of any size a
while strict quality management will help
cost-effective tracking system for the food
minimise waste. A major contributor to
manufacturing process. It is designed to
reducing operating costs is the real-time
help food-processing companies address
monitoring of equipment with respect to its
FDA regulations for the establishment,
availability, performance and the quality of
Over the recent past, the food chain has got
maintenance and availability of specified
its production. These three parameters are
more complicated. In 2002, the European
records.
collectively known as Overall Equipment
Food and beverage industry challenges Regulatory compliance
Parliament drew up a comprehensive set of regulations laying down the general principles and requirements for food safety.
Effectiveness (OEE). It’s becoming
Product genealogy and batch traceability
The bottom line is that food producers will
increasingly commonplace in this industry for companies to have large-screen displays showing the current, real-time status of
not be able to export their products to the
While regulatory compliance makes this
Availability, Performance, Quality and the
European Union without conforming to strict
mandatory, a production audit trail and
resulting OEE for all to see since the actions
traceability and health regulations.
intelligent alarming is the fastest way of
of operators has a direct effect on this crucial
nipping problems in the bud and diagnosing
aspect of efficiency. OEE can also help
The Mad Cow Disease outbreaks in the UK
their causes. It’s also one of the best ways
determine maintenance schedules based on
and the discovery of BSE in the US, had
of retaining customers who operate quality
reality rather than the calendar.
4 | www.protocolmag.co.za
Wonderware in the Food and Beverage industry
Wonderware provides excellent integration between the existing planned maintenance system and the shop floor ensuring automatic update of “statistics” (e.g. running hours, bearing temperature, vibration, etc.) and provides for links into the maintenance system to facilitate emergency work orders.
Integrating business and manufacturing processes Invensys Operations Management Southern Food and beverage companies are in
Africa is fortunate in counting South Africa’s
the consumer market and as such, have
major food and beverage producers among
to contend with fluctuating supply and
its discerning customers who don’t usually
demand where the shop floor is there to
buy mission-critical process control and MES
meet the business needs of the top floor.
solutions on impulse.
Downloading production schedules and uploading production realities is one of
Wonderware’s innovative and proven
the duties of the MES group of functions,
technology is backed by a training and
which is responsible for all aspects of
support organisation that ensures customers
production, maintenance, quality and
get the most from their investments. In 2012
inventory. Wonderware has one of the most
Invensys Operations Management Southern
comprehensive range of MES solutions in
Africa received the prestigious Distinguished
the business as well as the links to connect
Distributor Award for the Europe Russia and
them to the factory at one end of the
Africa (EURA) region for, among other things,
spectrum and the supply chain at the other.
the highest customer satisfaction index.
And it can all be done in an incremental and cost-effective manner where the ROI of one
In 2012, Invensys Operations Management
implementation is realised before initiating
Southern Africa and its Wonderware range
the next.
of solutions also won the coveted Frost & Sullivan 2012 Growth Leadership award
Wonderware have been working
for the Automation and Control Solutions
aggressively with the major ERP system
market in this region. The award is presented
providers (SAP in particular) to ensure that
to the company that has demonstrated
the integration between MES and ERP
excellence in capturing the highest annual
follows strict ISA-95 guidelines and is a front-
compound growth rate for the last 3 years
runner in this market space.
and which has demonstrated a diversified product portfolio, product innovation and
The benefit of Wonderware solutions
excellence in technical service support.
System integrator network
Wonderware has always pioneered solutions most wanted and needed by industrial
Wonderware Southern Africa’s customers
automation engineers. From InTouch 1.0 in
are system integrators or end-users who
1990 to ArchestrA technology in 2003 and
have the technical expertise to implement
System Platform 3.0 in 2007, Wonderware
their own solutions. We are fortunate to
has always stayed ahead of the pack. Today,
be associated with system integrators who
Wonderware’s extensive range of integrated
are true experts in the field of food and
solutions conform to and facilitate the use
beverage production. We have a network
of international standards so that you never
of nearly 70 system integrators who are well
get stuck with proprietary solutions that can’t
versed with our solutions, your needs and
be maintained beyond the longevity of their
who are in the habit of delivering results on
creators.
demand.
January/February 2013 | 5
imagine a better future Cost Reduction
Security
Resources Optimization
Building intelligence
Better Services
Public Utilities management
integrated management of the City
Traffic that flows. Intelligent buildings that save energy. A public infrastructure that delivers whole new levels of service at lower cost. Systems, assets, people and the environment living in harmony. You have imagined ArchestrA, the Wonderware technology that lets you manage your infrastructure as you like in an integrated way. Open, scalable, affordable. Turn imagination into reality with Wonderware. Visit wonderware.com/Infrastructure for more info.
Facility Management • Environment • Power • Smart Cities • Transportation • Waste • Water & Wastewater Avantis
Eurotherm
Foxboro
IMServ
InFusion
SimSci-Esscor
Skelta
Triconex
Wonderware
6 | www.protocolmag.co.za © Copyright 2012. All rights reserved. Invensys, the Invensys logo, Avantis, Eurotherm, Foxboro, IMServ, InFusion, Skelta, SimSci-Esscor, Triconex and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.
Wonderware industry solutions for the Food and Beverage industry
Wonderware industry solutions for the Food and Beverage industry The Wonderware difference oday’s Food and Beverage manufacturers
Industry-specific platform built for food & beverage manufacturing
face challenges throughout the supply chain; from prices and availability of incoming raw
Lower total cost of ownership
materials, through the many production
With over 40,000 licences in food and beverage industries, you can count on Wonderware for your performance, quality and operations management needs.
processes and systems to finished goods.
Access to training, service and applications
Wonderware Industry Solutions for Food
experience is available directly from the
& Beverage, built on the open ArchestrA®
Wonderware world-class distribution or
software architecture, provide manufacturers
independent System Integrator channels,
with a scalable platform to enhance cross-
providing a competitive environment
company collaboration, quality enforcement
for software, SCADA and MES solutions.
and effective asset management.
Sustainable software solutions are tightly
Wonderware InTouch® HMI, SCADA,
integrated, but decoupled from the
manufacturers including assembly
Manufacturing Execution Systems (MES)
proprietary hardware devices offered by
equipment, control systems and Packaging
and reporting applications help enable
many vendors. This allows for commercially
equipment
manufacturers to create solutions that meet
available, off-the-shelf computer hardware,
these manufacturing challenges:
software and support. Additionally, Wonderware is renowned for its unparalleled
• Manufacture consistent products, across different sites, across the world
• Easily integrates with multiple equipment
• Solid architecture provides common services based on ArchestrA technology
migration capabilities and award-winning training, with formal classroom instructorlead courses offered to experience
• Meet stringent quality, regulatory and
Functions and capabilities of Wonderware solutions
• Open, flexible systems based on industry standards such as ISA95
Wonderware technology first hand.
safety requirements
• Broad distribution channel provides more
Unparalleled system security
choices for maintenance services
• Manage complex products and bring them to market quickly • Maximise performance, productivity and efficiencies (leveraging existing systems)
System security is a critical requirement
advanced application-maintenance and
operations, particularly with the demands
reporting capabilities
dictated by the FDA, USDA and other regulatory agencies. Wonderware offers
• Provide fast and accurate production and process information
• Flexible development environment offers
for food and beverage manufacturing
• Robust IT-based security model
a security model that can be managed and integrated with the IT department’s Microsoft® Windows® Operating System
• Minimise waste throughout the manufacturing processes
security, while providing robust data level security. This model optimizes the management of security within the IT
• Respond to changing market demands,
department while protecting SCADA
price pressures, rising costs of raw
and MES systems from cyber, internal or
materials and volatile commodity costs
physical risks. Wonderware offers extensive
January/February 2013 | 7
knowledge on securing critical networked applications that coexist with other systems
Performance optimisation and data analysis
within an open infrastructure. Wonderware
and transformed into useful information, enabling real-time decision making. This information can be displayed via web-based
achieves the creation of securable
The Wonderware industry solutions for food
clients throughout an enterprise and used to
applications, tools and architecture as well
& beverage offer many capabilities that can
optimise team performance.
as best practices, deployment guidelines
help corporations measure key performance
and prescriptive guidance for maintaining a
indicators (KPIs), such as equipment
secure environment, by collaborating with
performance, daily energy consumption and
customers and other industry experts.
costs, efficiency calculations, operational
Easy to configure and easy to change
costs and regulatory compliance. The
Wonderware provides a single, scalable and
ability to track these KPIs over the entire
unified software platform for integrating
organisation can significantly improve
real-time information with all of your
visibility into the profitability of the
business critical operations applications in
The Wonderware Historian provides
business. Data, alarms and events from all
the food and beverage environment such as
out-of-the-box ease of use and flexibility for
parts of the operation can be aggregated
industrial automation, asset management
Collect, analyse and report critical site data
defining how data is acquired, compressed, stored, archived and retrieved. All data, regardless of its source or time of entry, is fully integrated into a unified and robust information database. Once collected, data can be displayed in a variety of formats for operators, managers and analysts. Standard trending features aid data analysis and the report generation functions make it easy to create and automatically produce standard or custom reports on a periodic or demand basis.
8 | www.protocolmag.co.za
Wonderware industry solutions for the Food and Beverage industry
and information management. It provides a
against loss of historical process and
common and strategic industrial application
product data, which could initiate enormous
services platform on top of virtually any
regulatory fines and penalties. If a network
existing system.
or server fails, Wonderware collects, stores and later forwards critical data required
Worldwide support
to generate necessary regulatory reports. Wonderware software easily extracts data
Wonderware engages a worldwide network
from equipment and transforms it into
of Distributors and Systems Integrators,
meaningful information and long term data
including Certified Solutions Providers,
storage makes data available for reports.
Value-Added Resellers (VARs) and Original Equipment Manufacturers (OEMs) to provide local, personalised support. This gives you flexibility in the way solutions are built and
• Growing costs of raw materials and energy
• Machine and system diversity • Waste management
Rising costs of raw materials and energy are straining food and beverage manufacturers.
Maintain product quality in real time
• Quality, safety and regulatory requirements
• Business factors
Growing costs of materials and energy, with commodity volatility
in your choice of who implements and maintains your system.
Wonderware addresses the needs of food and beverage manufacturers in the following areas:
• New product management
Margins are especially tight, so efficiency and productivity in all phases of the supply chain
• Operational discipline
are important to remaining financially viable. With consumer demand for high product
Reducing costs in every area is a primary
quality and consistency and the need to
concern. And fluctuating commodity prices
software and hardware. Many different
reduce waste in all stages of production,
make streamlined operations imperative.
types, technologies, makes and models of
Wonderware enables food and beverage
Wonderware software monitors process
manufacturing equipment – some of which is
manufacturers to monitor the quality of their
variables in real time so that operators can
isolated from other equipment and business
products and manufacturing processes in
use live data to identify losses–down to
systems – make the tasks of manufacturing
real time. Confidence in the product quality
the particular station, machine, process or
quite daunting. And global corporations
increases and operators can respond more
material that caused the problem.
often have multiple sites, sometimes
quickly to issues that would otherwise result
the result of corporate acquisitions that
in greater losses or waste.
Business factors
The Wonderware approach
Food and beverage manufacturers
manufacturing systems, reducing the need
face significant market pressure against
to replace equipment and is installed
increasing prices, but raw material
cost effectively to provide more modern
prices continue to inflate. Manufacturers
operations management systems that
continuously seek ways to make the most
provide advanced control of manufacturing
Food and beverage manufacturers are
of the equipment and systems that they
operations.
expected by both regulatory agencies and
have to offset rising material costs. So,
demanding customers to manufacture
finding ways to reduce operating costs
high quality products. Wonderware
(including engineering and maintenance
software helps ensure that products are
costs) to remain more competitive is
manufactured according to specifications,
critical. Wonderware software saves
To support the requirement to test and
in compliance with regulatory and quality
countless hours of engineering time and
measure many product samples in various
standards. Likewise, the software helps the
associated costs by allowing customers
stages of manufacture, LIMS are needed.
manufacturing processes run as designed,
to develop “standardised” engineering,
These range from simple Excel or Access-
with monitoring, control and data archiving of
objects and graphics that can be utilised
based systems to proprietary systems to full
manufacturing processes. When a potential
again and again. Maximising resources,
LIMS applications. Wonderware brings third
safety or regulatory problem surfaces,
while limiting expenditures, is another
party LIMS, SCADA and MES data together,
fast and accurate product traceability and
challenge manufacturers face. Wonderware
providing faster response time to potential
genealogy are critical. Without it, recall costs
software helps monitor, control and analyse
quality problems.
can balloon, sometimes with devastating
product and process data to assist in the
financial impact and damage to the corporate
identification and reduction of losses and
image, product brand and customer
inefficiencies.
Enterprise Resource Planning and business system integration
Machine and system diversity
Tight coordination between Enterprise
must work together toward the same goals. Wonderware software coordinates
Quality, safety and regulatory requirements
Laboratory Information and Management Systems (LIMS)
confidence. Wonderware MES software provides this traceability and genealogy, quickly and reliably. The Wonderware System Platform guards
Resource Planning, Supply Chain Manufacturers today are facing an
Management and other critical business
unprecedented complexity of systems,
systems with factory floor operations is
January/February 2013 | 9
required to handle today’s rapidly changing
Recipe or Formula Management Systems,
regardless of location or equipment–with
consumer demands. To make the most of
downloading recipes and formulas and their
set-point management, procedural
existing equipment and materials and to
associated equipment set-points, monitoring
enforcement, production tracking and
maintain operational discipline, Wonderware
batch levels with statuses, then reporting any
inventory tracing. Wonderware software
integrates with business systems to facilitate
deviations from production plans.
helps to improve production execution and control, allowing food and beverage
interaction of production schedules and plans with factory floor manufacturing systems.
Waste management
Integrated equipment with maintenance management systems
Slim margins require a reduction of waste
accuracy of production information gives
in the manufacturing processes. This waste
great insight into the daily food and
takes the form of scrap, downgrades,
beverage operations.
manufacturers to achieve high product consistency. Increasing, the amount and
rework, shrinkage or any issue that lowers Integrate actual equipment data with
yields. And waste in the form of ‘giveaways’,
Wonderware software stores and analyses
maintenance systems to avoid calendar-
as in filling operations, must be minimised
massive amounts of data, transforming it
only scheduled maintenance. Wonderware
while meeting net content requirements.
into actionable information. Monitoring
provides the ability to get real-time data
Wonderware software provides detailed
performance on equipment helps to identify
needed to generate work orders. This also
information about processes and materials,
and lift bottlenecks, increasing throughput,
coordinates efforts between operations
granting greater real-time visibility and
efficiencies and productivity. Wonderware
and maintenance functions for better asset
awareness of waste.
software allows the detailed monitoring of equipment performance, including
management.
Meet reporting demands
Managing numerous and complex products
Using real-time quality feedback,
Some food and beverage manufacturers sell
Wonderware software helps operators to
to fast-changing and varied markets, have
meet quality requirements at all times. And
thousands of products, or make complex
with so much regulatory oversight, food and
products. Managing products along with
beverage manufacturers need information
their unique specifications creates a great
about the ingredients in each product
deal of complexity. And ever-changing
(genealogy) and where and when those
market and customer preferences make
ingredients went (traceability). Wonderware
the addition of new products unavoidable.
software stores the required data and
Managing new products, from the
makes it available for analysis, including
required business systems updates, to the
traceability and genealogy reports – quickly
manufacturing system changes required
and with a minimum of data manipulation.
and assimilation into existing manufacturing
Even environmental requirements are
lines and processes is a central capability of
accommodated with massive stores of
Wonderware software. Manufacturing recipe
process and environmental data.
or formula-based products adds significant complexity, too. Wonderware software
Energy management
simplifies these complexities while ensuring that the products are manufactured correctly.
Increasing energy costs are driving the demand for energy optimisation techniques, which improve manufacturing efficiencies to
Operational flexibility, discipline and performance
better meet production schedule and market demands. Wonderware provides historical
The flexibility to make many products across
data for demand forecast needs and allows
equipment, with fast changeovers between
the easy analysis of operations data. Twenty-
product runs, gives food and beverage
four hours a day, Wonderware software keeps
manufacturers the ability to respond to
track of starts and stops and overall usage,
market demands quickly. This flexibility
allowing schedule adjustments to match
increases inventory turns and decreases
demand, and enables manufacturers to
the need for “safety stocks.” Automating
maintain the minimum power profile.
changeovers reduces manual interactions and the possibility of mistakes. Wonderware
Manage complex recipes / formulae
software delivers on these needs. Companies that depend on product
Wonderware software integrates to
10 | www.protocolmag.co.za
consistency require operational discipline,
Overall Equipment Effectiveness (OEE) and downtime tracking.
Here’s what some customers in the food and beverage industry have to say about Wonderware solutions: “Imana Foods would not have achieved HACCP accreditation
“I think that Wonderware technology and products have helped
without this solution in place“.
increase our level of knowledge and control to the degree that
Paul Alcock, MD, Imana Foods
we can now think about improving our processes rather than just keeping up with them.”
“The installation of the Wonderware System Platform has meant
Jan Barnard, Process Engineer, Woodlands Dairy
that we can aim higher. While it can now help us optimise production, it’s also laid the foundation for much more.”
“From an administrative perspective, we save a lot of time. From a
Noël Alleaume, Factory Manager, Hudson and Knight.
user’s perspective, we minimise frustration. That’s the number one benefit.”
“The ability of the System Platform to integrate and consolidate
Igor Valuyev, New Belgium Brewing Company
data across the different systems and deliver the data to managers’ desktops in a presentable format enables us to be
“Wonderware software is critical to our ability to effectively
pro-active, rather than reactive”
respond to market pressures, and gives us the information we need
Pieter van Tonder, Instrumentation Engineer, TSB Komati Mill
when we need it. It supports our vision of the future.” Jørgen Greve, Arla Foods
“This has been one of the best prepared, executed and commissioned projects, with excellent results! All our
“Wonderware software enables us to run a much leaner
expectations were exceeded, especially the accuracy of the
manufacturing operation, and help us demonstrate our abilities
dosing.”
to customers, giving them a greater level of confidence in our
Gilles Suter, Engineering Manager, Nestlé South Africa
manufacturing operations.” Thom Iwancio, Amcor PET Packaging
“After the testing and development phase, we were able to roll out the project to the rest of the sites and commission within
“With regards to metrics, what we’re seeing is consistency in
2 months! This is a reflection on the power of the underlying
throughput. We are able to tell when problematic areas arise and by
ArchestrA technology. Then there’s the matter of cost. The time
having it automated, we are able to take preventive action in order
saved with the project roll-out had a direct impact on the cost
to maintain consistent operation.”
and we were able to finish within budget.”
Harry Crigler, Bean Global Spirits and Wine
Hein du Toit, Business Analyst, SAB Ltd.
January/February 2013 | 11
IntelaTrac in the Food and Beverage industry In a nutshell ...
Industry challenges • Product quality consistency
IntelaTrac is an enterprise-level software and hardware solution that delivers a
• Unscheduled downtime
mobile workforce management solution to a wide range of industries.
• Maintenance costs
IntelaTrac enables Food & Beverage
• Sanitation and cleaning costs
manufacturers to achieve reliable, safe and profitable operations through
• Cost of regulatory compliance
consistent execution of all manual plant floor tasks. IntelaTrac facilitates and
• Personnel turnover and training costs
reinforces standard practices fostering a culture of accountability and asset
• Inefficient paper-based data collection
stewardship.
Business value
IntelaTrac mobile solutions deliver
• Provides a framework for driving
Improved product quality consistency
sustainable operational excellence • Enforces consistent execution of best practices across all lines and shifts • Provides a strategy for monitoring non-instrumented assets • Drives increased equipment reliability and reduces unplanned downtime
through: • Enforcement of best operating practices across all lines and shifts • Enforcement of proper product quality checks and data collection • Immediate focused advice when product
equipment operating procedures
quality is out of specification • Immediate reporting of equipment
• Guides new plant workers in best practices immediately.
