Industrial 20 Industrial Weighing News · The Digitization of Production Enabling Profitable Growth...
Transcript of Industrial 20 Industrial Weighing News · The Digitization of Production Enabling Profitable Growth...
News
The trend towards digitalization will
allow fully integrated production-control
strategies, end-to-end supply chain in-
tegration and reduced qualification ef-
forts. But how will it help to put these
into practice?
Date Analytics
With more complex supply chains and
higher customer expectations, tight pro-
cess control is the key. The ability to
gather, analyze and access relevant pro-
cess and product data is the basis for
this control, but transferring data from
multiple sites is still a challenge for many.
Predictive maintenance
Controlling and monitoring device per-
More companies are being challenged to implement increasingly stringent operational controls
while remaining reactive to quickly changing market demands. Digitalization is one of the key le-
vers to improve plant efficiency and implement true manufacturing-control strategies. The right in-
vestments in sensor technology, interfaces and software make implementation easier.
The Digitization of Production Enabling Profitable Growth
20Industrial Weighing
Industrial
formance is a critical aspect of com-
plying with local weights and measures
authorities. Built-in predictive mainte-
nance and condition monitoring sim-
plify maintenance and compliance ac-
tivities to ensure critical measurements
are reliable.
Modular Production
Modular production allows manufactur-
ers to create standardized production
units giving them the flexibility to adjust
capacity according to rapidly changing
market demands. A reliable automation
process and standardized interfaces be-
tween modules along with plug-and-
play principles help realize this concept.
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Thre
e W
ise
Inve
stm
ents
for D
igita
lizat
ion
METTLER TOLEDO Industrial News 20
Three Investments that Pave the Way for Digitalization
Many manufacturers are already planning or experimenting with the implementa-
tion of digital concepts into daily operation. When it comes to measurement tech-
nology however, there are a few basic principles that are here to stay: when up-
grading existing manufacturing sites or working on Greenfield projects, investing in
the right sensors, interfaces and software will help you to fully leverage the poten-
tial of digitalization.
Digital sensors Sensors are the foundation of a digital world. To play this critical role, they must provide more than simple analog signals. Signal conversion built into sensors improves signal quality signifi-cantly, while monitoring environmental parameters such as temperature or sensor condition are the basis for predictive maintenance. Stored calibration data speeds up sensor installation and replacement.
www.mt.com/powercell-video
Standardized interfaces With an increasing number of devices and sensors in production plants, data processing and transfer can be a painful process not only in automated systems but also when communicating to ERP systems. Innovative new interfaces hold the promise to make modularization possible and integration faster.
www.mt.com/ind-ACT350
Smart softwareIncreased data volumes require smarter, faster selection and processing. Lags in making collected data
available can create production bottlenecks. New software can simplify information gathering and impro-
ve data-processing speeds. Data visualization supports process insights, cloud services ensure uptime
and data collection software increases production efficiencies.
www.mt.com/prodX
www.mt.com/collectplus
3METTLER TOLEDO Industrial News 20
Learn about connectivity Efficient transfer of weighing process data to more
advanced MES or ERP systems results in a more
transparent manufacturing process.
Download the white paper
www.mt.com/ind-data-integration
Save up to 50% in
maintenance costs with POWERCELL®-based scales
Integrate your PLC up
to 10x faster with the
ACT350 transmitter
Reduce data collection
and reporting costs up to
70% with ProdX and
Collect+
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Stan
dard
ized
METTLER TOLEDO Industrial News 20
Historically, equipment in production has been integrated into the plant IT infrastructure following the
automation pyramid (ISA95). In most cases, sensors provided only simple data. Today sensors can
provide more robust data, such as status monitoring, predictive diagnostics and calibration alerts. In-
tegration choices are driven by the kind of data required, the existing infrastructure and the type of data
network available. Sensor data is complemented by prioritized information such as alarms and condi-
tion data.
Moving toward Industrial Ethernet
Industrial Ethernet (IE) is the use of Ethernet (IEEE 802) in an industrial environment with protocols that
provide determinism and real-time control. Examples such as PROFINET, EtherNET/IP, EthernetTSN are
replacing classic fieldbuses and serial communication when connecting with automation systems be-
cause they provide more flexibility and are easier to install, troubleshoot and replace.
