Material & Process Tracking - Rockwell Automation & Process Tracking ... Functional Requirements...
Transcript of Material & Process Tracking - Rockwell Automation & Process Tracking ... Functional Requirements...
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Material & Process Tracking A Track & Trace Application in Support of Food Safety
Craig Winterland
Business Development ManagerNovember 2016
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Agenda
Implementation Process
Tracking Application
Food Industry Business Drivers
Food Safety Modernization Act (FSMA)
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Agenda
Implementation Process
Tracking Application
Food Industry Business Drivers
Food Safety Modernization Act (FSMA)
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Food Safety Modernization Act (FSMA)
Most comprehensive changes to food safety regulation since the 1930’s
Stemmed from number of high-profile outbreaks of food borne illnesses over the past decade
FSMA will affect stakeholders across the food supply chain, including food packaging and
equipment manufacturers
Changes the focus from reacting to contamination incidents (recalls) to prevention of incidents
The law will be governed and implemented by the FDA – giving it new powers to enforce
compliance
FDA proposes rules
Public Comment Period
Incorporation of Public
Comments
Publication of Final Rules
Implementation & Enforcement
2013-
2014
Through Mid
2014
Late
2014
Aug
2015
2016+
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Food Safety Modernization Act (FSMA)
5
Three main aspects of FSMA most likely to impact food producers and equipment manufacturers:
Record Keeping and Traceability – show compliance to the food safety planand that operations are within preventive control limits. Expected to be oneof the greatest costs of FSMA compliance.
Preventive Control – implement a written food safety plan that focuses onpreventing hazards. Clear understanding of the hazards that may occur andhave preventive controls to minimize or prevent the hazard.
Sanitary Equipment Design – new equipment design considerations toprevent bacteria harborage and ease to clean/sanitize
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Agenda
Implementation Process
Tracking Application
Food Industry Business Drivers
Food Safety Modernization Act (FSMA)
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Business Challenges in Food Processing
Dairy Processing Example
7
Maximizing Yield Critical to Profitability
Maximize Yield• 80% of the cost in production
is cost of Milk.• Milk prices continue to be
volatile and at all time highs.Also true for many rawmaterial ingredients used infood processing.
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Business Challenges in Food Processing
Food Safety Food Quality
Confident Quality Assurance
Data Collection in support of
CCP’s & other data parameters
linked to material in process
Increased number of food borne
illnesses - CDC estimates that food
borne diseases sicken 1 in 6
Americans (48 million) and kills
3,000
Link CCP’s (and all process data) to Material in Process
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Business Challenges in Food Processing
Record Keeping FSMA
Supplier to Table
Modern traceability systems can
reduce liability. Can show which
supplier shipments it took in and where
products went.
When recalls do occur, traceability
systems can make these recalls
“surgical,” with only affected
products having to be pulled from
shelves
11 Recalls Reported Already 1/1/16- 1/14/16
Genealogy & Traceability to Packaged Unit Produced(Narrows Recall Bracket)
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Agenda
Implementation Process
Tracking Application
Food Industry Business Drivers
Food Safety Modernization Act (FSMA)
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Challenge – Material Tracking Through Many Types of Manufacturing Processes
Cooling/
Stacking
Mixing
Forming/Baking
Spray/Salting
Packaging
Batch
Processing
Motion
Control
Discrete
Control
Continuous
Processing
Safety
Motors/
Drives
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Track & Trace Application Key Features
Functions / Features NGT2
Material Receiving
Material Inventory Management (Raw, WIP, Finished)
Material Tracking & Traceability
Material Dispositioning & Quality Sampling
Data Collection at Process Steps (Manual & Automated)
Real-Time Yield Analysis
Product Genealogy & Traceability
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Track & Trace ApplicationSoftware Architecture
FactoryTalk Transaction Manager: Manages data flow between control layer and
information layer. Also incorporating the use of AOI’s in next version.
FactoryTalk Historian: Time Series process data collection
FactoryTalk VantagePoint: Enterprise-wide process manufacturing dashboards
SQL
Database
FactoryTalkTransactionManager
FactoryTalk VantagePointFactoryTalk Historian Track & Trace Core
Components
OP
TIO
NA
L (
No
t
Incl
ud
ed)
OP
TIO
NA
L (N
ot
Inclu
ded
)
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Track & Trace ApplicationDemonstration Application - Storyboard
1
The Track & Trace Application
is tracking material through a manufacturing
process beginning with raw material receiving,
storage, movement and transformation
of material into final product.