Reduced cost of unplanned downtime
operating in ‘out of tolerance’ conditions
through: • Enforcement of scheduled maintenance • Consistent enforcement of approved
rounds
start-up, changeover, and equipment operating procedures
Reduced sanitation and cleaning costs through:
• Immediate notification and ‘approved’ guidance to the user when problems are detected • Scheduling and enforcement of rounds ensuring checks are made properly
• Consistent enforcement of accepted cleaning and inspection procedures • Immediate visibility of cleaning time variations across different plants lines and shifts
Reduced maintenance costs through: Reduced employee turnover and training • Consistent enforcement of accepted
12 | www.protocolmag.co.za
costs through:
IntelaTrac in the Food and Beverage industry
• Consistent enforcement of best practices from day one of employment • Immediate guidance and additional
• Inspections of boilers, turbines,
crews, drag-and-drop scheduling, handles
bearings, air lines, seals and lubrication
non-standard shifts
systems • Task Sequence Enforcement − operators
reference information availability when a problem is detected
• Flexible Scheduling − create and modify
compressors, pumps, stream traps, valves,
• Verification of: flow rates, temperatures, pressures
must follow a specific task sequence to complete a round
• The ability to create step-by-step procedures as part of on the job training
Quality assurance
• Location Enforcement − IntelaTrac supports RFID (radio frequency
Increased manual data collection
• Finished product sampling procedures
efficiency through:
identification) and barcode location tags, allowing verification of where tasks were
• Raw material receiving procedures
executed or data collected
• The use of an electronic handheld device instead o f paper and clipboard
Employee safety
• Multi-Task View − allows multiple tasks to be executed from a single mobile screen
• Immediate filtering of manually collected
• Fire extinguisher inspections
− saving time for field operators
data to minimise data entry errors • Safety shower inspections Leveraging existing plant floor
• Trends − on-board historical trends allow plant operators to easily compare today’s
technologies through:
• Eye wash station inspections
• Integration with Wonderware Historian
• Fall zone inspections
operating levels with nominal historical values − helping operators to spot growing problems faster
and System Platform • Regular plant safety inspections management systems
• Attached Documents − efficient delivery of digital equipment or
• Integration with maintenance Sanitation department
process documentation to field workers (including: schematic diagrams, standard
Food and beverage applications for IntelaTrac
• Equipment cleaning procedure verification including − Clean In Place
operating procedures (SOPs), equipment disassembly procedures)
(CIP), equipment disassembly and IntelaTrac can be used throughout any food
reassembly procedures
applications of IntelaTrac include:
• Procedure Import/Export − easily share best operating or inspection practices
or beverage production facility. Typical • Post cleaning equipment inspections and
with other units or plants
verification • Calculation Engine − configurable and
Production department • Manufacturing waste handling procedures • Line start-up procedures
calculations based on current operating • Rodent bait station and fly trap
• Product change-over procedures
extensible tool for creating process
inspections
parameters (encapsulate propriety process calculations and embed in an plant round)
• Product zone safety inspections
Employee training
• Plant HACCP inspections
• Attached training materials to plant floor
Integration procedures • Daily plant floor inspections
which can deliver a “mobile” capability • Create “training” rounds for new plant
• Regular product quality inspections
IntelaTrac is a mobile infrastructure solution
workers
to many plant systems. Systems such as historians, CMMS/EAM systems, laboratory information systems and others. Procedures
• Line shutdown procedures
• Analyse performance to spot where additional training is required
• Lean Manufacturing procedure enforcement
systems using the IntelaTrac Extensibility Software Development Kit (SDK). Now you
Advanced features and capabilities
Maintenance department
can deliver information collected by mobile workers to almost any plant system and extend the application to meet changing
IntelaTrac delivers many advanced features • Equipment maintenance rounds
can be automatically created by these plant
requirements.
for the food & beverage industries: Historians: OSIsoft PI Historian, Honeywell
January/February 2013 | 13
Typical configuration
IntelaTrac system overview PHD, AspenTech IP21, Wonderware Historian
IntelaTrac is an enterprise-level software and hardware solution that delivers a mobile
Use IntelaTrac to “mobilise” your plant
workforce management solution to the food
historian. Stranded asset data collected
and beverage industries.
by Mobile IntelaTrac can be easily added to your historian’s data record. Now you
Server components and integration
have a complete view of all of your plant’s
software
assets. • IntelaTrac Database Server: Microsoft® CMMS/EAM Systems: Avantis, SAP PM,
SQL Server based database management
IBM Maximo
server
IntelaTrac can generate work requests and communicate these back to the CMMS
• IntelaTrac Application Server:
system − saving time and effort by field
Integration Server (synchronisation,
operators and getting problems fixed faster.
scheduling and extensibility)
Wonderware System Platform: IntelaTrac
• IntelaTrac Report Server
can exchange data with Wonderware System Platform; delivering stranded asset
14 | www.protocolmag.co.za
• Integration Modules: Wonderware
data to a System Platform application or
System Platform, Wonderware Historian,
receiving historical data for field viewable
InFusion Control and Foundation Editions,
trends.
Avantis, SAP PM, IBM Maximo, OSIsoft PI
IntelaTrac in the Food and Beverage industry
System, AspenTech IP21, and others IntelaTrac desktop clients
Mobile devices and peripherals IntelaTrac supports a broad selection of hazardous environment rated handheld
• IntelaTrac Procedure Builder
computers from Motorola/Symbol, Intermec, Bartec and others. Supported peripherals
• Scheduler Manager
include RFID and barcode readers, vibration probes, temperature guns and wireless
• IntelaTrac Auditor Plus
communication devices.
• Administration and Security • IntelaTrac Web Reporting IntelaTrac mobile clients Mobile IntelaTrac is a Windows Mobile client that provides a “best in class” browser-style user interface for IntelaTrac procedures and data collection tasks on mobile devices.
January/February 2013 | 15
ArchestrA Workflow in the Food and Beverage industry In a nutshell ...
Introduction
The solution
A leading bottler for a major global
The solution had to provide closed loop
ArchestrA Workflow was used to ensure
beverage brand in Europe is a trend setter
remediation of issues across platforms, and
that best practices were standardised,
in the European business community for
also had to be plant user friendly to ensure
providing closed loop remediation
corporate policies, as well as for excellence
maximum productivity. ArchestrA® Workflow
and facilitating collaboration to ensure
in business administration and talent
from Invensys was the obvious choice.
operational excellence for a leading
management. They provide best in breed
European bottler.
services and products to their clients. In
ArchestrA Workflow will be implemented to
order to achieve this level of excellence,
standardise best practices in manufacturing.
this European bottling firm ensures rigorous
In addition, with ArchestrA Workflow,
compliance with the highest standards
processes can easily be replicated across
of food quality and safety and is agile,
multiple locations to ensure maintenance
proactive and locally sensitive in order to
workflows are quickly triggered and
meet the needs of a constantly changing
optimally executed to provide closed loop
market.
remediation of issues.
This bottling firm operates plants across
Why ArchestrA Workflow?
Business value • Easy process replication globally • Comprehensive compliance • Closed loop remediation • Standardisation of best practices
multiple locations in Europe and Africa which often leads to a challenge in terms of
After evaluating a number of workflow
centralised organisation of information and
offerings in the market, ArchestrA Workflow
specific task allocations:
was found to be the most agile, allowing for dynamic process modification and
• There were no automated/standardised
deployment. ArchestrA Workflow was
processes in response to disruptive events
the only product that offered seamless
on the plant floor. Most of the processes
connectivity and amalgamation across all
were of a manual nature.
Wonderware® platforms and the industrial IT infrastructure.
• Critical information concerning maintenance was known only to a few
There are multiple advantages in deploying
individuals and there was no means of
ArchestrA Workflow:
sharing this information. Additionally, manual information exchange led to
• In comparison with other workflow
a delay in processing orders as well as
products, ArchestrA Workflow exceeded
delays in maintenance response.
expectations in terms of performance, process agility and scalability.
• There was a need for a solution that enhanced their MES software
16 | www.protocolmag.co.za
• The solution is easy to use and fully
(Manufacturing Execution System) by
compatible with other Invensys offerings like
combining it with workflow to provide
Wonderware MES, IntelaTrac, Wonderware
complex workflow support, process
Historian, Wonderware InTouch and the
monitoring and security.
ArchestrA System Platform.
ArchestrA Workflow in the Food and Beverage industry
• Workflows are easily replicated across various locations and monitored centrally.
processes. They also intend to deploy workflow solutions powered by ArchestrA Workflow in newly acquired plants in Iceland
• ArchestrA Workflow enabled multichannel, context-sensitive information to
and North Africa. Some examples of the wide range of processes being planned:
be communicated to stakeholders. • Automation of the due diligence process
Benefits of ArchestrA Workflow
in asset management • LIMS solutions linked by workflow to
Upon implementation, ArchestrA Workflow
production
will result in gains from: • Time-based report generation and • Standardisation of processes for the operators • Optimisation of processes and better
notifications on machine down time and maintenance time linked to workflow • Direction communications
analytics ArchestrA Workflow ensures best practices • Continuous process improvement
are standardised and provides closed loop remediation while ensuring collaboration
• Closed loop and collaborative remediation
and compliance. With ArchestrA Workflow, companies can institutionalise work processes that manage normal, unscheduled
Future plans
or disruptive events within their operations environment—providing the right people
In the future, the bottling firm plans to
with the right information at the right time.
automate a number of core and non-core
January/February 2013 | 17
21 CFR Part 11 at a glance – introduction and what’s in it Roberto Zerbi, Global Industries Solutions Life Sciences, Invensys Operations Management
Introduction
electronic data archiving and management designed to keep paper at minimum and
21 CFR Part 11 is a Food and Drug
decrease operational costs.
Administration (FDA = 21) Rule (Code Federal Register = CFR) regarding electronic records
Many ‘interpretations’ and ‘clarifications’ were
and electronic signatures (i.e. Part 11).
made between 2001 and 2003. An ISPE GAMP (Good Automated Manufacturing Practice)
Being a rule (law) you can obey it or not. It’s
guide called ‘A Risk-Based Approach to
as simple as that. This rule was introduced 15
Compliant Electronic Records and Signatures’
years ago on 20th March1997. Just after the
was published in February 2005.
‘Millennium bug’ storm, the pharmaceutical industry ‘discovered’ this law to deal with
‘Part 11’ is different from ISPE ‘GAMP’. GAMP is a guideline or an approach to develop automated pharmaceutical projects better and easier in order that they may be validated according to the relevant regulatory bodies. ‘Part 11’ is concise. The official wording fits in two and an half pages and is divided in three subparts:
18 | www.protocolmag.co.za
21 CFR Part 11 at a glance – introduction and what’s in it
Subpart A – General Provisions
Electronics records can be modified,
Access control
created, deleted, distributed, archived, • 11.1 Scope
maintained and retrieved. The requirements
This is used to limit system access to
for doing this are:
authorised individuals who are then allowed
• 11.2 Implementation
to: • The ability to recognise invalid or altered
• 11.3 Definitions Subpart B—Electronic Records • 11.10 Controls for closed systems.
records (tamperproof) • It must be possible to be copied in human
• Use the system • Sign a record (or verify a record). Note:
readable format (for inspection, review,
Individuals could use the system but not
transmittal to the agency)
sign for a record.
• 11.30 Controls for open systems.
• Retrievable through the retention period
• 11.50 Signature manifestations.
• Time stamped (UTC, to avoid time zones
• Access the operation or computer system input or output devices to change process
differences)
parameters. Data have to be checked for validity
• 11.70 Signature/record linking. • Previously recorded information must Subpart C—Electronic Signatures
• Alter a record such as, for example, a
be retained (record past and new values
recipe change. Old and new values must
every time an event happens)
be recorded
• 11.100 General requirements. • Could be signed. There must be a way to • 11.200 Electronic signature components and controls.
• Perform the operation at hand
link an electronic record to an electronic signature. This link cannot be removed
The standard security supplied with modern operating systems is considered adequate
• 11.300 Controls for identification codes/ passwords.
What’s in it
• Authorisation checks could (optionally)
for this type of access control.
be required (a second verification level to ensure that only authorised individuals
Authorised individuals can have different
can electronically sign a record)
levels of access (roles). These different roles could be grouped together, so that access
21 CFR Part 11 deals with three topics: • Audit trail (what electronic records should register and how to manage them)
• Data coming from input devices (remote
privileges could be inherited. An individual
terminals, scales, etc) connected to the
can have different roles in different plant
system must be checked to determine the
areas. This is common practice but is not
validity of the source (it is good practice
‘dictated’ by 21 CFR Part 11.
to record the communication status of • Access control (how to access a ‘regulated’ environment)
any connected device which is providing
Signature
critical data) Electronic signature has nothing to do
• Signature (how to sign for and verify an electronic record)
Audit trail
Electronic records could require to be
with access control. The act of ‘signing’
signed although this may not apply to all of
(or ‘verifying’) is distinct from the system
them. This implies that an individual action
access privileges. A risk-based approach
be recorded in an event (including alarm
calls for limiting signature to ‘critical process
acknowledgement).
parameters’. An individual can have system
An ‘Audit trail’ is a collection of ‘electronic
access, sign, and/or verify privileges.
records’ like:
When a record is signed it must contain:
• Alarms. Usually linked to alarm priorities
• The printed name of the signer
• Events. Like starting a batch, modifying a
• The date and time of the signature
It is common practice for an individual authorised to sign to have access to the system. Different plant areas could result in different individual capabilities.
threshold or writing an operator note. In general, this includes operator changes/ actions
Signatures employ at least two distinct • The reason why the signature is required (a system fixed test)
identification components (usually: UserID and Password) which must be unique and secret. This is done by encrypting
• Data (process trends) and equipment (e.g. valve) status (from automatic sequences).
• The comment (or note) why the signature was applied (example: to correct a wrong
the password and checking for UserID uniqueness.
process parameter). Comments could be • System access
free-text, pre-filled, or blank
The UserID and signature must always be executed together except in the case
January/February 2013 | 19
of several signings being made during a
Electronic Signatures are managed
continuous session where only password is
(periodically checked, recalled, or revised)
• Retired (if a user has been transferred or service 3rd party individuals are no longer
required. It is acceptable to always ask for
to:
enabled)
UserID and Password and to have the UserID prefilled.
• Maintain uniqueness
A ‘signature’ event is defined as:
• Ensure validity of identification
• Deleted (if suspected to be lost or compromised)
(procedural) • Use of an authorised and unique UserID and Password couple
An electronic signature cannot be reused or reassigned. Repeated or serious attempts at
• Ensure password periodic expiration
unauthorised use need to generate an event and to be reported to management.
• Printed (full) name of the signer
Each signature can be in the following states:
• Date/time of signing
in this article can be found in the dictionary • Active
• Reason for the signature (also described as individual comment or note. A prefilled drop-down list could also be required)
20 | www.protocolmag.co.za
NOTE: An explanation of the terms used
• Disabled
segment of this magazine.
The clearest path to modernisation. Bypass the risk and cost of obsolescence through our unique and comprehensive approach. To start mapping out your path, visit us at iom.invensys.com/Modernise.
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January/February 2013 | 21 Š Copyright 2012. All rights reserved. Invensys, the Invensys logo, Avantis, Eurotherm, Foxboro, IMServ, InFusion, Skelta, SimSci-Esscor, Triconex and Wonderware are trademarks of Invensys plc, its subsidiaries or affiliates. All other brands and product names may be trademarks of their respective owners.
21 CFR Part 11 at a glance – scope and summary of requirements Karen Ashworth. Karen Ashworth Consulting Ltd. (www.karenashworth.co.uk)
“The persons performing and double-checking the cleaning and maintenance shall date and sign or initial the log indicating that the work was performed.”
Scope This would mean that if a control system sequence starts with a check Here’s an example of what is meant by a ‘predicate rule’:
that a manual cleaning operation has been correctly completed (signed electronically by both the person who did the cleaning and the person
Rule 21 CFR 211.182, relating to equipment cleaning and use log,
who double-checked it), the record of that check falls within the scope
states:
of 21CFR part 11.
Figure 1: 21 CFR Part 11 as originally worded
22 | www.protocolmag.co.za
21 CFR Part 11 at a glance – scope and summary of requirements
Figure 2: 21 CFR Part 11 as modified by the guidance on scope and application. This clarifies what is in the scope even if a paper copy is also kept.
Electronic records What do we need to do to make them as trustworthy as paper records?
AREA Validation
HIGH LEVEL SUMMARY OF REQUIREMENTS
21 CFR PART 11 TEXT
If the system which produced the
11.10(a) ‘Validation of systems to ensure accuracy, reliability, consistent intended
records has never been validated,
performance, and the ability to discern invalid or altered records.
who is likely to trust them? (Modified by scope and application guidance to take into account the impact the
Inspectability
The equivalent to having
systems have on ability to meet predicate rule requirements and the impact systems
pre-approved procedures and
might have on the accuracy, reliability, integrity, availability, and authenticity of
templates for paper records
required records and signatures.)
If the FDA inspector can’t read
11.10(b) ‘The ability to generate accurate and complete copies of records in both
the record then he/she is not
human readable and electronic form suitable for inspection, review, and copying by
going to trust it.
the agency.’
The equivalent of a manual filing
(Modified by scope and application guidance to allow use of common portable
system for paper records
formats and of established conversion or export methods and also review by the agency at the site using end user’s own hardware and procedures). 11.10(c) ‘Protection of records to enable their accurate and ready retrieval throughout the records retention period.’ (Modified by scope and application guidance to allow archive to non-electronic media or to standard electronic file format providing content and meaning are preserved such that predicate rules are still met).
January/February 2013 | 23
AREA
HIGH LEVEL SUMMARY OF REQUIREMENTS
Control of
If you can’t prove that only
Access
authorised people can use the
21 CFR PART 11 TEXT 11.10(d) ‘Limiting system access to authorised individuals’
system then how do you prove
11.10(g)‘Use of authority checks to ensure that only authorised individuals can use the
that the equipment was by
system, electronically sign a record, access the operation or computer system input or
trained personnel using the
output device, alter a record, or perform the operation at hand’
correct procedures? 11.10(i) ‘Determination that persons … have the education, training, and experience The equivalent of physical access
to perform their assigned tasks’
controls / procedures to determine who can do manual actions – but
11.10 (k) Use of appropriate controls over systems documentation including:
more so because computerisation makes it ‘easier’ to access plant
(1) Adequate controls over the distribution of, access to, and use of documentation
controls
for system operation and maintenance. (2) Revision and change control procedures to maintain an audit trail that documents time-sequenced development and modification of systems documentation.
Audit Trail
If the actions were supposed to
11.10 (e) Use of secure, computer-generated, time-stamped audit trails to
be carried out in a particular time
independently record the date and time of operator entries and actions that create,
sequence, is there evidence that
modify, or delete electronic records. Record changes shall not obscure previously
this actually happened? Is there
recorded information. Such audit trail documentation shall be retained for a period at
evidence that the record has not
least as long as that required for the subject electronic records and shall be available
been tampered with?
for agency review and copying.
The equivalent of manual recording
(Modified by scope and application guidance to allow risk based decision on whether
of who was responsible for each
audit trail is required provided predicate rule requirements (such as date, time,
critical process step
sequencing of events, ensuring that changes to records do not obscure previous entries) are met).
The equivalent of single line through erroneous value, write correct value and explanation, sign and date. Automatic
Did the system have checks
11.10 (f) Use of operational system checks to enforce permitted sequencing of steps
Checks
built in to prevent wrongful or
and events, as appropriate.
fraudulent actions? 11.10 (h) Use of device (e.g., terminal) checks to determine, as appropriate, the The equivalent of physical
validity of the source of data input or operational instruction.
interlocks and procedures – but more so because computerisation makes it ‘easier’ to access plant controls And if the
If the records have been out into an
records have
uncontrolled environment, how do
been outside of
we know they didn’t get tampered
Persons who use open systems to create, modify, maintain, or transmit electronic
our controlled
with?
records shall employ procedures and controls designed to ensure the authenticity,
environment…
11.30 Controls for open systems:
integrity, and, as appropriate, the confidentiality of electronic records from the point of their creation to the point of their receipt. Such procedures and controls shall include those identified in Sec. 11.10, as appropriate, and additional measures such as document encryption and use of appropriate digital signature standards to ensure, as necessary under the circumstances, record authenticity, integrity, and confidentiality
24 | www.protocolmag.co.za
21 CFR Part 11 at a glance – scope and summary of requirements
AREA
HIGH LEVEL SUMMARY OF REQUIREMENTS
21 CFR PART 11 TEXT
Accepted
As with a handwritten signature,
11.100 (c) Persons using electronic signatures shall, prior to or at the time of such
as being a
the electronic signing has to be
use, certify to the agency that the electronic signatures in their system, used on or
Signature
accepted by its owner as being
after August 20, 1997, are intended to be the legally binding equivalent of traditional
legally binding
handwritten signatures.
Equivalent to signing a cheque and expecting the bank to honour it… Traceable to the
The whole purpose of a signature
11.100 (b) Before an organisation establishes, assigns, certifies, or otherwise sanctions
Individual
is to identify the person taking
an individual’s electronic signature, or any element of such electronic signature, the
responsibility for an action
organisation shall verify the identity of the individual.