OPC-UA brings another level of standardization
OPC Unified Architecture (OPC UA) is a machine-to-machine communication protocol for industrial
automation developed by the OPC Foundation. It focuses on communicating with industrial equipment
and systems for data collection and control, is freely available without restrictions or fees, is not tied to
one operating system or programming language and is one of the leading standards for cloud connec-
tivity inside and outside the facility. Combined with IE, it becomes the basis for future industrial devices.
Learn how to reduce installation effort when connecting to PLCs: www.mt.com/ind-video-PLC-integration
Future Gateways to the Digital World Standardizing Industrial Connectivity
While an increasing number of devices and sensors are being used in production
plants, data processing and transfer in automated systems that must communicate
with ERP and MES systems can still be painful. Modern interfaces and open data stan-
dards hold the promise to make interoperability possible by extending the amount and
type of valuable data available.
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Data protocol Industrial EthernetPROFINET, EtherNet/IP, EthernetTSN
OPC UA Server or Gateway OPC UA
Classical Data IntegrationRS232 (for PC systems)4-20mA (DCS, PLC)
Advantage Standardized robust network Standard for data transfer Installed base
Disadvantage Relative newness Requires a server Limited data availability
Control strategy Centralized/decentralized Centralized/decentralized Centralized
Layout Network Network Point-to-point
Transfer rate 1ms NA 100ms
Bandwidth High High Low
Determinism High High Low
Installation effort Medium Low Medium-high
Use in industry Growing Growing Stable
Component cost Low-to-medium Low Low
Use in hazardous areas
Through fiber optic or increased
protection
NA Use of 20ma, 4-20ma and
Profibus PA
Typical use Tank-weighing system; filling
machine integrated into plant
automation system
Scales connected to cloud system
for documentation and tracking pur-
poses, process inspection solutions
Traditional integration either to au-
tomation systems or data-collection
systems
Example Transmitters with IE, ACT350
www.mt.com/ACT350Gateway with OPC UA ` www.mt.com/pi-omac
Classic terminals
www.mt.com/terminals
OPC UA RS232Industriel Ethernet
METTLER TOLEDO Industrial News 20
6 METTLER TOLEDO Industrial News 20
Define Expectations
A producer of herbal sweets that exports more than 60
different lines of lozenges and teas to over 50 countries,
wanted assurance that they were working with equipment
that could maintain efficiency, optimize production and re-
duce waste. They asked themselves:
• Can we further optimize processes and reduce waste?
• How do we know we are using the right scales for the
processes that we are running?
• How can we ensure high performance and consistent
quality?
Perform a Risk-based Verification
The company then performed a GWP® Verification on 12
scales to evaluate if every scale in production was the op-
timal solution for the specific process step in which it was
being used. GWP Verification is based on a comparison
between the documented measurement uncertainty from
calibration (under scale production conditions) and the
required accuracy, weighing process requirements, the
weighing process risk and defined tolerances.
Equi
pmen
t Ver
ifica
tion
Are Your Scales Running at Peak Performance?A Risk-Based Approach Reduces Cost
A cough-drop manufacturer wanted assurance that it was running optimized processes. A simple risk-
based test provided guidance on how management could reduce maintenance cost and confirm that
all of the company’s scales were fit for purpose with regards to accuracy. See how you can benefit
from this service and remain in line with your quality requirements.
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7METTLER TOLEDO Industrial News 20
Benefit from Reduced Calibration Costs
GWP Verification showed all scales were well-placed and
running optimally within their predefined process toler-
ance. However, the test also provided clarity on which ser-
vices and effort would be required to maintain this level of
performance. The outcome resulted in a clearly defined
program for routine testing between an optimized calibra-
tion service. As a consequence, the herbal producer could
significantly reduce calibration costs and steadily ensure
high process consistency for the future.
Discover GWP® VerificationVisit our GWP library to see how Good Weighing Practice can help you opti-mize routine testing, simplify compli-ance, and maintain overall equipment effectiveness (OEE).
www.mt.com/gwp
3Learn More
8 METTLER TOLEDO Industrial News 20
A Be
tter W
ay: F
orce
Cal
ibra
tion
Innovative New Tank Calibration Easily Improve Accuracy and Traceability
Gone are the days of various types of time-consuming and expensive calibration meth-
ods with unsatisfying accuracy and traceability results. The new innovative Force Cal-
ibration method offers economical and fast calibration without using huge amounts of
test weights and liquids.
