MES Excellence for Brewing Industry
Industry Challenges
Breweries are facing an increasingly competitive market in terms of product quality and reduced production costs. To excel in the marketplace, they must increase production capacity, optimize quality control processes and standardize information received from their production facilities to provide management tools to compare results and make decisions. The overall role of the Manufacturing Execution System can be broadly described as implementation of a highly integrated management information system that uses modern concepts and technology to reduce costs, improve business processes and standardize the brewing industry by embedding best practice technology. The primary goal and strategic advantage of the Siemens Opcenter Execution (formerly SIMATIC IT) MES solution is to capture manufacturing-related data and turn it into information that can drive business decisions and improve KPI scores, process and product quality and productivity.
Data Acquisition
- Batch System Interface
- PLC Interface
- SAP Interface
- Planning System Interface
- LIMS System Interface
- HMI
Production Execution
- Planned order execution
- Process order execution
- Material movement
- Equipment Status Management
- Line Status Management
- Audit Trail and Logs
Quality Management
- LIMS Data Visualization
- ALT Parameters Acquisition and Visualization
- Material movement
- Equipment Status Management
- Line Status Management
- Audit Trail and Logs
KPIs Management
- KPIs Calculation and Visualization
- Efficiency KPIs Calculation and Visualization
Reporting
- Reports
- Scorecards
Main Opcenter Execution Process (SIMATIC IT UAPI) Functionalities
- Standard interface to obtain information from the ERP solutions (material master, planned production schedule, product definition) based on the ISA-95 standard
- Define standard interface to acquire batch data from the shopfloor automation system (batch data, procedure data, work instruction data, parameter values, material movement) based on the ISA-88
- Production execution linking batch information coming from the shopfloor interface with the process order information coming from the ERP system
- Manage process order status and process order operations
- Acquire and archive key operational Parameter links to Process Orders (Production parameters, Quality parameters)
- Analysis of process and production parameters (KOPs) by equipment and calculation of Key Performance Indicators (KPIs)
- Synchronization of material master data
- Capture and calculate material movement, material consumption and material production
- Manage automatic or manual breakdown and maintenance notifications
- Manage and calculate Overall Equipment Effectiveness (OEE) in the packaging lines and other strategic KPIs (TEEP, MTBF, MTBR, Speed Loss, Quality Loss, Performance Loss, Micro-Stoppages, etc.)
- Production status - information on tank status and occupation time and cycles
- Visualize and analyze production parameter trends comparing different data sources and periods
- Define a set of brewery-specific KPIs (Extract Loss, Yeast Growth, Mash Liquor (Grist Ratio), Brewhouse Cycle Time, Boiling Duration etc.)
- Aggregate and visualize KPIs in a central data system across plants
- User management - configure user access levels
- Audit trail - log chronological sequences of records