You don’t expect the bank to pay
11.100(a) Each electronic signature shall be unique to one individual and shall not be
out if someone else signs one of
reused by, or reassigned to, anyone else.
your cheques… 11.200(a) Electronic signatures that are not based upon biometrics shall: • 11.200(a) 1 Employ at least two distinct identification components such as an identification code and password. • 11.200(a) 2 Be used only by their genuine owners; and • 11.200(a) 3 Be administered and executed to ensure that attempted use of an individual’s electronic signature by anyone other than its genuine owner requires collaboration of two or more individuals. • 11.200(b) Electronic signatures based upon biometrics shall be designed to ensure that they cannot be used by anyone other than their genuine owners. Clear Signature
It should be obvious what is being
11.50(a) Signed electronic records shall contain information associated with the
Meaning
signed for both at the point of
signing that clearly indicates all of the following:
signature and in the record of that signature.
(1) The printed name of the signer;
You wouldn’t sign a blank cheque…
(2) The date and time when the signature was executed; and
And you would expect the value on the cheque to match the value
(3) The meaning (such as review, approval, responsibility, or authorship) associated
paid to the recipient and the value
with the signature.
shown on the bank statement. 11.50(b) The items identified in paragraphs (a)(1), (a)(2), and (a)(3) of this section shall be subject to the same controls as for electronic records and shall be included as part of any human readable form of the electronic record (such as electronic display or printout). Signature
Signature should be indelibly linked
11.70 Electronic signatures and handwritten signatures executed to electronic records
Linking to the
to the record to which it applies
shall be linked to their respective electronic records to ensure that the signatures
Record
cannot be excised, copied, or otherwise transferred to falsify an electronic record by You wouldn’t sign a cheque in
ordinary means.
pencil…
January/February 2013 | 25
AREA
HIGH LEVEL SUMMARY OF REQUIREMENTS
21 CFR PART 11 TEXT
Signature
It is necessary to demonstrate
11.300(a) Maintaining the uniqueness of each combined identification code and
Controls
control of the ID / password /
password, such that no two individuals have the same combination of identification
token system in order to have
code and password.
confidence that signature cannot be fraudulently used.
11.300 (b) Ensuring that identification code and password issuances are periodically checked, recalled, or revised (e.g., to cover such events as password aging).
You wouldn’t give the PIN number for your cash-point card to anyone
11.300 (c) Following loss management procedures to electronically deauthorise
else…
lost, stolen, missing, or otherwise potentially compromised tokens, cards and other devices that bear or generate identification code or password information, and to
You expect the bank to have
issue temporary or permanent replacements using suitable, rigorous controls.
suitable checks in place to ensure that the PIN used does correspond
11.300 (d) Use of transaction safeguards to prevent unauthorised use of passwords
to the correct card.
and/or identification codes, and to detect and report in an immediate and urgent manner any attempts at their unauthorised use to the system security unit, and, as
And you would expect the bank to
appropriate, to organisational management.
be able to cancel your card if it got stolen.
11.300 (e) Initial and periodic testing of devices, such as tokens or cards, that bear or generate identification code or password information to ensure that they function properly and have not been altered in an unauthorised manner.
NOTE: An explanation of the terms used in this article can be found in the dictionary segment of this magazine.
About the author Karen Ashworth graduated from Jesus College, Cambridge in 1989.
management of control systems projects for major pharmaceutical
During her time at Cambridge her achievements included a foundation
industry clients including validation to FDA standards and batch control
scholarship as well as the Percival Prize for engineering. She gained
to ISA 88.01. It was here that Karen developed the expertise in control
chartered engineer status in 1994.
system validation which led her to set up Karen Ashworth Consulting in October 2000.
Prior to setting up Karen Ashworth Consulting, Karen had already spent 12 years in the control systems industry and gained deep
As a consultant, Karen has worked on control system projects for over
understanding of the industry from the perspective of both an end user
30 different end users worldwide and has experience using GAMP
and a supplier of control systems.
techniques over the full range of projects from small data monitoring systems through to large DCS systems and embedded control systems
Initially she worked on a control refit for the main nuclear fuel
for complex machines.
reprocessing plant at Sellafield; taking responsibility for meeting handover dates in a £1 million a day shutdown. Karen then moved to run a shift team of 25 on the Sellafield vitrification plant. Here, she was responsible for achieving safety, production, quality, and maintenance
Karen is an active member of the GAMP forum. Within the GAMP
targets in complex plant where radiological conditions require all work
testing SIG she was part of the editorial group for the Good Practice
to be done remotely and where detailed batch records are required to
Guide ‘Testing of GxP Systems’ and one of the speakers for the
guarantee product quality during thousands of years of storage.
Copenhagen launch conference. Karen is currently an active member of the Validation of Process Control Systems group and recently led the
Following a move to Eurotherm in 1994, Karen specialised in the
26 | www.protocolmag.co.za
‘Risk Management’ session at the VCPS conference in Barcelona.
The Consumer Packaged Goods (CPG) industry and solution providers
The Consumer Packaged Goods (CPG) industry and solution providers Jay R. Jeffreys, PE; Director, Wonderware Solution Provider Programmes
value-added resellers (VARs) and Original
linens, and consumer electronics and
Equipment Manufacturers (OEMs), and
appliances.
over 3,000 systems integrators (SIs) worldwide. The Wonderware Solution
However, things may not really be that
While the CPG industry is traditionally
Provider community is an important part
simple. It’s actually more meaningful to
associated with such products as appliances,
of Wonderware’s success. Wonderware
describe the CPG industry as a set of
hardware and electronic devices, it applies
relies on their services and expertise to
consumer behaviours rather than trying
equally well to packaged food and beverage
take it into new opportunities and markets.
to draw boundaries around a specific list
products since most foods that are not
From the 625 VAR/OEMs, approximately
of product names or brands. And the key
shipped in bulk are packaged, one way or
2.5% use Wonderware software to create
behaviour that best describes the CPG
another. And, as we shall see, what is food if
solutions for food-products machinery in the
market is that of replenishment on some
not the very definition of “consumer product”.
Consumer Packaged Goods (CPG) industry.
regular or frequent basis. The items are in
Out of almost exactly 3,000 SI companies
fact consumed, in some sense or another,
currently active in the Wonderware
fairly rapidly. This means that they do have a
Solution Provider Program, more than 46%
shelf life – whether it’s the perishable nature
The Wonderware Solution Provider
devote some portion of their practice to
of a snack food item or the fleeting glamour
Program currently involves some 625
serving customers in the CPG industry.
of a cell phone with features like text or
The CPG industry
63 % of Wonderware
pictures or videos. And of course that can
Certified SIs and 82% of
mean that the value of an entire warehouse
Wonderware’s ArchestrA
inventory, for a whole generation of product
Certified SIs are involved
can go to zero in a hurry!
in the CPG industry. Those behaviours tend to result in a steady But just what do
flow of small recurring expenses (for a
we mean when we
tube of toothpaste, a pack of beverages
talk about the CPG
or even the latest personal electronic
industry? The free
gadget) rather than large infrequent ones
reference section at
like the acquisition of a major capital asset
Hoover’s online (www.
for manufacturing. The problem for our
hoovers.com/free/
manufacturing customers is that those small
ind/dir.xhtml) includes
replenishable items still require the major
a useful directory of
manufacturing assets to produce them. The
industries and the
ability to rapidly reconfigure and re-task
following general
those expensive production machines and
definition:
factories when customer whims change – in other words, agile manufacturing – can make
Consumer Products
the difference between profitability and
Manufacturers -
receivership.
Companies that design, manufacture and/or
Industry comparisons
market apparel, cleaning Figure 1: Companies that are able to maintain high profit margins
products, hand and
The financial research tools at www.etrade.
while growing revenues are more attractive than companies with
power tools, home
com (account membership required)
lower profit margins and slower revenue growth.
furniture, housewares,
offer some useful comparisons between the
January/February 2013 | 27
Figure 2: top five segments by market capitalisation
consumer goods industry and other major
Figure 3: Top five segments by overall profit margin
and demands. Those internal drivers include:
industry sectors. It’s not necessarily the fastest-growing business sector – compared
complicated) new products. • Protecting or increasing profits
to general technology, financial or energy companies – but certainly respectable when
Now, with all those pressures facing our • Reducing costs related to:
it comes to overall sector profit margins. The non-cyclical sub-category of the CPG
• Speed to market with more (and often
Consumer Packaged Goods manufacturing customers, what can we – a world-class
Supply-chain management – Net asset
community of solution providers and a
industry, in fact, ranks well above the
turns on raw materials and finished
world-class software supplier – provide to
Transportation, Basic Materials, and Capital
goods inventories, efficient sourcing
help them face such challenges?
Goods and Services industries.
decisions and reducing scrap or return rates
The consumer cyclical category includes apparel, recreational products, personal electronics, automobiles and
for growth – an eco-vision – that can Manufacturing – Improving operational efficiency and employee productivity
replacement parts such as tires. The non-cyclical category includes beverages,
First of all, we can provide a platform grow and evolve as the fickle customer marketplace changes and the companies adapt. We can offer an architecture built
Information technology – Cost
around re-usable components – not just
tobacco, personal products, office supplies
containment and outsourcing,
software objects, but encapsulated best
and food items.
standardisation and consolidation of
practices and intellectual capital. That
server assets, increasing reusability
means lower project-to-project costs
The Industry Browser information tools at the
and an application infrastructure that
and a common service architecture from
Yahoo! Finance Industry Centre (biz.yahoo.
protects and maximises key databases
production to process.
com/p/3conameu.html) may surprise you in
and information assets
terms of the relative sizes and profitability of some segments in the Consumer Goods categories. For instance, the top five
We can deliver an architecture for • Mergers, acquisitions, breakups and spin-offs
segments by market capitalisation are shown in figure 2. But the largest segments are not necessarily the most profitable, however. The
bang” approach that held back the promise of advanced manufacturing execution
Integration (or disconnection!) of supply-chain linkages
top five segments by overall profit margin are shown in figure 3.
incremental investment, avoiding the “big
systems (MES) for so long, for example. And we can help them realise the full potential of their significant investments in
Operational complexity and start-up
enterprise resource planning (ERP) systems
costs – dealing with dissimilar best-
by delivering real-time information from the
Somewhat surprisingly, the largest
practice philosophies, variations in
shop floor to improve the strategic decisions
segment by market capitalisation – Auto
processes, applications and technology
that drive production, performance and
Manufacturers – is one of the least profitable
and training to improve and align vital
profitability.
at just 1.8%. The sizable and highly visible
human resources.
– but keenly competitive – Electronic Equipment category is squeezed down to
External forces and demands that our CPG
just 2.5% overall net margin.
customers face include:
What CPG companies need from solution providers
• Meeting changing customer needs and
For our Consumer Packaged Goods
• Preserving brand integrity through
requirements
customers to succeed, they must deal with
product quality and safety as well as
a number of internal and external pressures
regulatory requirements
28 | www.protocolmag.co.za
Wonderware solutions at work in the South African Food & Beverage industry
January/February 2013 | 29
Coca-Cola Swaziland uses Wonderware solutions to optimise energy usage and reduce costs
“... after the Swaziland Electricity Company validated the results and achieved a discrepancy of less than 1%, the business completely bought into the system.” Paul Kotze, senior software engineer, Systems Anywhere Coastal
Goals
• Increase visibility into production
• Empowering energy users to take control
processes • Reduce energy consumption by 20% in one year.
Challenges
Solutions and Products • Corporate Energy Management
• Enlist the active cooperation of management and staff
30 | www.protocolmag.co.za
• Taking a holistic view of energy cost rather than usage
application
Coca-Cola Swaziland uses Wonderware solutions to optimise energy usage and reduce costs
“This just goes to show that energy cost need not be dependent on energy usage.” Wiseman Magagula, automation engineer, Coca-Cola Swaziland
is concerned, only the incoming supply is
• Creating contingent strategies for
usually measured and these data disappear
emergent future scenarios – This
into storage rarely to be seen again.
involves rehearsing specific aspects of the
Monitoring systems tend to only provide
future, including substantial and sustained
historical analysis tools and don’t offer any
swings in energy price and supply, severe
control functions. But electricity isn’t the only
weather events and penalties or incentives
cost – what about, air, steam, water, gas, etc.
around energy use and greenhouse
And, most important, where does one start?
gas emissions. It also means actively managing exposure to risks, and readying
It starts right here
plans to take full advantage of what the future brings and which “road ahead” is
• System Platform
Before diving in and installing technology,
emerging.
it’s important to understand that energy • Information Server
management involves a culture change in
• Taking personal action - Corporate
the company and a different way of looking
leaders can take a number of “to-do”
at the broader picture. Conco was fortunate
actions today for tomorrow. All can be
in accepting and understanding the
taken individually, in companies, on
• Historian
following long before the project started:
corporate boards and across industry.
• Historian Client
• Mastering the fundamentals – It’s vital to
• InTouch
• SmartGlance
– Whereas ISO 14001:2004 specifies
executive leadership, goal reviews etc.
requirements for an environmental
and then to:
management system, ISO 50001:2011
Results
specifies requirements for establishing, Track energy performance for all
• Visibility into energy usage and cost per
operations
plant and subsection
cost control protocols
implementing, maintaining and improving an energy management system, whose purpose is to enable an organisation to
Extend energy accountability to the • Implementation of smarter energy usage/
• Evolving from ISO14001 to ISO50001
instil an energy efficiency culture through
follow a systematic approach in achieving
line/shift/product level rather than in
continual improvement of energy
the catch-all “overheads” basket
performance, including energy efficiency, energy use and consumption.
• Tighter grip on corporate departmental budgets and targets • Ability to control high energy operations to take place during low-cost periods • Staff awareness of their immediate impact on energy cost
Monitor the performance of assets and technology choices Measure the effectiveness of the facility’s location Balance more assured returns of energy
• Reduce energy consumption by 20% in one year. • Formulate a series of strategic initiatives
project investments against lower initial
that would enlist the commitment of
returns in the long term
corporate management and create
Recognising the need for an effective energy management strategy, Coca-Cola Swaziland
Corporate objectives
employee awareness while helping meet • Taking a longer and broader view about
departmental targets and investing in
(Conco Ltd.) decided to investigate further
strategic decisions - Energy can be seen
tools that assist with energy management.
and what they found surprised everyone.
as a lever for positive growth and change
One of the most important initiatives
within the business, not simply a cost. It’s
was to form a focus group to drive down
While there are many definitions for energy
possible to make the most of the strategic
energy costs. “We shifted out priority to
management, they mostly focus on two
value of energy by thinking in terms
reducing energy cost rather than usage,”
aspects; maximising profits or minimising
of “Embedded Energy” and “Energy
says Wiseman Magagula, automation
costs through lower energy consumption.
Productivity.”
engineer at Coca-Cola Swaziland. “After all, if a process requires 500kWh there is
However, it’s rare to see actual practical examples of how one actually goes about
• Creating awareness about the way
not a lot that can be done about it apart
achieving these desirable goals and that’s
energy is managed, procured and
from shaving off say 5% energy usage, but
because the solution is a great deal more
used – It’s important to be innovative and
if the process is shifted to non-peak hours,
complex than switching off something when
aggressive in pursuing and publicising
costs can be reduced significantly. This
it’s not in use.
new product and service offerings
just goes to show that energy cost need
based on new energy technologies and
not be dependent on energy usage.”
There are no best practice guides for specific industries and, insofar as electricity
suppliers. • Formulate a series of tactical initiatives
January/February 2013 | 31
Figure 1: System topology
that would optimise energy usage on the shop floor. These would include charging forklifts and running cold rooms only during off-peak periods, running the dust extractors only during working hours and basing lights and air-conditioning on someone’s presence. • Increase visibility into the factory and other processes. • Enable limited, non-intrusive control functions for certain processes.
Implementation Coca-Cola Swaziland selected system integrator Systems Anywhere Coastal for the implementation of the energy management project who, in turn, selected a range of software solutions from the Invensys Wonderware stable. These solutions included the System Platform based on ArchestrA technology, Historian and
Figure 2: Two sections of the InTouch screen showing the plant overview (top) with demand
Client, InTouch SCADA / HMI, Information
displayed at the top right corner and plant areas (bottom) with access tabs to other areas as well
Server, SmartGlance for mobile reporting
as water steam and air status.
32 | www.protocolmag.co.za
Coca-Cola Swaziland uses Wonderware solutions to optimise energy usage and reduce costs
and Wonderware’s Corporate Energy
reporting facility. This real-time information
Management (CEM) package.
availability allows for the study of causeand-effect scenarios which were previously
“We were pioneering the CEM
invisible to everyone.
implementation with version 1.2 of the software using the water, steam, air and
Benefits
power modules,” says Paul Kotze, senior software engineer at Systems Anywhere Coastal. “The Wonderware CEM fits into
• Visibility into energy usage and cost per plant and subsection
the System Platform environment and is an “off the shelf” product that has multiple metering options. It enables real-time
• Implementation of smarter energy usage/ cost control protocols
visibility of usage and cost and makes data available to any delivery vehicle.”
• Tighter grip on corporate departmental budgets and targets
When the first results were made available they came as a shock – notably, this was the
• Ability to control high energy operations
first time that measurements included data
to take place during low-cost periods
from sources other than the mains supply. “The company had its own ideas about usage and cost and did not accept these
• Business/people awareness of their immediate impact on energy cost
initial figures,” says Kotze. “But after the Swaziland Electricity Company validated the
Conclusion
results and achieved a discrepancy of less than 1%, the business completely bought
Passive monitoring of energy usage is never
into the system.”
going to achieve the desired results – energy
Figure 3: SmartGlance in action
needs to be controlled and the only way
degree, it can be accurately allocated to
The InTouch system keeps operators
to do that is to incorporate it into the
the manufacturing costs of individual items
informed on the exact real-time status of
manufacturing process. After all, energy
if necessary and that level of knowledge
the plant and its various departments while
can be regarded as a raw material, just
empowers people to make the right
management is kept informed on their
like any other, which is transformed by the
decisions and take control rather than being
smart phones via the SmartGlance mobile
process into added-value goods. To that
the victims of soaring costs.
January/February 2013 | 33
Orley Foods’ Oompa-Loompas maintain world-class standards with help from Wonderware “We found that the Wonderware solution was best suited as it had a proven track record in food and beverage (we spoke to their customers) and was used in many local and international plants involved with food production.” Henk de Villiers, Operations Manager, Orley Foods.
34 | www.protocolmag.co.za
Orley Foods’ Oompa-Loompas maintain world-class standards with help from Wonderware
Goals
effective decision support.
• Greatly improved product tracking and
Background
traceability Orley Foods is fully HACCP (Hazard • Seamless and transparent integration
Analysis and Critical Control Point – a FDA
of manufacturing and business systems
programme) compliant and the company’s
throughout the company
quality management system conforms to ISO9001. Compliance is audited regularly
Challenges
About Orley Foods
not only by Orley but also by the South African Bureau of Standards (SABS) and it is
Over the past 40 years, this proudly family-
within this context of mandatory regulatory
owned, Cape-Town-based business has
requirements and to be able to provide
compliance that a material tracking solution
produced a comprehensive range of quality
immediate auditable reports on
was sought.
ingredients for the South African food industry.
The Orley Foods plant is made up of four
The business has evolved into two distinct
main areas (figure 1). From Raw Material
streams, one involving the ongoing innovation,
Receiving to Finished Goods, tracking and
manufacture and distribution of Orley
• Solution to comply with regulatory
traceability of product
Solutions and Products • System Platform • InTouch SCADA/HMI • Information Server
traceability is key to regulatory compliance.
Products and the other the highly collaborative,
This is especially true of the chocolate
development-driven Orley Solutions service.
manufacturing facility which manufactures chocolate in bulk according to the
Orley Solutions is a dynamic and extremely
specifications of downstream chocolate
responsive service through which the
confectionery manufacturers whose products
company’s New Product Development division
• Application Server
are found on the retail market.
researches and develops food solutions for
• Historian
Project objectives
Results
“Before this project, we were working with
South Africa’s leading brand owners. Orley Products consist of a large range of
• Batch size consistency • Raw material allocations tracked • Improved process control tracking • Significant savings in fat usage
successful packaged goods for wholesale
a failing system while our multinational
distribution to the catering, confectionery
customers demanded more traceability
and baking trade, as well as limited retail
information,” says Henk de Villiers,
distribution to consumers.