9METTLER TOLEDO Industrial News 20
Planning a new tank installation?Contact METTLER TOLEDO for consulting!
Visit our websitewww.mt.com/ind-force-calibration
Higher accuracy and assured traceabilityUsing the force applied by hydraulic cylinders and monitored by reference load cells, it
is possible to reach a high level of accuracy. The S-type reference load cells are trace-
able to test weight standards and provide accuracy and traceability comparable to cal-
ibration with physical weights.
Up to 32 tons full capacityMETTLER TOLEDO service offers calibration for tank scales with capacities from 1 to 32
tons, where using test weights is time consuming and cumbersome. Regular re-cali-
bration can be scheduled to comply with quality systems. Furthermore, for weights in
excess of 32 tons, a material substitution calibration is possible using the calibration
technology offered by our service team.
Saves thousands of dollarsTraceability to the international weight standard is best ensured by frequent calibration
with certified test weights. However, the test-weight method is expensive for large ca-
pacities. Instead of traditional calibration services, you can use this innovative solution
to maintain traceability at lower costs.
Minimum time investmentForce Calibration can be performed at any time with a minimum amount of preparation.
The calibration is done quickly, thanks to equipment portability. Moreover, the whole cal-
ibration process is significantly faster than calibration with test weights. This lowers the
effective downtime of your production facilities dramatically over the course of a year.
No wasted waterMaterial substitution calibration requires a huge amount of purified water in this ca-
pacity range. Consuming this valuable resource for a one-time purpose creates a lot of
waste and can be prevented easily. By using Force Calibration, not a single liter of pu-
rified water is wasted. This helps to increase both the efficiency of the calibration cycle
and the sustainability of the ecological footprint.
Avoid contact with tank contentsThe tedious emptying and cleaning of tanks during substitution calibration can be
avoided by applying this new method. For certain weighing applications, such as food
or pharmaceutical processing, the risk of tank contamination is eliminated and the cost
of extra pure material is saved.
Scale
attachment points
Reference S-type
load cells
Hydraulic cylinders
Floor attachment points
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Pharma Workflow
Improve Productivity and SafetyInnovative Weighing Solutions Across Your Processes
PowerDeck™ Floor ScalesPowerDeck™ digital floor scales offer many benefits, including real-time operator guid-ance, reduced maintenance cost – and more!
www.mt.com/powerdeck
1 2Bench ScalesOur high precision compact scales with global Ex approvals provide safety and performance – where it matters most.
www.mt.com/ICS466x
Mea
sure
men
t Sol
utio
ns
11METTLER TOLEDO Industrial News 20
Pharma Workflow
Improve Productivity and SafetyInnovative Weighing Solutions Across Your Processes
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Weigh ModulesPrevent costly bad batches and rework by monitoring the performance of your tank-weighing systems in real-time.
www.mt.com/ind-powermount
Formulation SoftwareAutomating your process with formulation soft-ware eliminates the number one cause of quality issues – human error in manual work flows.
www.mt.com/rms
5Weighing TerminalsOur user-friendly terminals help to reduce the overfilling of drums by up to 40% – and higher speeds increase efficiency.
www.mt.com/IND570
POWERCELL® PDX® Load CellsReduce maintenance costs by up to 30% and avoid costly downtime with our POWERCELL® PDX® truck scales.
www.mt.com/powercell
For more information
METTLER TOLEDO GroupIndustrial DivisionLocal contact: www.mt.com/contacts
Subject to technical changes©09/2018 METTLER TOLEDO. All rights reservedDocument No. 30403374MarCom Industrial
www.mt.com/ind-generic
Proven POWERCELL® technology has been helping customers worldwide to maximize their yield for over 30 years.
3 Ways to Maximize Your Yield With POWERCELL® Technology
1 2Improved reliability with
POWERCELL® PDX® at the
Truck Scale.
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3Elimination of bad batches with
PowerMount™ Load Cells for
Tanks Scales.
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Increased operator guidance
with PowerDeck™ Digital
Floors Scales.
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WATCH VIDEO NOW! www.mt.com/powercell-video