Receiving, Inspection
Storage
Pasteurization
Extraction
Drying
Packaging
Union Pacific RR
LAB SAMPLESupplier Lot 050
1 2 3 4
5 6 7 8
Raw Material Silos
SL 001
SL 619
unused
Silo 1
Reject
Consume Mtl into ProcessAdjust Silo Inventory
Consume into Pasteurization from Silo Inventory
Capture Material Temperature
Material Silos
T-1 T-2 T-3 T-4
Lot 193
Lot 267
unused
Silo A-1
A-1 A-2 A-3 A-4
Material Silos
Consume Mtl from
PasteurizationCreate new Lot
IDAdjust Silo Inventory
Consume Mtl from Pasteurization
Create new Lot IDAdjust Silo Inventory
Lot M04
Lot M72
unused
Silo T-4
SL001
Dryer
Consume Mtl into Dryer FIFOAdjust Silo Inventory
Create Lot ID Lot ID D289
LAB SAMPLELot ID D289
Reject
Reject Silo
R-1 R-2 R-3
Consume Mtl into FG Packaging
Create FG Lot ID
FG Lot ID FG5-289
Create Pallet LabelEncapsulate FG Lot
ID to Pallet ID
SL619
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Inventory Management
1
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Inventory Management
1
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Inventory Receiving - Manual
1
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Inventory Receiving - Sampling
1
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Lab Sample – Grid View
1
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Material Movement Between Inventory Locations
2
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Inventory Reject
2
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Consume & Produce
2
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Consume & Produce
2
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Forward Genealogy
2
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Backward Genealogy
2
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Agenda
Implementation Process
Tracking Application
Food Industry Business Drivers
Food Safety Modernization Act (FSMA)
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Implementation Overview
Functional
Requirements
System Design
System Build
Factory
Acceptance
Test (FAT)
Site
Acceptance
Test (SAT)
Deployment
Support
Re late d To
Functional Requirements Specification
Initial Engagement Qualify
Opportunity
Approx 1 to 2 Weeks
Approx 1 to 3 Weeks
Up to a Mximum of 8 Weeks
Approx 1 Week
Approx 1 Week
Approx 1 Week
We don’t Shortcut the Implementation Process
It takes less time than a more comprehensive track and trace implementation might take.
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Task Sequence Diagram
2
Track & Trace System
Task Sequence Diagram
Task 2 Functional Requirements
Subtask 2.1 Develop Functional Specification
Subtask 2.2 Issue to Customer for Approval
Subtask 2.3 Scope & Work Plan Review (Toll Gate)
System Planning
Task 6 Acceptance Testing
Subtask 6.1 - Site Acceptance Testing
Subtask 6.2 - Deployment
Technology Transfer & Deployment
Task 7 Documentation & Training
Subtask 7.1 - System Documentation (FS & SDS)
Subtask 7.2 - System Training
Project Closeout
Task 4 Application Programming / Development
Subtask 4.1 Plant Model
Subtask 4.2 Material Receiving
Subtask 4.3 Production / Consumption
Subtask 4.4 Data Collection
Subtask 4.5 Interfaces unknown (LIMS, Weigh Scales, Printers…)
Subtask 4.6 Visual Displays / GUI’s
Task 5 Application Testing
Subtask 5.1 - Unit Testing & Integration Testing
Subtask 5.2 - Factory Acceptance Testing
Development & Testing Process
Task 3 System Design
Subtask 3.1 System Design Specification (SDS)
Subtask 3.2 SDS Review
Subtask 3.3 Site Acceptance Test Specification (SATS)
Subtask 3.4 Work Plan / Scope Review (if needed)
Task 1 Implementation Planning
Subtask 1.1 Project Kick-off Meeting
Subtask 1.2 Project Management Plan (PMP)
Task 8 Project Closeout
Subtask 8.1 - Project Acceptance
Subtask 8.2 – Final Project Closeout
Task 0 Project ManagementSubtask 0.1 Project Administration
Subtask 0.2 Project Management
Subtask 0.3 Project Status Meetings
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Implementation Resource Model
3
Project SponsorCustomer
Project ManagerCustomer
Project ManagerRockwell Automation
Project EngineerRockwell Automation
System Architect Technical Lead
Rockwell Automation
Technical LeadCustomer
Operations LeadCustomer
SME (Process)Customer
SME (Other)Customer
Customer Change
Management
Committee
Customer
Support Team
Rockwell
Application
Support
Account ManagerRockwell Automation
Support Model
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Post Implementation Support Model
3
Project Sponsor
Customer
Project Manager
Customer
Project Manager
Rockwell Automation
System Architect
Technical Lead
Rockwell Automation
Technical Lead
Customer
Operations Lead
Customer
SME (Process)
Customer
SME (Other)
Customer
Customer Change Management Committee
Customer Support Team
Rockwell Application
Support
Account Manager
Rockwell AutomationSupport Model
Project Engineer
Rockwell Automation
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