Operations Manager, Orley Foods. “These large companies want certificates of analysis
The company’s wide range of chocolate
and conformity and can demand a full
products (over 100 different formulations)
traceability report within two hours. They can
include couverture chocolate made to
also do flash audits on site without warning
international CODEX standards.
and ask any questions they wish about any • Standardisation of batch processing times
batch. So we looked for a solution that would provide seamless and transparent
• Minimised batch/formulation corrections
integration of manufacturing and business systems throughout the company.”
Needing to know the quantities of the costly materials that make up a batch
The manufacturing system would have to be
of raw chocolate, Orley Foods selected
capable of as yet undefined expandability,
Wonderware technology and the capabilities
ease of integration and the ability to provide
it offers to allow for accurate consumption
data in context for the benefit of more
and production monitoring per batch
informed decision-making. All the important,
and to never again have to wonder about
relevant and contextual information was to
their constituents. The merging of an
be published to a portal for easy access by
effective production solution with their
personnel who could make best use of it
newly-implemented ERP system through
and it was imperative that the system have
Wonderware MES functionality gives Orley
the ability to trend and trace process issues
full visibility on detailed manufacturing
in order to speed up trouble shooting while
information per works order and more
conforming with regulatory requirements.
January/February 2013 | 35
Figure 1: Structure of Orley Foods, its chocolate manufacturing process, areas addressed by this project and ArchestrA model classification of functional groups
Project Requirements
upgrade to the latest technologies that would address its Network and Windows
In order to achieve its objectives, Orley
/ SQL Server environment as well as its
Foods would have to implement some
SCADA and PLC system needs.
far-reaching initiatives that included the re-engineering of its process control and
About chocolate manufacturing Chocolate is an emulsion based on fat,
• Ingredient management of recipes - As
sugar and sometimes, milk products.
information delivery infrastructure. Some of
Orley Foods has over a hundred different
It starts with mixing cocoa butter (one
the considerations included:
recipes for liquid chocolate including
of the fats of choice for chocolate
• Traceability of fat usage and additions against work orders - In the chocolate
different colours and fat combinations, the
manufacturers because of its unique
company needed a system that would be
“melt-in-the-mouth” characteristic) and
able to handle this variation seamlessly.
sugar products.
manufacturing process, the different fats used are incompatible with one another
• Introduction of expandable reporting
Next comes grinding (done in conches)
so it is vital to ensure traceability of the fat
infrastructure - With the new business
which coats the sugars ground to a
used at all times.
environment and the need for key
specific size (35-40 microns) with the
• Monitoring / logging of process
information, Orley Foods developed KPIs
fat at precisely controlled pressure and
to which the manufacturing system had
temperature (since proteins are present).
parameters - The chosen system would
to respond so as to deliver reports from a
be used to monitor and track process
central source.
parameters in the plant and for each recipe batch.
Then, depending on the type of chocolate (Orley has over 100 different
Solution selection
formulations), cocoa mass or powder, emulsifiers (to stabilise the chocolate) or
• ERP integration with Syspro – Orley
While realising that there were a number
powdered milk is added to the mixture.
Foods needed one version of the truth for
of potential technologies to address their
the Bill of Materials in order to minimise
needs, Orley Foods decided to step things
formulation failures and so needed this
up a notch and look for prospective solution
process complicated by the fact that fats
information to be fed directly from Syspro
providers who could use the technologies
are incompatible with one another and
to the manufacturing system.
they thought most appropriate to the task
that grinding sugar produces undesired
at hand.
water which must then be evaporated
technologies - As the company’s system
“We started the project by defining our
and ruining a time-consuming and
could no longer cope, it needed to
needs and then drew up a tender process
expensive process.
• Overall system upgraded to latest
36 | www.protocolmag.co.za
This must all be done in a water-free
without overheating the final mixture
Orley Foods’ Oompa-Loompas maintain world-class standards with help from Wonderware
the raw materials to be used as well as the tank and equipment allocation / scheduling. Operators then use the dual-screen SCADA system (InTouch) to view the state of all the conches in the system and the works orders they are executing. “We use the SQL data grid from Wonderware to show the production plan which displays which work orders are queued or being processed and a simple click on the column headers will sort the display according to the chosen criteria,” explains la Grange. “Operators can modify the execution time of work orders or switch machines for a specific work order if authorised by production supervisors. This is useful for bypassing breakdowns or maintenance problems.” The Wonderware Information Server reports tabulate all aspects of work order Figure 2: InTouch screen showing the fat storage and transfer process
status and production information such as temperature vs. pressure charts, process variations, timings and operator interactions
Solution architecture
for traceability purposes.
that we had a well-known system but it was
Wonderware’s System Platform, based on
Realised benefits
equally important that we had a Cape-
ArchestrA technology, was used to develop
Town-based system integrator who needed
a model of the plant. “Although the project
to have experience in the development
only addressed certain aspects of the
this could be a hit-and-miss- affair with
of PLC, SCADA and databases, especially
chocolate production facility, we designed
corrections having to be made for
SQL. It was also a prerequisite that the SI
the model to cater for the entire plant,” says
marginal or failed recipes. Today, that’s all
should have prior experience in a food
Stefan la Grange of AMR Automations. “
in the past.
allowing various vendors and systems to be evaluated,” says de Villiers. “It was vital
• Batch size consistency – Previously,
and beverage environment and was well • Raw material allocations tracked - What
acquainted with the complexities of working
An important part of the project was
in a HACCP environment. We chose AMR
the PLC upgrade where the previous
fat goes where? Previously this was done
Automations because they met all these
PLC was replaced with an Allen-Bradley
manually and prone to operator error.
criteria.”
CompactLogix unit and Beckhoff Ethernet TCP/ IP remote I/O units which AMR
• Better process control tracking –
Several prominent technology suppliers
found to be a good and rapid solution for
Alarming (e.g. motor trips) are now
were considered but eventually Orley Foods
upgrading installations where PLCs could be
available at the SCADA level as is trouble-
selected Wonderware. “We found that the
kept out of harm’s way.
shooting information (temperatures,
Wonderware solution was best suited as
pressures, grinding times, etc.) as well as
it had a proven track record in food and
“We design PLC programmes to run
beverage (we spoke to their customers) and
autonomously with no interference from the
was used in many local and international
SCADA system,” says la Grange. “In this
plants involved with food production,” says
case, the PLC runs the recipe and handles
chocolate industry, Cocoa Butter is called
de Villiers. “We were also demonstrated
the fat transfer route allocation. Obviously,
Liquid Gold because of its high cost.
examples of integration between
processes for which the necessary raw
Wonderware production and control systems
materials (e.g. fat) are not available are not
with our chosen ERP system, Syspro. Lastly,
started.”
there are numerous system integrators
operator involvement. • Significant savings in fat usage - In the
• Standardisation of batch processing times – Allows for critical evaluation of plant performance reduced consumption
and solution providers with an extensive
Orley Food’s ERP system, Syspro, places the
knowledge of the Wonderware suite of
work orders into a “holding” or intermediary
or resources, especially electrical power.
solutions which meant that we wouldn’t be
Wonderware Historian production (MES)
stuck in the case of an emergency.”
database from where they are picked up by
- Savings in having to add raw materials to
the SCADA system. The works orders specify
batches which could result in batches that
• Minimised batch/formulation corrections
January/February 2013 | 37
Figure 3: Orley Foods system topology for phases 1 and 2 of the project
were larger than the customer ordered and were therefore wasted.
Conclusion
About the health benefits of chocolate And now for the really good news: Scientists agree that, not only is eating chocolate a powerful
Phase 2 of this project will capitalise on the
protector against heart disease, but to extract the maximum benefit for our arteries, we should
gains already made and extend functionality
drink a sip of red wine with each Fresh Coffee Creme or Hazelnut Truffle that passes our lips.
across the entire plant while closing the loop with feedback directly into the Syspro
Like red wine, chocolate contains chemicals known as phenols, which prevent the oxidation of
ERP system. Orley Foods has shown itself
low-density lipoproteins (“good” blood fats) into a more dangerous form which clogs up the
to be a prime example of adaptability in
coronary arteries.
a more demanding world with a globallycompetitive marketplace. There’s no
One scientist is quoted as saying that “the pleasant pairing of red wine and dark chocolate
doubt that the integration of information
could have synergistic advantages beyond their complementary tastes.”
technology at the business and production levels is helping the company deal with the mechanics of sustained profitability. But it’s doing much more than that. It’s allowing Orley Foods to focus on its original mission of delighting all of us.
38 | www.protocolmag.co.za
Can it get any better than this?
TSB’s Komati Mill consolidates SCADA and industrial IT with help from Wonderware
TSB’s Komati Mill consolidates SCADA and industrial IT with help from Wonderware
“The ability of the System Platform to integrate and consolidate data across the different systems and deliver the data to managers’ desktops in a presentable format enables us to be pro-active, rather than reactive” Pieter van Tonder, Instrumentation Engineer, TSB Komati Mill
Goals
• Measuring the throughput of continuous
Solutions and Products
systems, as well as downtime • Migrate from the old legacy DCS control to PLC and SCADA control
• System Platform
Challenges • InTouch
• Implementing an MES solution that would track plant performance and events
* Integrate new and legacy DCS, LIMS and PLC systems in order to make accurate
• Historian
MES reports for throughput and downtime • Implementing standards • Measuring plant performance and
measurement
• Information Server • MES Performance
equipment availability
January/February 2013 | 39
Results
predicting final volumes. The downtime tracking would focus on identifying
• Real time measurement and reporting of plant availability
repeat failures, as well as areas of concern which would require the assistance of the engineering team.
• Real-time measurement and reporting of low throughput to determine lost
The new system would also need to provide
production
for device-layer booking, unit-, and arealevel booking, which would automatically
About TSB (Pty) Ltd
• Faster reaction time to LIMS quality figures
link to the reporting layer in order to provide detailed, as well as summary reports.
Tsb Sugar was founded in 1965 and has grown to become one of South Africa’s leading producers
• Reduction in callouts on standby
refreshed its image by adopting a new brand identity, and changing its name to TSB as part of
This would mean having to integrate the new Quantum PLCs, legacy Provox and
of refined and raw sugar. The company recently • Availability of downtime data, downtime information and downtime management.
DeltaV Distributed Control Systems, as well as the LIMS database to provide a unified way of tracking device utilisation.
its drive to reposition itself for future growth. • Fully-integrated system
Other requirements included implementing
TSB sugar is marketed nationally as Selati and is exported through the South African Sugar
• Company standards • Improved decision making • Increased plant availability
providing important desktop information to Management and allowing maintenance and
from strength to strength, opening a second mill in 1994 near Komatipoort, a small town
measuring plant performance and equipment availability (OEE) in real time,
TSB’s first sugar mill in Malalane was commissioned in 1967 and the company grew
standards that would be used throughout TSB, integrating with the SAP ERP systems,
Association (SASA).
• Potential problems highlighted
support personnel remote access.
• Improved accuracy and less paperwork
Solution selection
bordering Mozambique In 2009 TSB acquired the Pongola Sugar Mill in KwaZulu Natal. The Malalane, Komati and Pongola mills together produce over 630 000 tonnes of brown sugar
As with many successful companies, TSB’s
“We chose Control Systems Integration as
and 460 000 tonnes of white sugar per annum - a
process control and industrial information
system integrator for this project because it’s
whopping 31% of South Africa’s annual sugar
assets were acquired as and when was
a well-established firm with good references
production! TSB also has a 27.42% stake in the
necessary, and on the basis of what was
indicating that they would ‘walk the extra
Royal Swaziland Sugar Corporation (RSSC).
considered the best solution at the time.
mile’ to arrive at a good solution,” says
However, when Komati Mill, one of TSB’s
Pieter van Tonder, Instrumentation Engineer
TSB employs approximately 4700 people
divisions began operations in 1994, no
at Komati Mill. “Being certified for the
and provides farming support to over 1 400
one could have predicted the mill’s needs
ArchestrA System Platform, they also have
commercial and small-scale farmers on 47 000
18 years into the future. Therefore, in
an excellent knowledge of Wonderware’s
hectares of irrigated land. The Malalane and
2012, Komati Mill decided it was time to
range of products and their application in
Komati mills are situated in the Lowveld region
modernise and consolidate its industrial
the production environment.”
of Mpumalanga and the Pongola mill in northern
automation and information assets.
KwaZulu-Natal.
About Komati Mill
Wonderware’s solutions were selected within
Project goals
keeping of the standard adopted at the Malalane Mill. TSB also saw Wonderware
As part of an ambitious upgrade
as having the best integrated and complete
Komati Mill, situated 26 km from Komatipoort,
programme, Komati Mill decided to migrate
SCADA solution available. “We felt sure that
was completed in 1994 with new generation
from the old legacy DCS control to PLC
the System Platform and its added modules
equipment. The original factory was designed
and SCADA control while at the same time
would be able to cope with our varied and
to process 1.15 million tonnes of cane with
implementing an MES solution that would
disparate data sources and integration
provision made to double this capacity.
track plant performance and events. This
needs,” adds van Tonder. “The results show
Expansion projects have brought the mill to its
would be used to measure the throughput
that we were right.”
present crushing capacity of 2.6 million tonnes
of continuous systems, as well as downtime.
of cane over a 38 week period (at an average
Plus it would evaluate reasons for any
Apart from the System Platform, the
rate of 500 tonnes per hour) to produce 320 000
stoppages.
solutions used in the implementation
tonnes of raw sugar. This raw sugar is dispatched
process included InTouch (SCADA / HMI),
to the Malalane Mill for refining and then on to
It was intended that the resulting reports
Wonderware Historian, Historian Client
Maputo harbour in Mozambique for export.
would assist with optimising sugar cane
(trending and analysis tool), Wonderware
throughput, reducing downtime and
Information Server, Wonderware MES
Today, Komati Mill is recognised as the most modern and sophisticated sugar mill in Southern Africa. 40 | www.protocolmag.co.za
TSB’s Komati Mill consolidates SCADA and industrial IT with help from Wonderware
Figure 1: System data flow diagram
Performance (OEE) and AutoSave change
for customised Wonderware Information
While the Wonderware MES (Performance)
management software from MDT Software.
Server reports as this would make it easier
solution measures the OEE parameters of
In addition, TOP Server OPC solution from
for Komati Mill to assume ownership of the
plant performance and availability in real
Software Toolbox was used to connect the
system on completion of the project.
time, other key process parameters such as throughput, low throughput and the LIMS
system to the new PLCs.
Implementation
A transactional database was created in
quality figures are made readily available to
order to integrate information from the
operators through three dual-screen InTouch
Wonderware Historian and the LIMS data.
stations
The project was completed in phases, with
“This database was also used to consolidate
the implementation of the first phase taking
data and to make it easy to configure
“We decided on using System Platform
place from January 2011 to April 2011.
custom reports on Wonderware Information
graphics whose feature of easy deployment
A 3-month off-crop season was sufficient
Server,” says Rabé. “The Wonderware MES
across multiple objects was found to
time to remove the old Provox DCS and
(Performance) throughput graphics were
replace it with the new, integrated system
used as a base and were further enhanced to
on Extraction Line 2. “All the other systems
meet Komati Mill’s specific requirements.”
remained the same and the System Platform was built on top of the existing systems
The Wonderware Information Server is now
to facilitate integration,” says Samantha
the single point of consolidated information
Rabé, Systems Engineer at Control Systems
for all current and legacy information.
Integration.
Its graphics are also embedded into PowerPoint presentations to display key
The first stage in the development of the
performance indicators and the real-time
system was the creation of standards in
throughput of the plant on large screens.
order to optimise the best implementation
This is helping operators to take action
of the System Platform and PLC for the
and resolve poor performance issues
plant. Microsoft Reporting Services was used
immediately.
“Now we can focus on the root cause areas as identified by the plant availability and low throughput real-time feedback from the PLC into MES Performance” Philip Pienaar, Production Engineer, TSB Komati Mill
January/February 2013 | 41
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January/February 2013 | 43
Figure 2: InTouch screen showing the cane preparation yard process as well cane throughput and trends
be most useful,” says Rabé. “The OEE,
breakdowns and the reasons for their
system calculations to easily provide relevant
LIMS, Provox and DeltaV data have been
occurrence. Historian Client’s trending
feedback on stoppages and low throughput
integrated into the System Platform to show
is used extensively on Wonderware
to managers thereby enabling them to make
KPIs on the InTouch dual-screen displays.”
Information Server by managers to track
more informed decisions.
throughput and performance. System Platform objects were used to import
“We are able to manage low throughput
daily CSV files exported from the LIMS
Microsoft Reporting Services was used to
because, for the first time, we can measure it
database, and a connection was made to
generate reports that filter events and alarms
accurately. Real-time feedback to record the
the database via SQLQuery objects to track
according to Komati Mill’s requirements.
plant LTA and OTE and have it available on
live LIMS data. Provox and DeltaV OPC
Alarms are prioritised according to the type
the managers’ desktops was unthinkable a
links were used to interface them to the
of failures on each device.
decade ago,” says van Tonder.
objects were created to read data directly
With regard to TSB’s ERP system, the
MDT Software’s AutoSave was used to
from these distributed control systems.
work breakdown structures from SAP were
track changes to PLC code and to back-up
used for the Wonderware Performance
versions automatically. This allows for
Historian Client (previously ActiveFactory)
breakdown reason. This made it easy to
instantly reverting back to a previous known
was installed to track instances of
consolidate with the business system. A
working version in case of problems.
Wonderware System Platform. Furthermore,
future plan is to incorporate the production
“Seamless integration of Wonderware MES into ArchestrA and the automation layer translates into accurate OEE information that enables our customer to better analyse and manage plant performance.” Dries van Schalkwyk, Director, Control Systems Integration
44 | www.protocolmag.co.za
information into the bigger SAP Business
“On a project of this magnitude and
Warehouse platform.
complexity, a partnership between Wonderware SA, the system integrator
Previously, Lost Time Availability (1) (LTA) and
and the end user is essential in order to
stoppages were recorded on SAP. This was
deliver an optimum solution,” says Rabé.
a very lengthy exercise and it was open to
“Involvement from all parties is required
faults. It was also expensive due to all users
throughout a project that is complex and
requiring SAP licences. A decision was taken
new.”
to use MES Performance which records LTA and Overall Time Efficiency (OTE) (2) on the
“From my point of view, the most appealing
extraction process to record all stoppages
aspect of this project was to give managers
and low throughput events. The entire
the power to control and view critical
factory’s LTA and OTE are now routed to
and live production information such as
the extraction plant’s MES Performance
throughput and stoppages conveniently
measurement. . Operators can now use
at their own offices or at home. This
TSB’s Komati Mill consolidates SCADA and industrial IT with help from Wonderware
“We are still seeing the benefits of the Wonderware Performance software, even months after implementation. With Wonderware Information Server and Wonderware Performance, LIVE and useful plant information representing real plant performance and efficiencies is readily accessible and easily understood by all levels within the organisation.” Samantha Rabé, Systems Engineer, Control Systems Integration
before and with measurement came an
through low throughput measurements
increase in plant availability and reliability • Improved accuracy and less paperwork – • Faster reaction time to LIMS quality
the automatic booking of devices causing
figures which were out of spec. Previously,
stoppages in units/areas as well as the
these figures were only available on a
process interlocks or safety interlocks
“next-day” basis
being automatically recorded means less paperwork for operators, as well as a
• Reduction in callouts on standby
100% accurate system which records the exact times of stoppages and the exact
• Downtime data, downtime information and downtime management. • Fully-integrated system - Wonderware
resulting reason for the interlock device that caused the stoppage at the plant.
Conclusion
System Platform and Wonderware information server have provided a single
Once again, the Wonderware System
point of data/information/reporting from
Platform has shown that it is the link
various sources (Provox DCS, DeltaV DCS,
between the past, present and future of
PLC, LIMS. etc.)
industrial automation and IT. By providing a single, unifying hub for disparate solutions
• Standards for sugar production were
and technologies, it safeguards past and
developed and are ready to be deployed
present investments and optimises their
across all TSB plants.
contribution to current requirements while
has resulted in better control of plant
making provision for future (and largely
performance,” concludes van Tonder.
Operational benefits
unknown) needs.
Business benefits
• Improved decision making by
(1) LTA = Lost time Availability -
• Real time measurement and reporting of
management based on readily-available
Operational and engineering downtime
information
hours / hours available (basically the inverse
plant availability
of engineering and operational hours • Increase in plant availability due to remote
• Real-time measurement and reporting
(2) OTE = Overall Time efficiency = Total
of low throughput to determine lost production. This was never measured
available)
access • Potential lurking problems highlighted
hours – total stops / total hours
The control room at TSB’s Komati mill
January/February 2013 | 45
Woodlands Dairy chooses Wonderware for its Dairy Production Monitoring and Control System “I think that Wonderware technology and products have helped increase our level of knowledge and control to the degree that we can now think about improving our processes rather than just keeping up with them.” Jan Barnard, Process Engineer, Woodlands Dairy
Goals
• Ease of system maintenance
• Compliance with ISO22000
• Making provision for future expansion.
