Rob Aleksa

1

• Rob Aleksa
• PG Corporate Controls
• OMAC Users Group meeting

2
PG Background

• 98,000 people in 80 countries
• 147 plants in 42 countries
• US56.7B sales in 140 countries
• 22 Brands gtBillion US
• 4 Global Business Units
• Beauty
• Family Health
• Household Care
• Gillette (Oct 2005)

3 billion times a day, PG brands touch the lives
of people around the world
3
Objectives

• Share why this work is important
• Status overview
• Solicit your involvement and support

4
Problem

• If you work with machines (end-user OEM, System
  Integrator)
• Do you consistently see well structured software
  from machine to machine?
• If you do see structured software, do you see the
  same software design from machine to machine or
  do you have to relearn every time?
• Do you spend more time than you think necessary
  to integrate your machine to another machine, to
  the process, or to the plant MES systems?
• Are there opportunities you cant take advantage
  of because your automation software is a barrier?
• Are you satisfied with how much youre spending
  in software automation, how long it takes, and
  with the results?

5
What Can Be Done?

• If the answer is no to any, what can be done?
• Define a better software design structure
• Reapply learnings from the process community
  (i.e. S-88)
• Build on OMAC PackML
• Communicate benefits enroll
• Strive for global consistency

6
What is Make2Pack?

• Development of common industry software methods
• Equipment system breakdown structure
• Conceptual software structure models
• Terminology
• Harmonize reapply
• Process-Batch S88 Model (Std for Flexible Mfg
  Batch Control)
• OMAC PackML Model (Packaging Machine State Model)
• S95 Part 3 (Std for Enterprise-Control
  Integration Activity Models of Mfg Op Mgmt)
• Drive PackML as ISA IEC standards
• Cooperative effort between WBF OMAC
• Impacts both process machine

7
Why is Make2Pack Important?

• More effective supply chain
• Horizontal Vertical integration
• Increases efficiency
• Customer response
• Make-to-pack-and-ship replaces make-to-stock

• Regulatory compliance
• Modular, structured, pre-tested code
• Reduces validation cost
• Simplifies implementation of science-based,
  Process Analytical Technology

• Reduce life cycle costs
• Consistent software across vendor platforms
• Modular, reusable software
• Reduced training and maintenance costs

8
System Comparison
Equipment Decomposition
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ISA S-88 Adaptation to Packing
S-88 Process Model
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Common Thread
Process ISA 88 State Model
OMAC PackML State Model
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Complementary Models
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The Work So Far
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The Working Example!
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Methodology Benefits

• Use of reusable code modules
• Use of software library
• Machine software modules built on tested function
  blocks
• Machine software modules that plug-in to the
  OMAC state model

15
Modularity Automations Future

• Modular software enables
• Flexible, modular mechanical designs
• Example packaging machines are becoming clusters
  of robotic modules

16
Software Engineering Concept
Early Make2P Execution
Douglas Machines
OEM Intellectual Property
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Modular Programming Savings
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Programming Comparisons
Conventional
New Direction
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Benefits to Machine Builders

• Shorter machine development cycle
• Standardized program structure
• Increase in machine features
• Ease of machine upgrade
• Increased breadth of machine offerings
• Removes engineers preferences
• Protection of Intellectual Property

20
Benefits to Manufacturers

• Common programming concepts
• Ease of line integration
• Easier connection between process packaging
• Easier connection to production management
  systems