• Single platform to integrate all the
Challenges
Solutions and Products • System Platform
disparate plants on site
• InTouch • No interruptions to production
• Preserving past investments in expensive assets and legacy systems
• Historian • Upgrades to be done during weekly shutdowns
• System redundancy
46 | www.protocolmag.co.za
• ActiveFactory
Woodlands Dairy chooses Wonderware for its Dairy Production Monitoring and Control System
About Woodlands Dairy Woodlands Dairy is situated in Humansdorp, right in the heart of the Eastern Cape’s Dairy region and along the South African Garden Route. The company, which has a staff complement of more than 400, prides itself in its innovative thinking, speedy development of new products and excellent customer service. The dairy was originally conceived in 1995 as a packaging plant for the milk produced on Woodlands Farm, owned by the Gutsche family.
Figure 1: InTouch view of the Pasteurised silo system
Today Woodlands Dairy is one of the largest
Results • Achieved compliance with ISO22000
monitoring and control system for the
manufacturers of Ultra Heat Treatment (UHT)
powder plant but that would also prompt
milk in South Africa, marketed under the FIRST
the company to consider how this expansion
CHOICE ® brand name. An additional line, the
could be integrated with the rest of the site.
Extended Shelf Life (ESL) chilled dairy products,
“This made us take a step back and consider
products.
• Reduced engineering cost • Improved quality control • Operator confidence • Improved troubleshooting capabilities
have a longer life than standard pasteurised what we really needed for the company as a whole,” says Jan Barnard, Process Engineer,
Other products include milk powder, cheese
Woodlands Dairy. “Up until now, all we
and butter and the company is also a major
had on site were OEM installations and an
supplier of milk powder to the chocolate
old InTouch system but no PLC or SCADA
industry.
standards.” • Accurate reporting
Woodlands Dairy is also a co-packer for Spar,
Project requirements
Woolworths and Nestlé.
• Standards in place for future use Top of the agenda was a single platform In these complex times, the supply of
that could integrate all the disparate plants
candidate to handle these diverse
primary foodstuffs such as dairy products is
on site while preserving past investments in
requirements, Wonderware’s System
subject to increasingly close scrutiny. To stay
expensive assets and legacy systems while
Platform consisting of the Aplication Server,
in business profitably in the dairy industry
making provision for future expansion.
InTouch (HMI / SCADA), Historian and
means the consistent provision of quality
ActiveFactory trending and reporting tool.
products and unswerving compliance with
“We needed a centralsied environment for
ISO standards. Humansdorp’s Woodlands
process data logging which would allow us
“We chose Wonderware for a number of
Dairy is well up to the challenge.
to analyse data in real-time and produce
reasons,” says Barnard, “not the least of
reports,” says Barnard. “We also needed
which was my previous experience with their
flexible security facilities that would allow
products.”
Background
operator access only to designated areas Woodlands Dairy bought a second-hand
of the plant. Finally, we needed system
powder plant from Denmark but whose
redundancy to provide for uninterrupted
control system was outdated and not
operation as well as the ability to develop
suitable for the modifications required to
and deploy solutions from a central point for
cope with Woodlands Dairy’s variety of
adapt the process to Woodlands Dairy’s
ease of maintenance.”
PLCs
Other reasons included: • Universal data connectivity - this would
specifications. This started a chain of events that would not only require a production
The stage was set for the best solution
• Object orientated technology – not only
January/February 2013 | 47
About UHT dairy products Ultra Heat Treatment is a process where the milk is heated to approximately 138ºC and held there for about four seconds. Aseptic Filling is a procedure consisting of sterilisation of the packaging material or container, filling it with a commercially sterile product in a sterile environment and producing containers which are sealed against recontamination. This technique allows products, formerly considered perishable, to be stored and distributed without refrigeration for prolonged periods ranging from 6 to 9 months depending
Figure 2: System topology
on the product. was this software more maintainable
System Platform checklist as a guideline
than its alternative but it also promoted
for our standards design,” says Barnard.
In addition, the aseptic package ensures a
standardisation
“This helped us progress to our naming
contamination-free product with virtually no
• Distributed system • Easy to create reports and retrieve historical data • Full redundancy
convention and plant model design as
loss of quality, taste or nutritional values. The
well SCADA standards such as navigation,
aseptic process can be used to package a wide
graphics and control modules. We used
range of products.
ArchestrA standard templates throughout which would help later with maintenance and reduced engineering costs. We also
the company’s specifications and ISO
implemented PLC standards with regard to
requirements is released
the ControLogix and SLC500 PLCs.” • Operator confidence – Now that they
• Scalability • The level of support available in South Africa
Implementation
So what’s next? According to Barnard,
have visibility into the entire plant,
they’re looking at making information such
operators are increasingly confident about
as KPIs more visible and widespread using
the status of processes and their effect
Wonderware’s Information Server while the
on them
Performance Module will prove useful on the sterilisers and Pasteurisers as well as the
The total implementation took about six
stand-alone TetraPak filler line.
months, half of which was spent on the new powder plant which was commissioned first.
• Improved troubleshooting capabilities - Accurate historical data results in equally accurate cause-and-effect scenarios for
Benefits
diagnostic purposes
While the Powder Plant was a greenfields project, the processing plant upgrade and
• Reduced engineering cost – This is a
• Accurate reporting – This includes real-
expansion was done live, during weekly
direct result of rolling out the standards
time reports on production performance
shutdowns and the standards developed for
that were defined at the start of the
and milk loss.
the powder plant were rolled out for these
project • Standards in place for future use –
projects. • Compliance with ISO22000 – An
System integrators who may have to work
Other process areas were also upgraded
important achievement with regard to
on the system in future have documented
and these included a new Clean in Place
local and international recognition as
reference regarding the company’s
(CIP) Station, a new cream pasteuriser/butter
applicable to food safety (since food
standards and requirements. This
plant, an upgrade to the milk pasteuriser,
safety hazards can occur at any stage in
improves understanding and helps make
new pasteurised milk silo and milk lines,
the food chain it is essential that adequate
sure everyone is on the same page.
new pasteurised cream silo and a new milk
control be in place)
reception area with its own CIP station. • Improved quality control – The silo milk
Standards design
release system is interlocked with the laboratory InTouch system and CIP reports
“Starting from scratch, we used the
48 | www.protocolmag.co.za
which means that only product that meets
SAB manages the big picture with help from Wonderware Intelligence
SAB manages the big picture with help from Wonderware Intelligence
“After the testing and development phase, we were able to roll out the project to the rest of the sites and commission within 2 months! This is a reflection on the power of the underlying ArchestrA technology. Then there’s the matter of cost. The time saved with the project roll-out had a direct impact on the cost and we were able to finish within budget.” Hein du Toit, Business Analyst, SAB Ltd.
Goals
interpreted and viewed from a divisional
• Wonderware Historian
level at head office. • Provide a centralised system for the early detection and warning of mission-critical
Challenges
problems
Results • Rapid deployment
• Collating data from a wide and disparate • Implement a centralised data repository for analysis purposes • Identify key KPIs for PLCs, Wonderware Historian, System
number of sources from seven breweries nation-wide. • Current historian performance to remain unaffected
• Risk reduction. Early detection of issues that impact system performance. • Cross platform comparison and analysis facilitates decision making.
Platform and MES hardware and software systems for all seven beer
Solutions and Products
manufacturing regions
• Cross-regional analysis highlights trends and areas to focus on for development or
• Wonderware Intelligence
support.
• Present the information in dashboard format so that it could be easily read,
• Wonderware System Platform
January/February 2013 | 49
50 | www.protocolmag.co.za
SAB manages the big picture with help from Wonderware Intelligence
South African Breweries Limited is a vast,
• Presenting the information in dashboard
geographically-distributed network of
format so that it could be easily read,
breweries involved with complex production
interpreted and viewed from a divisional
processes that have to satisfy the demands
level at head office.
of millions of discerning customers in real-time. While this may sound challenging
Solution selection
enough for the management of a single brewery, coordinating the efforts of seven
“We selected Wonderware Intelligence
manufacturing regions so as to provide
because not only would it provide the
an in-depth, unified and comprehensive
functionality we were looking for but it would
view of KPIs was best done with help
also fit into SAB’s strategic architecture and
from an application known as Enterprise
alignment with our standardising on the
Manufacturing Intelligence or EMI.
Wonderware Application Server (System Platform),” says Hein du Toit, Business
Introduction
Analyst at SAB Limited. “Buying into suite-
About The South African Breweries Limited (SAB)
based products gives long term value and it Before this project, there were limited
also gave us seamless access to time-based
Founded in 1895, SAB is the South African
facilities to proactively monitor critical
Wonderware Historian production data.
subsidiary and historical birthplace of SABMiller
systems in SAB’s beer manufacturing
It also allowed us to plug into MS SQL
plc, one of the world’s largest brewers by
systems department and this led to the
databases for MES and other applications.”
volume with more than 200 brands and brewing
centralised monitoring system that would
One of the main functions of any EMI
countries across six continents.
detect and warn about mission-critical
application such as Wonderware Intelligence
manufacturing systems within SAB that were
is to collate data from a wide and often
SAB is the second largest listed company on
in difficulty with respect to meeting their
disparate number of sources and to provide
the JSE Securities Exchange, South Africa’s
KPIs.
data warehousing, data aggregation as
leading producer and distributor of alcoholic
well as roll-up and drill-down functionality.
and non-alcoholic beverages and one of the
Although distributed in nature,
But this information is less than helpful if it
nation’s largest manufacturing firms.
manufacturing enterprises such as SAB still
can’t be displayed in a format that is easy
need to operate as unified entities with
to define and understand. “Wonderware
The company operates seven breweries and 42
respect to meeting their business objectives
Intelligence provides user-friendly, drag-
depots in South Africa with an annual brewing
and it is in this regard that the company
and-drop dashboarding functionality,”
capacity of 3.1 billion litres. Its portfolio of beer
looked for a solution that would provide a
says du Toit. “Once you have explored the
brands meets the needs of a wide range of
collated picture of its production facilities
Dashboarding tool, Tableau Server, it really
consumers and includes brands rich in heritage
and that made the best use of its existing
does make creating dashboards easy. It is an
such as Castle Lager, Hansa Pilsner, Carling
information assets while providing the least
extremely powerful tool.”
requirement for the implementation of a
interests and distribution agreements in over 60
change to operators and users.
Black Label and the iconic Dutch beer brand Grolsch.
Since it’s an SAB rule that all system
Project objectives
integrator work done on the System Platform
SAB employs more than 9,000 people, 75%
be performed by ArchestrA-Certified SIs,
of whom are from previously disadvantaged
Project Dash (short for the dashboard view
SAB chose system integrator Advansys for
groups. In addition SAB’s operations support
it was to provide into the individual and
the implementation. The company has a
an estimated 48,000 jobs at SAB’s first round
collated production facilities of SAB) was
good knowledge of the Food and Beverage
suppliers. For each job offered by SAB and
started and it had to plug some important
industry in general and the brewing industry
its first round suppliers, 5.7 additional jobs
information holes by:
in particular. “Advansys’ specific advantage
are supported in the rest of the South African
is knowledge of not only the beer making
economy. In all 378,000 full time jobs in South
process but also the manufacturing system
Africa can directly or indirectly be traced back
early detection and warning of mission-
architecture that we use such as our eQMS,
to the production of SAB’s products.
critical problems
which is our quality/MES system,” says du
• Providing a centralised system for the
Toit. • Implementing a centralised data repository for analysis purposes
In addition, if any custom development had to be done, the expert use of the
• Identifying key KPIs for PLCs, Wonderware
ArchestrA Application Object Toolkit was
Historian, System Platform and MES
important. This gives the ability for any
hardware and software systems for all
custom development to conform with SAB’s
seven beer manufacturing regions
architecture and standards while making it easy for the engineers at regional level to
January/February 2013 | 51
An Advansys perspective on Wonderware Intelligence Wonderware Intelligence is essentially a data warehousing solution for manufacturing. For example, simply stating that the OEE (Overall Equipment Effectiveness) is currently 92% (a Measure), isn’t particularly informative. However, stating that team 2 achieved 92% OEE for the morning shift on packaging line 1 while producing Castle Lager is true information because it’s put the measure in the context of teams, time, equipment and product (all of which are known as Dimensions). Figure 1: Required regional system architecture
Wonderware Intelligence operates at two levels: • Data collection and organisation into measures and dimensions. Data can be collected in near-real-time from a multitude of disparate data sources and linked by time and time ranges. • The visualisation of information through dashboards (Dashboarding). “A dashboard is a visual display of the most important information needed to achieve one or more objectives; consolidated and arranged on a single screen so the information can be monitored at a glance” Stephen Few, 2006. They provide everyone with the same version of the truth and increase the speed of decision-making. Figure 2: Required national system architecture
understand and maintain the system.
regional system architecture shown in
install-base, providing centralised change
figure 1 which collates KPIs from the PLCs
management, change propagation and
“Lastly, Wonderware Intelligence is a
as well as the Historians and MES servers
it’s user-friendly Integrated Development
Business Intelligence tool and Advansys’
for storage in the regional data warehouse
Environment (IDE) for all data retrieval
knowledge of data warehousing was
from which it can be extracted and viewed
configuration,” says Advansys Director
important to understand and implement
in dashboard form according to the needs
Graeme Welton.
the project on a tight timeline,” concludes
of users.
du Toit.
The main reasons for this were that SAB This regional architecture was replicated
didn’t want another system to maintain
seven times for each of the regions and
and ArchestrA is already the standard
connected to the central data warehouse
system control platform at all the breweries.
“Starting at the regional level, we wanted
at head office as shown in figure 2 where
Systems engineers are familiar with its IDE
to make use of the existing infrastructure at
the dashboard views not only represent
and the System Platform provides built-in
the regions and did not want to introduce
an aggregated picture but also allow
change propagation and object derivation,
anything that would affect the performance
drilling down to the views of each region
a deployment installation model as well as
of the historians, application object servers
independently.
an integral security model. In other words,
Implementation
or even the PLCs,” says du Toit. The project team drew up the required
52 | www.protocolmag.co.za
everything was in place to allow Advansys to “SAB stipulated that we make use of
focus on the Intelligence application and not
the existing ArchestrA System Platform
spend engineering time on fundamentals.
SAB manages the big picture with help from Wonderware Intelligence
This phase of project Dash focused on collecting and collating diagnostic data with respect to system performance, traffic volumes, CPU usage, scan times, memory usage, message status (MSMQ), I/O Server item counts (total, active, etc.), disc space availability, unprocessed SQL messages and many more. This would include everything from the PLC, Server Platform, the process and the ArchestrA engine to the I/O Server, the file system, Microsoft Message Queue and any SQL database (MES). “Because of the nature of this data, most of which comes from operating system diagnostics, as well as SAB’s requirement to use ArchestrA, we decided to use the ArchestrA Object Toolkit which gave us full use of the ArchestrA Object Framework and access to low-level C#.Net coding,” says Welton. “This approach also allowed
Figure 3: Final regional architecture
us to use standard, out-of-the-box alarm and history primitives and compile editors for easy configuration. This all meant that no scripting was required for engineers to configure the data retrieval objects.” Welton believes that the dashboard development tool is much more than it appears at first and that Wonderware have produced a solution whereby almost anyone with some basic training can collect and collate information from virtually any combination of sources to suit their needs. “This is rather different to traditional Business Intelligence tools that require large IT teams to support and develop.”
Benefits
Figure 4: Final national architecture showing the addition of another instance of Wonderware Intelligence at head office and an identical structure to that found at the regional level.
“I feel I should comment on three important aspects of the project,” says du Toit. “First of all, time; after the testing and development phase, we were able to roll out the project to the rest of the sites and commission within 2 months! This is a reflection on the power of the underlying ArchestrA technology. Then there’s the matter of cost. The time saved with the project roll-out had a direct impact on the cost and we were able to finish within budget. The third point is the exceptional quality of the work delivered by Advansys.” • One immediate benefit was risk reduction. With an immediate view of the status of each system, engineers were able to detect issues that impact performance of the various systems under scrutiny.
January/February 2013 | 53
• Cross platform comparison and analysis makes decision making easy when deciding on deployment of areas. • Cross-regional analysis shows trends and areas to focus on for development or where support should be given.
Conclusion “At the moment, we are only using a tiny fraction of the power of Wonderware Intelligence,” says du Toit. “The next step is Manufacturing Intelligence at every level of production and we have no doubt that the product’s ability to connect easily to different
Figure 5: Drill-down status determination of the status of the Application Object, eQMS, Galaxy
data sources and reporting flexibility will
Repository and Historian servers at all breweries
be of real value in the real-time production arena.” With Wonderware Intelligence, the “islands of information” of a decade ago have vanished and companies can become the unified entities they were always meant to be.
54 | www.protocolmag.co.za
Imana Foods get HACCP accreditation with help from Wonderware
Imana Foods get HACCP accreditation with help from Wonderware “Imana Foods would not have achieved HACCP accreditation without this solution in place.” Paul Alcock, MD, Imana Foods
Goals
• Production Events Module
• Full traceability of all materials entering
• Formula Management Module
and leaving the Savoury Powders blending process
• Sequencer
• Visibility into the blending process
• InTouch
• Production data to be linked in to the
• ActiveFactory
company’s ERP system
About Imana Foods Imana Foods was started in 1984 by co-founders John and Jean Alcock with the
Results • Gain HACCP certification
dream of providing food products of high quality and nutrition “from Cape to Cairo”.
• HACCP certification achieved within three • Improve the quality of finished goods
months of going live
Today, Imana Foods is the leader in the South African Soya Mince market and the number 2
• Reduce inventory discrepancies
• Better insight into the blending operation in the factory
Challenges
player in the Stock Cubes and Economy Soup market. The Imana Foods range also includes Packet Soups and Super Sheba Gravy Mix.
• Improved raw material stock control • Tracking of all incoming raw materials used in more than 150 recipes
The vision of Imana Foods is not just to produce • Real-time blend closure in the ERP system
high quality great tasting products, but to make a difference in the lives of Imana consumers,
Solutions and Products
• Factory procedural deviations are
traders, suppliers and employees.
highlighted • System Platform • More consistent product quality from • Historian
following recipes exactly
January/February 2013 | 55
system for the automation of real-time work order administration 4. Gain HACCP certification 5. Improve the quality of finished goods 6. Reduce inventory discrepancies The scope of the project was to include SCADA, MES and enterprise integration initiatives that would place Imana Foods in control of their existing production and ready to meet future business and operational challenges.
Solution requirements To achieve the expressed goals, Imana Foods would rely on a scalable system
Figure 1: Mobile computer and printer from Intermec
design where there was to be minimal data • Improved management of the physical blending process
providing a systems solution for product
duplication between the ERP and production
traceability.
systems. The ERP system would still be responsible for the queuing and prioritising
• Proper temperature control of sensitive
Background
of work orders.
blends Prior to this project, team leaders had no
All incoming raw materials needed to be
Since its inception in 1984, Imana Foods
clear visibility of the blending operations.
lot-managed and scanned into their storage
has expanded in leaps and bounds but to
“Blenders worked from instructions printed
locations. They would then be tracked into
realise its dream of “Redeeming Eden”
manually from the ERP system,” says Murray
the blenders. This would need to be done
through caring for its consumers, traders,
Irvine, Project Engineer at IT Dynamics. “This
for all materials used in the more than 150
suppliers and employees, the company
meant that the work schedules depended
recipes in Imana Foods’ range of products.
needed to gain certification in internationally
on the reliability of a printer and the recipe
Bags of work in progress from the blenders
recognised quality and food safety
integrity on the reliability of the operator. On
needed to be individually weighed and
standards such as ISO 9001 and HACCP
the ingredient side, while every effort was
tagged with bar-coded labels for tracking
(Hazard Analysis, Critical Control Point
made to stick to a first-in-first-out transfer of
through to the packing lines. Full traceability
Methodology). This in turn, required detailed
raw material, this was not always guaranteed
would then be achieved by ink jet coding
traceability of production processes and
and stock discrepancies were identified at
the packed product.
materials.
the end of every month. There was no real traceability”.
Imana Foods is a member of the Kwaden Investments group and is supported in
the system was that it must guide operators
Project goals
systems development by a sister company, IT Dynamics, which was tasked with
“In my opinion, the system’s most outstanding feature is the scalability of the ArchestrA environment and the ease of adding, configuring and deploying changes due to its objectoriented framework.” Murray Irvine, Project Engineer, IT Dynamics
“what to do when”, so that printed instructions would no longer be necessary.
For the Imana Foods’ leadership team, faced with an expanding marketplace demanding
“The SCADA system would verify all
increased food safety focus, there was a
transactions and would be the source of
need to review its production operations.
daily shift reports,” says Irvine.
This led to the launching of a blender project with the following goals:
Solution selection
1. Full traceability of all materials entering
“A small ‘InTouch’ application was already
and leaving the Savoury Powders
in use, monitoring PLCs in the factory,”
blending process
says Irvine, “that was not however the deciding factor for solution selection.
2. Visibility into the blending process
For Wonderware, the availability of the PEM (Production Events Module), FMM
3. Production data (from Wonderware) to be linked in to the company’s ERP
56 | www.protocolmag.co.za
One of the most important requirements of
(Formula Management Module) and the Sequencer objects were core to the
Imana Foods get HACCP accreditation with help from Wonderware
Figure 2: System topology
solution. The decision was made to go with
Sequencer are now all part of Wonderware’s
network engineers, instrumentation
Wonderware and the purchase of all the
Equipment Operations Module
technicians, network administrators and
other Wonderware solutions necessary to
technical support personnel.
this project (System Platform, ActiveFactory,
Mobile computers for use by the operators
Historian and Information Server). Paul
and mobile label printers were both sourced
Figure 2 shows the system topology. The
Alcock, Imana Foods’ MD also believed that
from Intermec due to good service levels,
MPI network was expanded to include the
Wonderware’s technology was a very good
pricing as well as being the only supplier
blenders, resulting in 22 PLC nodes being
match for the company’s future goals.”
that could support both narrowband and
connected to the Wonderware system.
broadband.
The blending area was set up for a wireless
PEM enables users to record production
infrastructure with handheld PCs and
events into a standard database and to
On the technology front, Imana Foods
wireless label printers. The handheld PCs
know the exact process conditions at a
chose barcodes over an RFID solution. This
are running a managed InTouch application
certain step. Users can also report forward
decision was based on price and the fact
through Microsoft Terminal Services which
and backward genealogy of materials,
that RFID as a technology is not yet mature
resides on the Application Object Server.
equipment and production events.
enough to give an easy, viable solution.
The office computers are connected via the
For wireless networking with the mobile
Wonderware Information Server portal to
The Sequencer Object coordinates tasks
computers and printers, broadband was
allow viewing of custom and PEM reports.
that must be executed in a certain sequence
chosen because narrowband could not cope
or order of operation. It is designed to
with the InTouch-based operator interface
The system is fully integrated with the
configure, execute and manipulate a
even though graphics and complex displays
company’s ERP system which passes
sequence of operations associated with
were eliminated.
the recipe information to the Formula
attributes from multiple application objects running within an Industrial Application. The
Manager which is queried for each
Implementation
Sequencer object exposes a comprehensive
ingredient on a bag-by-bag basis in order to load the blender. The PEM objects store
set of attributes that allows users to
Because of the scope of the project, many
acknowledged data from the operators
create SmartSymbols and regular InTouch
disciplines and skills would be required
and provide the traceability for lot-tracked
animations to monitor and control the
including a project manager, engineers,
raw materials as well as for finished goods.
Sequencer operation. PEM, FMM and
business analysts, software developers,
The Sequencer object is used to sequence
January/February 2013 | 57
the blend process. The ERP system is sent the resultant blending process information in order to close the loop and monitor stock levels and any accounting variance anomalies. In addition, custom reports calculate equipment utilisation from time data captured in the Wonderware production database. “The most important item of information supplied by the system is the raw material lot tracking data as fed into the blenders,” says Irvine. “This is giving Imana Foods a far greater level of control than previously.” On the handheld units (figure 3), the blender operators are shown the recipe details as well as an ingredient by ingredient breakdown of what they have to scan or acknowledge as having been fed into the blender. The
Figure 3: Examples of handheld unit displays
blender is on load cells which register its weight increase as it is loaded. There are built-in timers that capture the total blend
• Improved raw material stock control
Conclusion
• Real-time blend closure in the ERP system
Imana Foods has achieved all its initial
time as well as any additional mixing times that may be required. When being unloaded, platform scales underneath the blenders register the weight of the offloaded bag and this data is captured by the PEM objects.
project goals and has ambitious plans for • Factory procedural deviations are highlighted
expanding and extending the capabilities of the system. This was made possible through the use of a flexible platform in the
Benefits
• More consistent product quality from following recipes exactly
• HACCP certification was achieved within three months of going live • Better insight into the blending operation variance point of view
58 | www.protocolmag.co.za
amply demonstrated that technology is no longer a barrier to achieving business and
• Improved management of the physical blending process
in the factory from a material usage
hands of a very capable project team which
• Proper temperature control of sensitive blends
operational objectives.
Internal Benchmarking
Internal Benchmarking A revolutionary approach toward Operational Performance Management
Introduction Financial and operational management are often at odds when discussing the reasons for performance variation. If the daily/weekly
praise given!
About Industrial Management Enhancement
If the daily/weekly KPI is negative,
Experience has shown that most production
operational management typically attributes
plants operate in an unstable or high risk state
it to machine breakdowns, untrained or
for 60% or more of the time.
KPI is positive (sometimes with a healthy margin), usually no questions are asked and
inexperienced personnel, variation in raw
Dr. Kobus van der Merwe of Industrial Management Enhancement
material inputs or some non-quantifiable
Operational risk encompasses the potential loss
aspect.
due to the breakdown of controls. Breakdown of control results in unpredictable and unstable
At year-end, profits are sometimes higher
production processes. By implication, this
than budget and everyone receives
condition results in an inability to meet
substantial bonuses. If this improved profit
production targets.
was the result of, say, a favourable exchange rate (even if the production was below
IME delivers Operational Performance
budget), the financial manager knows that
Management solutions to the process and
this is deceptive and sending out the wrong
manufacturing industry. A structured and proven
message.
methodology is utilised to construct process status maps and to analyse and troubleshoot
Some aspects that every Financial Manager
the process to quantify Operational Risks.
thought, or is aware of, include:
Projects are characterised by high returns, a strong emphasis on training and development,
• Middle and, sometimes, higher
and solutions facilitating asset sweating.
operational managers do not set stretch goals. Yet these suboptimal targets form the basis for annual bonuses!
weekly favourable KPI performance? Exceptional performance seems
• The performance bonus system is not completely fair. Some individuals, who
to occur randomly and without any explanation for its cause.
made little or no contribution, receive bonuses.
If the operational managers ask for capital, they find it very difficult to
• Financial Managers ask themselves the following questions:
motivate it in terms of additional income/return on investment. Usually, when we analyse their motivations in
How much better can we do in terms of our operations?
retrospect, we find that their figures are not realised in practice. Is there a better way?
If we really achieve our true potential in terms of operational output, what will
Management tried traditional benchmarking
the bottom line look like?
but the operational managers rejected it. Their (valid) objection relates to differences
Why can we not repeat the daily/
between your operation and the one you are
January/February 2013 | 59
Most personnel underestimate the importance and do not know the value of the “lesser” variables. In general, this misunderstanding of the variables is more prevalent at the lower levels like process controllers who operate the plant at night. Although it might appear that the above refers to metallurgical or chemical processes, the same basic principles apply to most production and manufacturing processes. 4. Determining optimum variable range - With the above information at hand, the optimum range for the variables can be determined to achieve a set objective. The objective may be to maximise output or target the lowest cost at acceptable quality, etc. Best performance, observed within the comparing against, even if it is in the same
3. Analysing the relationship and
selected time interval, defines “IDEAL
industry.
interrelationship of the variables using
STATE”. “IDEAL STATE” is therefore
proprietary software. The analytical
synonymous with best energy efficiency, high
The answer is not for the financial manager
process defines the value for each variable
yield, low variable cost, high production rate
to learn more about the technical aspects of
under conditions of optimum production.
and product meeting quality standards.
Our analyses of a large number of
At this point, the analytical process
operations indicate the following:
delivers insight into root causes of poor
the operations! The answer lies in INTERNAL BENCHMARKING.
The Internal Benchmarking process
performance. Information obtained during • In the large majority of processes, the
analysis, is shared with operating personnel
relationship / interrelationship between
and subsequently facilitates change
A large number of variables (production
the variables are too complex for the
management.
functions) influences modern production
human brain to analyse. This often leads
processes. Production functions include
to incorrect perceptions.
temperature, pressure, reagent dosage/
An accurate and quantified definition now exits of conditions that delivered
strength, reaction time, raw material
Automated control systems (PLCs, DCSs)
good performance. This provides a
fineness, impurities, electricity consumption
control process variables in the majority of
platform that facilitates REPEAT good
and many more.
operations. The control system is largely
performance.
limited to safety and / or equipment The Internal Benchmarking process consists
protection issues rather than on
5. Continuous monitoring of on-going
of six distinctive elements:
optimising output. It does not contribute
operations - The “IDEAL STATE” definition
towards any better understanding of the
delivers the ability to monitor and report the
1. A facilitation process: During these
real variable interrelationships that affect
percentage time in ideal state. Operating
structured sessions, operational personnel
plant performance.
for 24 hours in “IDEAL STATE” is the daily
provide their opinions regarding the relative importance of your production functions.
INTERNAL BENCHMARK. The objective of • When comparing the initial perceptions of the operating personnel to analysed
2. Combining all measurable variables
in “IDEAL STATE”.
results, it is always found that :
into a single data set. This data set also contains input and output quantities, quality
operating personnel is to maximise the time
6. IME Solutions analyses the relevance of Most personnel know which variables
set limits for the respective variables on a
and consumption of consumables, and raw
are important but they do not
regular basis. This ensures that the “IDEAL
materials input. Data representing several
understand the interrelationships or
STATE” definition remains appropriate
weeks or months of operation are typically
have the correct value for the important
especially when changes are introduced in
considered.
variables
the plant.
60 | www.protocolmag.co.za
Internal Benchmarking
Five questions:
3. How much better can we do in terms of our operations and what will the
1. How can the Internal Benchmark
bottom line then look like?
figure(s) be used to set stretched KPI objectives?
Other benefits of Internal Benchmarking • The King III report on corporate
It is not possible to operate on Internal
governance requires a higher level of
Benchmark for 365 days a year because
reporting on operational efficiency.
“IDEAL STATE” defines best performance.
of shutdowns, machine and equipment
Internal Benchmarking is a scientific and
Prior to implementing Internal
planned maintenance and unplanned
verifiable process designed to achieve
Benchmarking, best performance was
breakdowns. The achievable utilisation
this.
achieved only on an ad hoc basis. Having
and availability can be calculated for each
the ability to monitor the time in “IDEAL
plant.
STATE” provides a platform to verify how the
• Risk Management: Internal Benchmarking integrates performance with operational
plant performs on a daily / weekly / monthly
The principle applied in Internal
risk management. Having the ability
/ annual basis relative to the set Internal
Benchmarking is to keep the availability
to monitor and quantify variability
Benchmark.
and utilisation of a plant or section as a
contributes towards the identification
separate issue from process optimisation.
of risk areas, risk profiling, quantifying
On a monthly or annual basis, performance
Improvements in availability and utilisation
progress on operational risk management
can be expressed as Equivalent Benchmark
will increase the opportunity to also increase
initiatives and the potential for
Days. Setting stretched objectives
the total time in “IDEAL STATE”.
negotiating lower insurance premiums.
subsequently becomes an easy, objective
A “war story”
and transparent process. In the context of
The cost of operating in “IDEAL STATE”
continuous improvement, the percentage
can also be calculated to a high degree
time in “IDEAL STATE” need to increase
of accuracy because the consumption of
An Internal Benchmark on a chemical
annually.
utilities, consumables and raw materials
process revealed that the process operated
under those conditions are monitored.
for only 23% of the time in “IDEAL STATE”.
2. How can KPIs become more useful for
Following the implementation of concepts
short interval management control and
From the above it can be calculated by how
described in this document, the “time
how can KPI based bonuses become more
much the bottom line can be improved. The
in ideal state” increased to 54% while
equitable?
pinnacle of performance would be to run for
production output increased by more than
100% of the time in “IDEAL STATE” minus
20%.
Traditionally, management downgrade
the unavailable and unutilised time.
Conclusion
annual performance indicators to a daily/ weekly/monthly AVERAGE figure that
4. How does this make it easier
includes AVERAGE unavailability and
for operating personnel to improve
This concept was originally developed as
unutilised standing times. Consequently,
continually?
a hands-on tool to improve operational efficiency. From there, it has grown into a
accidental (or unplanned) higher availability and utilisation can hide poor performance.
Information is available to the operator in
tool for higher management to manage
With Internal Benchmarking, this becomes
real time. Developing trends, like a variable
the operational function and to set goals
transparent.
drifting towards or away from its ideal limits,
for continuous improvement. Internal
facilitates timely corrective action. The
Benchmarking uses easy-to-understand
By setting KPIs based on time in “IDEAL
actions of operators can also be analysed
principles with its single focus on “IDEAL
STATE”, KPIs now relate directly to higher
retrospectively and utilised to improve
STATE” operation.
output and lower cost.
training and development. The managers can now ask the correct questions.
The ability to sweat assets and increase performance are two key business benefits
Prior to implementing Internal Benchmarking, it would be common for
5. How can this assist in the motivation
of Internal Benchmarking. Increasing
operations to blame equipment downtime
for capital expenditure?
efficiency in this manner delays or eliminates the need for capital projects earmarked to
for production losses (e.g. 6 hours
realise the latter.
equipment downtime). Now, managers can
The analysis of deviations, from “IDEAL
ask the further question: “For how many, of
STATE” operations, now facilitates the
the remaining 18 hours, did we operate in
effective identification of the real root
For more information contact:
“IDEAL STATE”?”
causes. Whenever such root causes can
Dr. Kobus van der Merwe
be attributed to inadequate plant or
Industrial Management Enhancement
The percentage time in “IDEAL STATE”
equipment, or if it is shown that operating
Mobile: +27 (0)82 656 5601
measurement facilitates monitoring
time in “IDEAL STATE” can be improved
Mailto: Kobus@imeSolutions.co.za
of individual plant sections. The latter
by capital expenditure, the forfeited
configuration provides a platform to attribute
potential can now be calculated as shown
performance to specific shifts and teams.
above.
January/February 2013 | 61
Invensys Operations Management Southern Africa gets ISO 9001 certification Invensys Operations Management, a global
• Consultative sales approach to ensure
provider of technology systems, software
that customers get the most cost-effective
solutions and consulting services to the
short and long-term solutions while
manufacturing and infrastructure operations
preserving the value of their existing
industries, has announced that its Southern
assets.
African operation has received ISO 9001:2008 certification for its sustained excellence of performance in the marketing, sales, design,
Operations Management Southern Africa
• Project planning, management and execution.
implementation and support of the Invensys solutions set. To qualify for ISO9001:2008 certification,
Smithson (right), Certification Manager - SGS South Africa (Pty) Ltd – Systems & Services Certification Division.
December 2015,” said le Plastrier. “There are • Formal escalations of issue resolution.
regulatory requirements and aims to enhance customer satisfaction through the effective
Invensys Operations Management Southern
• Customer satisfaction surveys.
to consistently provide product that meet customer and applicable statutory and
and Nirusha Moodley, Quality Manager Africa, receive the certificate from Brian
• In-depth customer training so that they get the most from their investments.
a company must demonstrate its ability
Mike le Plastrier (left), MD - Invensys
no grades of competence within ISO 9001: either a company is certified - meaning that
• Continuous evaluation of the status and
it is committed to the method and model
application of the system. This includes
performance of customer systems as well
of quality management described in the
processes for continual improvement of
as solution updates (Customer FIRST and
standard, or it isn’t. But there’s no ‘resting
the system and the assurance of conformity
Invensys Sentinel Services initiatives).
on our laurels’ because we have three
to customer and applicable statutory and regulatory requirements.
years to prove that we have significantly “Conforming with ISO 9001:2008
improved our level of quality management
requirements means that we have to keep
from its current ranking. In addition, two
“We are very pleased to have achieved this
a highly visible audit trail for both internal
surveillance audits are carried out annually
certification and it’s a reflection of the hard
and external audits,” said Nirusha Moodley,
for two consecutive years after certification
work and dedication of everyone here at
Quality Manager, Invensys Operations
to ensure that we are still complying with the
Invensys Operations Management Southern
Management Southern Africa. “This includes
standard and a re-certification audit must
Africa,” said managing director Mike le
strict control of documents and records
be carried out before expiry of the current
Plastrier. “For many years we’ve made it our
while taking immediate corrective action
certificate in 2015.”
business to steadily improve the quality of
to address issues of non-conformance with
service delivery across the board because our
quality criteria. Having an effective quality
customers expect nothing less.”
assurance process means that we can take preventative action before potential
Invensys Operations Management Southern
problems develop into more serious issues.
Africa’s Quality Management System (QMS)
Effective feedback also means that we know
is a formal and structured approach to the
what worked and what didn’t, which creates
company’s internal processes in order to
the right conditions for continuous and
optimise customer value. This includes:
incremental improvement.”
• Informative marketing initiatives such as
“An ISO 9001 certificate is not a once-
the annual X-CHANGE User Conference
and-for-all award, but must be renewed
and MaXimyse Partner Conference, road
at regular intervals recommended by the
shows, bi-monthly Protocol magazine and
certification body, usually once every three
web site.
years – this certificate is valid until 4th
62 | www.protocolmag.co.za
Invensys Operations Management SA wins prestigious Frost & Sullivan award
Invensys Operations Management SA wins prestigious Frost & Sullivan award Invensys Operations Management Southern Africa wins the Frost & Sullivan 2012 Growth Leadership award for the Automation and Control Solutions (ACS) market
Frost & Sullivan’s global research platform Frost & Sullivan is in its 50th year in business with a global research organisation of 1,800 analysts and consultants who monitor more than 300 industries and 250,000 companies. The company’s research philosophy originates with the CEO’s 360-Degree Perspective™, which serves as the foundation of its TEAM Research™ methodology. This unique approach enables us to determine how best-in-class companies worldwide manage growth, innovation and leadership. Based on the findings of this Best Practices research, Frost & Sullivan is proud to present the 2012 South African Growth Leadership Award in the Automation and Control Solution (ACS) Industry to Invensys Operations
interfaces (HMI), supervisory control
revenues from the sale of hardware,
Management Southern Africa and its
and data acquisition systems (SCADA)
as hardware prices keep falling. As
Wonderware range of solutions.
and manufacturing execution systems
a result, ACS suppliers are offering
(MES).
hardware components at low prices in
Significance of the Growth Leadership award Key industry challenges addressed by increased growth leadership
an attempt to win new customers. This Challenges that have impacted South
trend is reducing the value of hardware
Africa’s ACS industry include the falling price
products, which are increasingly viewed
of hardware, cyber security concerns and
as a commodity by suppliers and
engineering skills shortage:
customers alike. The overall result is to limit the total revenue growth potential
• Falling price of hardware - Increased
of the ACS market. To mitigate falling
The ACS market includes distributed
commoditisation of hardware and
hardware prices, industry suppliers
control systems (DCS), programmable
the use of open architecture systems
are continuously shifting their focus
logic controllers (PLC), human machine
have had a negative impact on
towards customer service.
January/February 2013 | 63
impact on the installed base growth of the South African ACS market.