21
Broad Interest Support
3s-Software Werner Manfred Aagard Smith
Brenton ABB Quirke John ARC Blanchard John ARC
Humphrey David Arla Foods Klemmensen Poul Arla
Foods Svendsen Arne Avid Solutions Rankin
John BR Industrial Automation Eder Franz BR
Industrial Automation Lang Siegfried BR
Industrial Automation Massey Nathan BR
Industrial Automation Sandhoefner Markus Beckhoff
Hoppe Gerd BR and L Consulting Brandl
Dennis Brewery Martens Bloemen Paul CAMC/ATC Ryan
Dr. Kenneth Capmatic Mosseau Michel Cognex Keup
Mark Cognex Bierbaum Kris Consultant - Jean-Marc
Vielle Jean-Marc Control Engineering Hoske
Mark Coors Brewing Company Gray Doug Douglas
Machine Faust Joe DOW Salomons Henry DuPont
Falkenau Larry DuPont Gianakiz Harry DuPont Julie
F Smith ELAU Jensen Tom Juergensen Leif Kowal
John Eli Lilly Hawkins Aubrey Eli-Lilly Sorrak
Ken Enterprise Ireland Mullen Joan Enterprise
Ireland O'Malley Brian Genentech Wheeler
Mark General Electric Leppiaho John Georgia-Pacifi
c Salminen Jarmo Grupo MPR Imass Alejandro GTI
Schreck Achim GTI Stegerwald Frank Hersheys
Rhoads Herman Hixson-inc Vanover Mitch
HLQ Hawkins Bill Honeywell Albano Mark Honeywell
Bohan Jamie Honeywell Mars Pam Invensys/Wonderware
Brennan Sean ISA Ferson Lois Janssen
Pharmaceutica N.V. Buys Kris Kraft Foods Laffan
Liam Lund Institute of Technology Johnsson
Charlotta Manufacturing Automation Assoc. Craig
Lynn Marchi Peter Putnam Fred Verstraeten
Eddy Masterfoods Rivero Jorge Masterfoods USA
Rieger Ron Mettler Toledo Jeffery
Rodger Millennium Chemicals Wilkins
Maurice Morinaga Engineering Sugiura Tony
(Akitoshi) National Instruments Bailey
Mike National Instruments Chandhoke
Sundeep Nestle Anthony Abbott Nestle Besson
Jean-Paul Nestle Desbaillets Jean-Marc Sponsors
and Members of the WBF-OMAC-SP88 Make2Pack
Effort 154 People representing 83
Companies Company Name Last Name First
Name Nestle Frochaux Jean-Daniel NNE (Novo
Nordisk Engineering) Kristensen Morten NNE (Novo
Nordisk Engineering) Petersen Lars NNE (Novo
Nordisk Engineering) Stenbakken Mikael NovaTech
Charpentier Leo Oklahoma State University
Rhinehart R. Russel Omron Andersen Dave Packaging
Digest Mans Jack Packaging World Reynolds
Pat Pfizer Sharma Vik Pfizer Lynch Ed Pfizer
Martell Bob
Pfizer Pillai Lou (Velumani) Pfizer Swodzinski
Paul PFM Peracchi Sergio PMMI Egan Tom Polar
Ferrero Francisco Pro Mach Leuschke Scott Pro
Mach Suchy Mark Procter Gamble Aleksa
Rob Procter Gamble Berg Eric Procter Gamble
Chappell Dave Procter Gamble Fischer
Achim Procter Gamble Fry David Procter Gamble
George Paul Procter Gamble Joyner Jay Procter
Gamble Koch Chris Procter Gamble Lamping
Mike Procter Gamble Van Dyke Rick ProLeiT Lutz
Martin Rexroth Bosch Group Wenzler John Rexroth
Bosch Group Kessler Klaus Rockwell Automation
D'Mura Paul Rockwell Automation Hood
Gavan Rockwell Automation Maki Adam Rockwell
Automation Morse Rick Rockwell Automation Ray
Kakali Rockwell Automation Tennant
Marcus Rockwell Automation Trobisch
Ruediger Rockwell Automation Vasan
Venkat Rockwell Automation Wagner Mike Rockwell
Automation Weatherhead Andy Rockwell Automation
Wodzisz Shoshana Rockwell Automation Seger
Dan SAB Miller Basson Garth SAB Miller Lotz
Willie SAB Miller Siddique Azim SAB Miller Trunek
Larry SAB Miller van Schoor Thinus Schering
Plough Nash Thomas Schering Plough Lees
Matthew Schneider Electric Hayler Steve Schneider
Electric Keiter Uwe Schneider Electric Owens Brian
Schneider Electric Riedel Martin Schneider
Electric Tyehimba N'kosi Siemens Backx
Ivo Siemens Broucke Mario Siemens Henderson
Bill Siemens Moors Bart Siemens
Mueller-Heinzerling Thomas Siemens Pareijn
Guido Siemens Pieper Mike Siemens Schumacher
Heike Siempelkamp Emmerton Mike Sponsors and
Members of the WBF-OMAC-SP88 Make2Pack Effort 154
People representing 83 Companies Company Name
Last Name First Name SLControls Loughlin
Shane SLControls McFeeley Garvan SLControls
Mcmorrow Darragh SLControls Moran
Keith SLControls Morrissey Joe Stone Technologies
Unger Keith Systematix Carmount Mark Systematix
Neidert Richard Thermo Electron Corporation
Broski Gerry Tokyo Institute of Technology Batres
Rafael TV-Munchen Voigt Dr. Tobias TWP Training
Consultancy Scholten Bianca Uhlmann Pac-Systeme
Armbruster Markus Unilever Mcdonald Andrew VDMA
Koldau Alexander Wago DeCramer Mark WBF Staff
Monahan Tom YASKAWA Downie John YASKAWA Gegg
Jim YASKAWA Urda Andrew Yokogawa Emerson
David Zarpac Rumi Eric Zarpac Zepf Paul
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Letter Of Support
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Specific Named Supporters
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Project Team?

• Dave Chappell Procter Gamble
• Chairman, representing World Batch Forum
• Lou Pillai -- Pfizer
• Vice chairman, representing ISA SP88 committee
• Fred Putnam -- Markem
• Representing OMAC Packaging Workgroup (OPW)
• 180 individuals from 90 companies

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Summary

• Shared why Make2Pack is important
• What it is
• Benefits

• Gave a short status overview

• Need your involvement and support
• OEMs
• System Integrators
• End-users