• Customers - Third-party industry recognition has been proven to be the most effective way to assure customers
• Narrowing supplier profit margins - Prices in the ACS market across the
that they are partnering with an organisation that is leading in its field.
world have been falling steadily. In South Africa, some price cuts have
• Employees - This Award represents the
been due to lower-priced imported
creativity and dedication of Invensys
products entering the market. Most of
Operations Management Southern Africa’s
these products are sourced from Asia
executive team and employees. Such public
and are driving prices down amongst
recognition can boost morale and inspire
smaller local ACS suppliers. Another
your team to continue its best-in-class
factor contributing to narrower profit
pursuit of a strong competitive position for
Chart 1: Best practices leverage for growth
margins is that there is downward price
Invensys and its Wonderware brand.
acceleration
pressure amongst the end-user markets to get lower-priced ACS solutions. The
• Cyber security concerns - SCADA
lower prices have, therefore, reduced
Invensys Operations Management Southern Africa’s Performance in the region’s ACS Industry
networks were initially designed to
ACS supplier earnings and overall profit
maximise functionality, with lesser
margins, impacting other initiatives
attention paid to security. However, the
such as research and development,
move from proprietary technologies to
which are critical to the evolution and
The Frost & Sullivan Award for Growth
more standardised and open solutions,
progression of the ACS market. Funding
Leadership is presented to the company that
together with the increased number of
limitations on research and development
has demonstrated excellence in capturing
connections between SCADA systems,
could impact the development of new,
the highest annual compound growth rate
office networks and the internet has
innovative technologies that can be used
for the last 3 years.
made them vulnerable to attacks. The
in industries or sections that typically did
adoption of modern IT solutions in
not use ACS systems. The thinning profit
Invensys Operations Management Southern
control systems exposes their inherent
margins could therefore hamper the
Africa has established itself as a leading
vulnerabilities. PLCs and other control
progress of the ACS market’s new product
ACS software supplier in this region. The
devices (even valves or temperature
development
company’s product portfolio includes
sensors) are nowadays directly connected to Ethernet, but with minimal security measures. Consequences can cover a
Supervisory HMI, GeoSCADA, Production
Impact of Growth Leadership award on key stakeholders
Management, Manufacturing Execution Systems (MES), Performance Management, Enterprise Manufacturing Intelligence
wide range, for example, the loss of control or safety, reduction or loss of
The Growth Leadership Award is a
(EMI) as well as integration with asset
production, damage or destruction
prestigious recognition of Invensys
management and Enterprise Resource
of equipment, injuries, spills and bad
Operations Management Southern Africa’s
Planning (ERP) applications.
public relations. An increasing awareness
accomplishments in the region’s ACS
of cyber security will help combat this
Industry with Wonderware products. An
The company commands dominance within
challenge
unbiased; third-party recognition can
3 segments in South Africa’s ACS industry. In
provide a profound impact in enhancing
2010, it was the market leader in the South
the brand value and accelerating the
African MES, SCADA and HMI market, with
shortage of engineering and technical
company’s growth. As captured in chart 1, by
market shares of 24.3%, 26.1% and 23.1 %,
skills at both the end-user and supplier
researching, ranking and recognising those
respectively.
level has adversely impacted the growth
who deliver excellence and best practices in
and progression of the South African
their respective endeavours, Frost & Sullivan
The company’s ability to provide value
ACS market. Migration of skilled labour
hopes to inspire, influence and impact three
through innovative and diversified product
to developing nations has resulted in
specific constituencies:
portfolio, strategic partnering and customer
• Engineering skills shortage - The
end users increasing their engagement of ACS suppliers with vast experience
value enhancement has enabled it to grow • Investors - Investors and shareholders
and engineering expertise to deliver on
always welcome unbiased and impartial
installation and maintenance and repair
third-party recognition. Similarly,
service projects. Increasing demand for
prospective investors and shareholders
engineering services from the end users
are drawn to companies with a well-
pressurises suppliers who have limited
established reputation for excellence.
time to focus on growing their business’
Unbiased validation is the best and most
product and solution-installed base. Skill
credible way to showcase an organisation
shortages therefore have an adverse
worthy of investment.
64 | www.protocolmag.co.za
significantly in the South African ACS industry.
Key performance drivers for Invensys Operations Management Southern Africa Factor 1: Diversified product portfolio As part of Invensys Operations Management
Invensys Operations Management SA wins prestigious Frost & Sullivan award
Southern Africa’s growth strategy, the
to the significant upward trend in demand
positioned itself to benefit from this
company has managed to expand its
for these technologies. To take advantage
anticipated upturn in demand. The
presence in the South African ACS market
of the demand opportunities from these
company has invested in developing a
by diversifying its product offering and not
capital investments expenditures, routine
highly-trained service support team that
solely relying on the performance of a single
maintenance and replacement orders, the
provides technical support for clients with
end-user market segment. The company has
company continues to implement products
installed ACS solutions. The company has
established a significant market presence in
that are tailored to meet customers’ ever-
invested significant resources to provide
various industries including oil and gas, food
changing requirements. In 2012, Invensys
existing and potential clients with ACS
and beverage, utilities, pharmaceuticals,
introduced a new programme called
product information packs that highlight the
electronics, metals and automotive. The
“Modernisation”.
benefits of employing ACS technologies, which has contributed significantly to end-
Wonderware MES, SCADA and HMI
user brand awareness.
software are the technology of choice
The Modernisation programme enables
within most of the aforementioned end-user
customers to modernise and improve the
segments. Within these end-user segments,
performance of aging control systems
Other customer value-added services
the Wonderware product offerings address
and other processing facilities assets. The
provided by Invensys Operations
all operational areas of processing facilities,
programme guides clients in justifying
Management Southern Africa include end-
including instrumentation, HMI, safety and
modernisation costs, reducing risk,
user workshops to support the distribution
critical control systems, turbo machinery
deploying advanced technology and
of the ACS product information packs. The
assets, process safety lifecycle components,
approaching plant upgrades strategically
company’s service support function has
cyber security systems and other cross-
and systematically. Customers also benefit
encouraged repeat purchases based on the
enterprise assets.
from this modernisation programme by
staff’s reputed product knowledge
linking their businesses and production processes.
Conclusion
hardware and software upgrades from key
To further enhance the company’s position
In a market that faces increasingly
industries such as power generation and
within the South African ACS industry,
intense competition, Invensys Operations
mining. Going forward, strong demand and
Invensys introduced standardised HMI/
Management Southern Africa has achieved
growth is forecast for South Africa’s ACS
SCADA products. This is because end-users
rapid growth rates. The company has
market. ACS industry revenues are forecast
are increasingly shifting towards purchasing
invested aggressively in diversifying product
to increase to $316.6 million in 2017 from
easy-to-install ACS technologies that
portfolio, focused innovation, customer
$193.1 million recorded in 2010, driven by
are flexible. The company offers inter-
service and support enabling the company
capital investment projects within key vertical
compatible solutions through software
to maintain its position within the ACS
markets (metals, minerals and mining,
packages that enable the Wonderware
market. These cumulative factors make
power generation, food and beverages and
System Platform and its InTouch HMI
Invensys Operations Management Southern
chemicals and petrochemicals).
solution to be integrated with solutions
Africa the deserving recipient of the 2012
from a wide range of vendors using a single
Frost & Sullivan Growth Leadership Award in
unifying platform.
the South African Automation and Control
In 2010, Wonderware experienced strong growth as a result of strong demand in both
As a result of a diversified Wonderware
Solutions (ACS) Industry.
product portfolio, Invensys Operations Management Southern Africa has built a
The growing installed base of mechanical
strong user base within the aforementioned
equipment within key end-user sectors is a
For more information on Frost & Sullivan,
vertical markets. The company is expected
factor expected to boost ACS demand, this
visit http://www.frost.com.
to increase profitability through greater sales
is expected to sustain revenue growth for
volume obtained from these products and
the company.
markets, thus sustaining its market share. Factor 3: Technical service support Factor 2: Product innovation In addition to product innovation, Invensys’ In the midst of intensifying competition,
focus on understanding client needs
Invensys Operations Management Southern
through the supply of quality products and
Africa has managed to maintain its growth
service support has been the key revenue
in the ACS industry through product
growth factors for the company. Within
innovation. Investment in improving
South Africa, service support is expected
process efficiency and energy usage of
to account for a significant portion of ACS
processing facilities within various sectors
market revenues in 2012 and beyond.
in Southern Africa is a facet expected to boost demand for ACS products. End-user
Invensys Operations Management Southern
awareness on the benefits of employing ACS
Africa is committed to delivering excellent
technologies has risen and is contributing
customer services and has strategically
January/February 2013 | 65
Food and Beverage industry dictionary
Food and Beverage industry dictionary Acronyms
for the content of electronic records that
• Grain mill products
are on the system. A closed system can CFR
Code Federal Register
also mean a system which has proprietary
• Bakery products
software or hardware that isn’t readily CIP
Clean In Place
cGMP
Current Good Manufacturing Practice
CPG
Consumer Packaged Goods
FDA
(U.S.) Food and Drug Administration
FMM
Formula Management Module
GAMP
Good Automated Manufacturing
available to other systems.
• Sugar
Critical Process Parameter - A product
• Chocolates, sugar confectionery and
quality parameter (e.g., temperature, pH) limits to ensure product SISPQ (strength,
Practice GCP
Good Clinical Practice
GLP
Good Laboratory Practice
GxP
Good X Practice (FDA compliance;
• Roasted peanuts and other nuts
identity, safety, purity or quality). • Coffee roasting, tea blending and Digital Signature - Digital Signature
packaging
means an electronic signature based upon cryptographic methods of originator
• Food products, not elsewhere classified
authentication, computed by using a set of rules and a set of parameters such that the
• Animal feeds
X can mean: Clinical, Laboratory,
identity of the signer and the integrity of the
Manufacturing, Pharmaceutical, etc.)
data can be verified.
Beverages
Electronic Record - Electronic record
• Distilleries and wineries
HACCP
Hazard Analysis, Critical Control Point
OEE
Overall Equipment Effectiveness
PEM
Production Events Module
means any combination of text, graphics, data, audio, pictorial, or other information representation in digital form that is created,
SIG
cocoa
that must be maintained within predefined
Special Interest Group
• Soft drinks and carbonated water industries
modified, maintained, archived, retrieved, or distributed by a computer system.
Audit Trail - (ISO) Data in the form of a
Handwritten Signature - This means the scripted name or legal mark of an individual
logical path linking a sequence of events,
Electronic Signature – This means a
handwritten by that individual and executed
used to trace the transactions that have
computer data compilation of any symbol
or adopted with the present intention to
affected the contents of a record.
or series of symbols executed, adopted,
authenticate a writing in a permanent form.
or authorised by an individual to be the
The act of signing with a writing or marking
A chronological record of system activities
legally binding equivalent of the individual’s
instruments such as a pen or stylus is
that is sufficient to enable the reconstruction,
handwritten signature.
preserved. The scripted name or legal mark, while conventionally applied to paper, may
reviews, and examination of the sequence of environments and activities surrounding or
Food and beverage industry – This
also be applied to other devices that capture
leading to each event in the path of a transaction
generally includes the following:
the name or mark.
Food
Inspection - A manual testing technique in
from its inception to output of final results. which program documents [specifications
A computer-generated and time-stamped record of who did what, when. CFR 21 Part
• Canned and prepared meats
independently of operators. An audit trail
• Dairy products
and disciplined manner to discover errors, violations of standards and other problems.
must capture all activities related to creating, modifying, and destroying records on a
(requirements, design), source code or user’s manuals] are examined in a very formal
11 requires audit trails to be generated
• Canned fruit and vegetables
Checklists are a typical vehicle used in accomplishing this technique.
system. • Fish products and similar foods
Open System - Open system means an
Closed System - Closed system means an environment in which system access is controlled by persons who are responsible
66 | www.protocolmag.co.za
• Vegetable and animal oils and fats
environment in which system access is not controlled by persons who are responsible
for the content of electronic records that are
Traceability - (ISO) Ability to trace the
test cases. It should be possible to look at
on the system.
history, application or location of that which
a specification and determine how it was
is under consideration.
tested, or to look at a test and determine
Predicate Rule - A previously published set
what specifications it challenges.
of rules (such as GLPs, GCP, or cGMPs) that
(IEEE) The degree to which a relationship
mandate what records must be maintained,
can be established between two or more
Validation - Establishing documented
the required contents of those records,
products of the development process,
evidence which provides a high degree
whether signatures are necessary and how
especially products having a predecessor-
of assurance that a specific process will
long the record must be maintained.
successor or master-subordinate relationship
consistently produce a product meeting
to one another; e.g., the degree to which the
its predetermined specifications and
Within the context of 21 CFR Part 11:
requirements and design of a given software
quality attributes. The action of proving, in
Requirements set forth in the Federal Food,
component match.
accordance with the principles of GxP, that
Drug, and Cosmetic Act (the Act), the Public
any procedure, process, equipment material,
Health Service Act (PHS Act), or any other
The ability to link a user requirement
activity or system actually leads to the
FDA regulation with the exception of 21 CFR
specification through functional
expected results.
Part 11.
specifications and design specifications to
January/February 2013 | 67
Events: X-CHANGE 2013
The human differentiator: Driving measureable, real-time performance improvements by improving the value of the contribution your people make to your business
of its kind in Southern Africa. System
from technical to more business-oriented
integrators, hardware and software suppliers,
and you will be able to choose those
end-users and international industrial
best suited to your current operational or
automation authorities come together to
business needs.
X-CHANGE 2013 will focus on how
Celebrating the conference’s 21st anniversary, X-CHANGE 2013 will be held from 21st to 24th April at Sun City and promises to once again add great value to the lives of industrial automation professionals country-wide.
X-CHANGE ideas, network and collaborate at what is widely regarded as South Africa’s
Technology stream
premier industrial event. Every year, Invensys Operations
Invensys can help empower your operational and business personnel to excel through the use of innovative technology. While there’s no lack of technology, it’s humans, at the end of the day, that are the differentiators between its success or failure. We know. We’ve been involved with enriching the
Management introduces new and significant products to its wide range of solutions. This is your opportunity to see what these products will do for your bottom line as the presentations highlight the features, advantages and benefits of each solution as applicable to your industry. This year, there are significant functionality upgrades and enhancements to your favourite applications
contributions of people for over a century.
So, we invite everyone who has something
as well as some new ones that continue to
That’s a lot of experience.
to share or something they want to learn
populate the Invensys InFusion enterprise
to X-CHANGE 2013. If you’ve never been
control system space (e.g. Intelligent
The road to success depends on a definitive
to X-CHANGE before, you’re in for a most
Marshalling, plug-in DCS migration,
automation and information strategy as well
pleasant and informative surprise. If you’re a
virtualisation, MES Quality Management
as some notable landmarks. These include
regular, on the other hand, we don’t have to
System, handling multiple ArchestrA
the Invensys Enterprise Control System
sell you on the idea and welcome you back.
galaxies, Overview Client and many more).
X-CHANGE 2013 presentation streams
Solutions stream
and its many integrated applications, the safeguard of past investments, integration with existing corporate assets, providing continuously current technology, supplying
The solutions stream takes a broader look
outstanding customer support and an
The presentation streams have been designed
at ways of addressing your enterprise
enviable track record of delivering optimised
to highlight and address the information needs
manufacturing intelligence needs, improving
industrial information and operational
of executives, system engineers, production
asset effectiveness, streamlining your
solutions to most of the world’s leading
managers, plant managers and engineers
manufacturing execution system for operational
companies.
involved in the mining and manufacturing
performance excellence, getting you started on
industries. That’s because they all need
the road to enterprise integration, empowering
X-CHANGE is your definitive window to
different information in the right context and at
your workforce, corporate energy management,
the industrial automation and information
the right time – all the time.
safety and reliability, business optimisation
landscape and brings together more industry professionals than any other event
68 | www.protocolmag.co.za
and other topics on which the health of your The contents of the presentations range
enterprise depends.
Events: X-CHANGE 2013
Vertical Industry stream
This stream will demonstrate how hardware
economic climate to the adoption of new
and software solution from Avantis,
approaches to information and control in
These presentations demonstrate how
Eurotherm, Foxboro, InFusion, SimSci-
mining and manufacturing. Once they leave
all of the above solutions are applied to
Esscor Skelta and Triconex all contribute to
their pedestals, you can have casual chats
address the needs of vertical industries
providing a seamless information continuum
with them or book sessions where you have
such as mining, manufacturing, food and
from sensor to boardroom.
the chance of discussing your production
beverage, utilities, etc. This stream will also feature user presentations compiled by
and business issues one-on- one.
User presentations stream
end-users, their system integrators or both
Their wide and varied industry experience
allowing you to determine “from the horse’s
End-users and system integrators present
will save you from reinventing the wheel and
mouth” if Invensys Wonderware products
the successful implementation of projects
cut through complexity to give you fresh,
performed as it said on the tin and how they
using Invensys solutions. From SCADA to
practical insights that you can apply when
helped end-users achieve their business and
MES and Manufacturing Intelligence to
you get back to the office.
operational goals.
enterprise integration, come and see how the concept of Invensys’ Enterprise Control
Invensys Operations Management stream
System is helping mining and manufacturing
Invensys Operations Management Open
companies map some of the world’s leading solutions to their needs in a practical way.
We have found that one of the most valuable
From valves to virtualisation and from
All user presentations are entered into the
ways to assess a product and its suitability is to
sensors to simulation, Invensys Operations
Invensys Operations Management Open
speak to the people who use it. The Invensys
Management does it all. Invensys
competition
Operations Management Open was introduced
Wonderware is only one of nine Invensys Operations Management business units, so
to encourage both end users and system
Keynote speakers
it’s no wonder that the range of solutions
integrators to document their experiences of successful implementations using Invensys
available to you has grown phenomenally
We are fortunate in having access to some
Wonderware solutions. These are customers
and very rapidly since the company started
of the leading local and international
who have used the products extensively and
operations in South Africa in 2011.
authorities on subjects as far ranging as how
their first hand experiences offer insights not
to survive profitably in the current world
available from any other source.
January/February 2013 | 69
On-line bookings
All user presentations are entered into
showcase their wares and achievements. They
the Invensys Operations Management
do so because nowhere else is there such
Open competition where prizes are
an opportunity to talk to a more qualified
Visit www.x-change.co.za if you want to do
awarded for the best presentations in
audience eager to see what they have to offer.
any of the following:
HMI, MES, EMI or Enterprise Integration
(Should you wish to exhibit your solutions,
• Book your attendance at X-CHANGE
implementation. The presentations are then
please see the booking information below.)
various categories such as best SCADA/ 2013
documented in the form of articles and,
Hands-on training
• Book a stand at the Expo
on the Invensys Wonderware web site and
At X-CHANGE 2013 you can look forward
• Enter the Invensys Operations
bi-monthly Protocol magazine as well as
to practical hands-on training sessions
Management Open and have a chance of
Invensys Operations Management’s annual
where you get to test-drive the products for
attending the conference free of charge
international booklet of success stories.
yourself. These practical sessions will allow
by doing a presentation and providing
you to evaluate how and where they may
prescribed material for us to write a
best be applied in your environment.
success story of the implementation
after approval, sent to various magazines for publication. These articles also appear
Delegates whose presentations are accepted for X-CHANGE automatically qualify to attend the conference free of
of Invensys solutions in an interesting
Spouse programme
application
charge! Such conferences are always better
Ask anyone who has ever attended
(If you are interested in submitting a
when shared with your partner – who
X-CHANGE in the last 20 years – you
presentation, please see the booking
may, however, not share your enthusiasm
won’t be disappointed – and neither were
information below.)
regarding the benefits of advanced
they!
technology. That’s why a rich programme of
Expo
entertainment has been planned for your partner ranging from sporting activities to
System integrators as well as hardware and
sightseeing and game-spotting (depending
software partners use this unique venue to
on the venue) among many other events.
70 | www.protocolmag.co.za
s e c i v r t e r S o p p u S d an
January/February 2013 | 71
Invensys Sentinel Services In a Nutshell ... Invensys offers advanced remote services technology that enhances our ability to deliver higher availability and reliability of plant assets to your company.
Key benefits • Increased uptime • Frees you to focus on looking after production rather than control systems
Key features • 24/7/365 remote monitoring and notification of issues
Who’s supervising the supervisors?
We achieve this by installing special “agent software” on each Wonderware server located at your sites. These agents monitor
You trust your Invensys Wonderware
the system on a 24x7 basis to ensure that
Industrial IT solutions to supervise your
critical resources are performing within best
wealth-creating processes but who’s
practice norms.
• Detect and rectify issues or problems before they become mission-affecting • Provide better management of system resources to improve asset performance
supervising them? Let Invensys Sentinel • Streamline diagnosis process
Services (ISS) be your SCADA’s SCADA
If an unacceptable threshold is reached, an
by remotely and constantly monitoring
alarm is raised and Invensys engineers are
and reporting 24/7 on the KPIs of your
alerted before an issue develops. Remote
Wonderware-based systems so that
connectivity is also designed to ensure
potential problems can be nipped in the
that, if there is a problem, Invensys experts
bud. This will give you the peace of mind
can work with you to make appropriate
you need to focus on improving your
adjustments to correct the issue and return
company’s bottom line rather than looking
your system to normal operation quickly and
after systems.
easily.
Using technology to provide world-class support
The process
Reporting
• Fast and systematic event resolution eliminates trial and error and cuts costs • Clear and regular reports provide insight into possible improvements
Our event management system monitors
A key aspect of Invensys Sentinel Services is
Peak performance in our operating plants is a
anomalies or events that occur in the
feedback to you. As a result, we ensure that
continuous process that is being threatened
Wonderware customer environment and
we provide monthly system health status
on a daily basis. As skills scarcity increases,
focuses on detecting issues and generating
reports which include:
most production technicians are stretched
meaningful notifications. These notifications
to the limit with their daily tasks. Little time is
are reported to the Invensys Command
left to maintain the running software systems
Centre which offers a single point of contact
and very few can find the time to develop and
for customer incidents and requests.
maintain specialist knowledge to diagnose
• Overall health status for the month • Critical, major, medium and minor system issues and errors for that month
faults on these systems. • Changes or corrections made to fix As a result, Invensys offers ISS whose job is
errors that occurred in the Wonderware
to monitor the performance of your Invensys
environment
Wonderware assets — continuously.
72 | www.protocolmag.co.za
Invensys Sentinel Services
• Proposals for Wonderware system modifications to ensure that the system
Optional value-added services
conforms to best practice standards
Contact us For more information please contact:
• Anti-virus reporting
Monitored events
Zaine Domingo, ISS Product Manager — Invensys Operations Management
• Wonderware and Microsoft patch Monitoring includes examining the KPIs
management
of the Wonderware System Platform and Historian, hardware performance, event logs,
T +27 (0)11 607 8191 | 0800 INVENSYS | zaine.domingo@invensys.co.za
• Operating system platform support
Wonderware machines (where applicable) among others. There is also a monthly audit of OS, Windows and Wonderware version control, Wonderware licence status, IP configuration and more.
January/February 2013 | 73
Customer FIRST Maximise asset performance
to meet contractual obligations to your customers and the loss of business that
Downtime costs businesses millions of Rand
Comprehensive Services
- Customer FIRST support gives you options to maximise productivity by keeping your operations running smoothly.
In a nutshell ...
may ensue. • Customer FIRST also gives you access to Invensys technical resources to
Customer FIRST is not just technical
help you ensure that your system is
support, it’s a comprehensive
Outages, both planned and unplanned,
back to capacity in as short a time as
programme to help you manage your
are costly; businesses increasingly need to
possible. Our world-class global service
systems and protect your investments.
employ effective pre-emptive strategies
organisation is available locally, so the
to reduce risks and employ efficient and
help you need is never far away.
Real Value
effective resourcing strategies to ensure that non-productive time is kept to a minimum.
Asset performance is not just about
Customer FIRST members enjoy the
maximising availability though; you need
many benefits of a closer collaborative
Customer FIRST is not just technical support,
to ensure that your assets are working to
relationship with Invensys.
it’s a comprehensive programme to help
their maximum potential. You also need
you manage your systems and maximise the
to minimise the risk to your business of
performance of your assets.
missed schedules, poor quality or regulatory violations, with the business consequences
Downtime hurts - Customer FIRST can help
• Responsive services • Depth of expertise
that may follow. • Proactive planning Customer FIRST gives you proactive remote
Even the most reliable equipment requires
health monitoring services to spot warning
downtime, perhaps for routine maintenance,
signs before problems occur and advanced
preventative maintenance, upgrades or
consulting services to tune your systems to
replacement. You need to ensure that
maximum performance.
downtime is kept to a minimum and to
• Continuous performance monitoring • Emergency contingency provisioning • Deep discounts on hardware
as a result.
Customer first – our mission: your success
• Software and services
• Customer FIRST provides you with
ensure that there is minimal production loss
Customer FIRST membership gives you
These important elements make the
access to great hardware maintenance,
access to award-winning technical support,
Customer FIRST membership an
software maintenance and comprehensive
hardware and software maintenance
essential part of your business success.
lifecycle management services to help
services, lifecycle management and remote
you optimise your planned downtime and
Services, training and consulting services
minimise unplanned downtime events.
and much more. The programme provides you with comprehensive services and flexible
Recovery time is critical and any delays
options to choose exactly the right kind of
in acquiring either replacement parts, or
programme to suit your business needs and
the expertise required to quickly resolve
help you to maximise asset performance.
problems, can have a significant financial impact on your business.
Contact information
• Customer FIRST provides you with timely
Support Telephone Number:
access to critical spare parts with the
0861-WONDER (0861-966337) or
ability to manage spares more easily and
0800-INVENSYS (Toll Free)
ensure the reliability of your systems. E-mail: What’s more, extended downtime presents other risks to your business such as failing
74 | www.protocolmag.co.za
support@wonderware.co.za or
support@invensys.co.za
2013 Training Schedule
2013 Training Schedule (Johannesburg)
i
Did you know that your bottom line is directly proportional to the effectiveness of your workforce?
As the owner of some of the world’s
• 6 – 10 May
most popular, advanced and versatile industrial automation, information and MES software solutions, you’ll want to get the most from your investment and
The dates shown apply to training • 22 – 26 July
that includes getting the best training in the business. We routinely train about 600 professionals like you every year not
at our offices in Bedfordview, Johannesburg. Regional training is
Historian (includes Historian Client)
only on how to use our solutions but how to turn our product features into real
NOTE:
• 24 – 28 June
presented on demand. A minimum of six delegates is required to arrange a course.
• 11 – 14 February
Regional training venues:
business benefits. • 13 – 16 May
InTouch Part 1 Fundamentals (includes New Graphics)
• 18 – 21 June
Morningside.
• 28 January – 1 February
• 19 – 22 August
Cape Town: Durbanville Conference
• 25 February – 1March
InBatch
• 27 – 31 May
• 4 – 8 February
• 1 – 5 July
Bundled courses
• 29 July – 2 August
In addition to the above, we offer the
Durban: Khaya Lembali,
Centre. Port Elizabeth: Pickering Park Conference Centre, Newton Park.
For system integrators:
following bundled courses at reduced rates:
InTouch Part 2 Advanced (includes New Graphics)
• System Platform – Application Server
For maintenance and engineering personnel:
• 4 – 7 March
(includes InTouch Fundamentals, InTouch Advanced, Historian, System Platform and Application Server)
• InTouch only (includes InTouch • 3 –6 June
Fundamentals and InTouch Advanced)
• 8 – 11 July
• InTouch and Historian (includes InTouch
For non-technical personnel (operators, managers, supervisors):
Fundamentals, InTouch Advanced and
System Platform – Application Server (includes new graphics) • 21 – 25 January • 18 – 22 February
Historian)
• Historian (includes ActiveFactory basics for non-technical staff)
• System Platform – Application Server (includes InTouch Fundamentals, InTouch
For all your training requirements, contact
Advanced, Historian, System Platform and
Emmi du Preez at
Application Server)
emmi.dupreez@wonderware.co.za or training@invensys.co.za or call Emmi on 011 607 8286.
• 11 – 15 March
January/February 2013 | 75
Use Protocol Magazine to generate business opportunities Protocol magazine continues to be well
you’re a solution supplier) or recognition
The Guideline is in the form of prompts to
received on a bi-monthly basis by 6500
(if you’re an end-user)
which you supply the answers to the best of your ability. This, together with the graphical
industry professionals like you, at every level of the country’s leading mining and manufacturing companies. You can
• It must generate market awareness of your capabilities
information required, will be used to write the article which will be sent back to you for editing, approval, etc.
leverage this highly-qualified readership to be heard.
• It must do all that at a reasonable cost
How do you promote yourself right now?
Protocol magazine meets all these criteria.
The Permission to Publish form must be signed by the end-user of the installation and system integrator / solution vendor
Some of the things you might be doing could include inserting opinion pieces,
If you’re an end-user, your stakeholders are
(if applicable) before work on the article is
adverts, editorials and other material
most interested to know how well you’re
started. This ensures that all the work that
into South Africa’s leading manufacturing
looking after their interests by lowering costs
goes into compiling the story will not be
and mining magazines. A good choice
and improving efficiency. Your colleagues
wasted.
since these are excellent and professional
in the industry are keen to see how you’ve
publications that land on decision-makers’
implemented Wonderware solutions so that
You are free to use the completed success
desks every month.
they can evaluate if these will have the same
story in any marketing sense you wish and
benefits in their environments.
you have hundreds of examples on our web site and in past issues of A2ware and
What Protocol offers is all the advantages of a professional magazine with a large
If you’re a system integrator, end-users
circulation but the cherry on the cake is
want to know what you’ve done so that they
that all the readers of Protocol have one
can consider you as a solution supplier for
thing in common – Wonderware solutions
their next project.
FutureLinx.
Opinion Pieces: Once again, there’s no cost involved and
in the areas of SCADA, MES, EMI, BPM and enterprise integration – in fact, anything to
If you’re a hardware or software vendor,
you don’t have to worry about probably
do with industrial and corporate production
end-users and system integrators want to
not having majored in English. Decide on a
IT. Everything in Protocol is aimed at helping
know about how well your offerings work
central theme and the idea(s) you want to
end users get more from their Wonderware
in the Wonderware environment and how
put across, then jot down all the reinforcing
investment and trigger them to look at new
they can help them do a better and more
arguments you can think of (as well as
possibilities. Nobody wants to reinvent a
cost-effective job.
references if applicable). Also include any supporting graphics you feel will better
costly development or investigation wheel to stopping that happening.
What medium will work best for you?
Let’s think for a minute about your perfect
Success stories:
and what you have to offer will go a long way
illustrate the point. Send your draft article to your account manager
you:
They won’t cost you a cent and you don’t have to write them. Simply send an e-mail
• It must convey your message in a
to your account manager stating that you
professional manner to a large, targeted
have the makings of a good story and why
and qualified audience
you think it is so. You will then be sent a
• It must generate incremental business (if
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Use Protocol Magazine to generate business opportunities
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So what are we really saying?
(if interesting and relevant).
and we have made it as easy as possible for As an end-user or supplier of Invensys
Material formats
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Wonderware and associated solutions, you form part of the world’s largest ecosystem
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automation and the delivery of actionable
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That makes what you have to say significant
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Did you know that if you don’t talk to anyone, they’re not likely to talk to you or send orders? January/February 2013 | 77
On the lighter side ‘Being British is about driving in a German
begun to complain of whiplash injuries
car to an Irish pub for a Belgian beer, then
and back pain.
travelling home, grabbing an Indian curry or a Turkish kebab on the way, to sit on
• Swedish business consultant Ulf af Trolle
Swedish furniture and watch American
laboured for thirteen years on a book
shows on a Japanese TV; and the most
about Swedish economic solutions. He
British thing of all? Suspicion of anything
took the 250-page manuscript to be
foreign.’
copied, only to have it reduced to 50,000 strips of paper in seconds when a worker
• In Budapest, early in January 2006,
confused the copier with the shredder.
firemen were needed to lift a 50 stone (320Kg) woman from her home so that
• A convict broke out of jail in Washington
she could attend hospital. They needed
DC then, a few days later, accompanied
to remove a window and break down the
his girlfriend to her trial for robbery.
wall so that the bed could be strapped
At lunch, he went out for a sandwich.
to a forklift truck. This took 13 firemen 5
She needed to see him and so had him
hours. The unnamed woman is now in
paged. Police officers recognised his
hospital on a weight loss programme.
name and arrested him as he returned to the courthouse in a car he had stolen over
• Police in Wichita, Kansas, arrested a
the lunch hour.
22-year-old man at an airport hotel after he tried to pass two [counterfeit] $16
Four Catholic ladies
bills.
• Police in Radnor, Pennsylvania, interrogated a suspect by placing a metal colander on his head and connecting
• A man in Johannesburg, South Africa,
it with wires to a photocopy machine.
together. The first one tells her friends, “My
shot his 49-year-old friend in the face,
The message “He’s lying” was placed
son is a priest. When he walks into a room,
seriously wounding him, while the two
in the copier and police pressed the
everyone calls him ‘Father’.”
practiced shooting beer cans off each
copy button each time they thought the
other’s head.
suspect wasn’t telling the truth. Believing
Four Catholic ladies are having coffee
The second Catholic woman chirps, “My son is a Bishop. Whenever he walks into a room, people say, ‘Your Grace’.”
the “lie detector” was working, the • A company trying to continue its five-year
suspect confessed.
perfect safety record showed its workers a film aimed at encouraging the use of
• When two service station attendants in
The third Catholic woman says smugly, “My
safety goggles on the job. According
Ionia, Michigan, refused to hand over the
son is a Cardinal. Whenever he walks into a
to Industrial Machinery News, the film’s
cash to an inebriated robber, the man
room, people say, ‘Your Eminence’.”
depiction of gory industrial accidents
threatened to call the police. They still
was so graphic that twenty-five workers
refused, so the robber called the police
The fourth Catholic woman sips her coffee in
suffered minor injuries in their rush to
and was arrested.
silence. The first three women give her this
leave the screening room. Thirteen others
subtle “Well.....?”
fainted and one man required seven
Epol diet
stitches after he cut his head falling off a She replies, “My son is a gorgeous, 6’2”,
chair while watching the film.
room, people say, ‘Oh my God...’.”
Strange but true
• The Chico California City Council enacted a ban on nuclear weapons, setting a $500
Yesterday I was at my local supermarket
fine for anyone detonating one within city
buying a large bag of Epol dog food for my
limits.
loyal pet and was in the checkout queue when a woman behind me asked if I had a
• One of the British national daily newspapers has been asking for comments
Since this issue is on the subject of food, the following story seems most appropriate:
hard bodied stripper. When he walks into a
• A bus carrying five passengers was hit
dog.
about: ‘what it means to be British’. Here
by a car in St. Louis, Missouri, but by the
is a comment from a chap in Switzerland
time police arrived on the scene, fourteen
What did she think I had, an elephant? So,
who lived in Britain for 12 years.
pedestrians had boarded the bus and had
since I’m retired and have little to do, on
78 | www.protocolmag.co.za
On the lighter side
impulse I told her that no, I didn’t have a
the dog in our garden so I did, now let’s
dog, I was starting the Epol Diet again. I
see how they like it.’
added that I probably shouldn’t, because I ended up in hospital last time, but I’d lost 20
• Murphy lost a hundred dollars on the Melbourne Cup, a famous Australian horserace. He also lost another hundred
• Gallagher is in Boston and he is waiting
on the television replay.
kilos before I woke up in intensive care with
patiently, also, he is watching the traffic
tubes coming out of most of my orifices and
cop on a busy street crossing. The cop
IVs in both arms.
stops the flow of traffic and shouts, ‘Okay
under his pillow. Hearing a noise at the
pedestrians’. Then he allows the traffic
foot of the bed, he shot off his big toe.
I told her that it was essentially a perfect diet
to pass. He did this several times and
‘Thank the Lord I wasn’t sleeping at the
and that the way that it works is to load your
Gallagher is still standing on the sidewalk.
other end of the bed,’ Kieran said to his
pockets with Epol nuggets and simply eat
After the cop had shouted ‘Pedestrians’
friends in Donegal’s pub. ‘I would have
one or two every time you feel hungry. The
for the tenth time, Gallagher approaches
blown my head off.’
food is nutritionally complete so it works
him and says, ‘Is it not about time ye let
well and I was going to try it again. (I have to
the Catholics across?’
mention here that practically everyone in the queue was now enthralled with my story.)
• Kieran O’Connor always slept with his gun
• O’Gara was arrested and sent for trial for armed bank robbery. After due
• ‘Why do you Irish always answer a
deliberation, the jury foreman stood up
question with a question?’ asked
and announced, ‘Not guilty.’
Horrified, she asked me if I ended up
President Franklin D. Roosevelt.
‘That’s grand,’ shouted O’Gara, ‘Does that
in intensive care because the dog food
‘Do we now?’ came New York Mayor Al
mean I get to keep the money?’
poisoned me. I told her no, I stepped off the
Smith’s reply.
pavement to sniff a Bull Terrier’s arse and a car hit me.
• Finnegan sells Michael a donkey, some weeks later they met in a pub in Killarney
I thought the guy behind her was going
and Michael says, ‘Hey, Finnegan, that
to have a heart attack he was laughing so
donkey you sold me went and died.’
hard. However, I’m now banned from that
Finnegan just sips his Guinness slowly and
particular supermarket.
retorts, ‘Bejabbers, Michael, it never done that on me.’
Better watch what you ask retired people... they have all the time in the world to think of daft things to say.
Some of the best short, funny and hilarious Irish jokes - to be sure: • Reilly is walking through a graveyard when he comes across a headstone with the inscription “Here lies a politician and an honest man.” ‘Faith now,’ exclaims Reilly, ‘I wonder how they got the two of them in one grave. • ‘O’Toole and his wife are in bed one night and they hear the neighbour’s dog is barking its head off in the garden. Somewhat disturbed by the noise, O’Toole explodes, ‘Botheration and that!’ and storms off downstairs. He comes back upstairs five minutes later and his wife asks, ‘What did you do, O’Toole?’ O’Toole replies with a wide grin, ‘I’ve put
January/February 2013 | 79
Protocol Crossword #58 When you’ve completed the crossword, the letters in the coloured boxes spell out the name of the ArchestrA-based human-level process enabler. Note: This magazine contains the answers to a number of the clues. E-mail your answer to: editor@wonderware.co.za. The sender of the first correct answer received will get a hamper of Invensys Wonderware goodies.
Clues across: 1. What this issue of Protocol is about (4,3,8) 11. Land which can be cultivated for food crops (6) 12. United Nations (2) 14. Rodent (3) 15. Feudal system slave (4)
75. “Ship of the desert” (5)
55. Ruthenium symbol (2)
76. One of the largest breweries in the world (3)
56. This SA company was started by John and Jean
77. Each (abbr.) (2)
Alcock with the dream of providing food products of
78. Public Relations (2)
high quality and nutrition “from Cape to Cairo” (5)
79. Myself (2)
57. Egyptian sun god (2) 59. Pulse (5)
16. He imparts knowledge (7)
Clues down:
20. Standard Play (2)
1. He cultivates the land for food production (6)
22. Russians wear them (5,4)
2. Plural of “os” (3)
24. Einsteinium symbol (2)
3. Cereal (4)
26. Hooter (3)
4. Unit of sound pressure (abbr.) (2)
28. Independent sultanate in the Middle East (4)
5. Amyotrophic Lateral Sclerosis (3)
29. Denotes hesitation (2)
6. Sewing tool (6)
30. Mexican farm worker or Ford vehicle name (8)
7. Ridiculous but amusing persons (8)
33. Title of Roman emperors (6)
8. Printing measure (2)
36. Leaf herder? (5)
9. Ever-lasting (7)
37. Wonderware solution for integrating the mobile
10. Technology behind Wonderware’s System Platform
workforce (10)
(9)
39. Electronic conversation snoopers (8)
13. Constellation _____ Major (4)
41. System of beliefs (5)
16. This feature of Wonderware software allows for audit
42. Movie alien (2)
trails (12)
43. Exists (2)
17. Expression of pain (2)
44. Ibidem (abbr.) (2)
18. Capital of Zimbabwe (6)
45. Half a laugh (2)
19. Extraterrestrial (2)
46. Indefinite article (2)
21. Used for storage in clothing (6)
47. Afrikaans blokes (3)
23. Denotes pensive hesitation (2)
49. Caustic substance (4)
25. Indian lady’s dress (4)
51. National Reconciliation Council (3)
27. To excite desire for something (e.g. appetite) (4)
52. Down (abbr.) (2)
31. Nostrils but sounds like a drum (5)
53. It’s the reason why we can have a predictable source
32. Tears (4)
of food (11)
34. Per person (4)
58. A silver-white metallic chemical element that starts
35. Radio Detection And Ranging (5)
with “L” (7)
38. Also known as Coca Cola Swaziland (5)
60. Cleopatra’s viper (3)
39. Dairy featured in this magazine (9)
62. One of the three musketeers (5)
40 Two-toed sloth (2)
63. Actor ________ Kutcher (6)
44. Intensive Care Unit (3)
67. Leading SA sugar manufacturer (3)
48. Bring together (5)
69. Roman emperor (4)
49. Not DC (2)
70. An army completely surrounded by water (1,4)
50. Delirium Tremens (2)
71. Israeli port (5)
51. Largest food company in the world (6)
73. His __________ and unconsidered remarks cost him
53. Horse’s foot (1,4)
the election (7)
54. Geographical Information System (3)
80 | www.protocolmag.co.za
61. Song in praise of God (5) 64. Beaches are full of it (4) 65. High Voltage Distribution (3) 66. Low tide (4) 68. British Telecom (2) 70. Expression of cognition (3) 72. Infant Mortality Rate (3) 74. Iron symbol (2)
Answer to Protocol crossword #57: Question: What is mined at Sishen? Answer: IRON ORE
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January/February 2013 | 3
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