Digital Manufacturing for a Coffee Roasting Facility in Netherlands using Siemens SIMATIC IT
Purpose
The European leader in coffee, tea and instant drinks chose Siemens Simatic IT MES to register and support the day-to-day manufacturing operations in their coffee roasting facility in The Netherlands.
The coffee roasting facility produces a high volume of Finished Goods that are shipped to hundreds of retail locations across Europe. ATS integrated Simatic IT MES into their daily operations and drove the project through the entire lifecycle from kick-off through to go-live.
Customer were looking for a digital manufacturing solution to streamline day-to-day manufacturing operations
- Integration with the existing ERP system
- Product Traceability
- Advanced Warehouse Management
- OEE Visibility & Downtime Management
Solution Approach
- The interface between ERP and MES also enabled shop floor personnel to make Operating Procedures available to the in a digital format. The Electronic Work Instructions can be viewed directly on screen by multiple people simultaneously.
- SIMATIC IT MES has been integrated with the ERP system to automatically download Material Master Data, Purchase Orders, Work Orders and Storage Locations.
- Integration with the production equipment on the shop floor helped to register production events and machine downtimes.
- Integration with the Date Coders and Label Printers to ensure the correct Use-By-Date and Production Lot is printed on the bags (sales units) and boxes (SKUs).
- Warehouse operations have been streamlined and optimized: Automatic assignment of
warehouse locations based on business rules for incoming Raw Materials and produced Finished Goods streamlines internal transportation of pallets that are being moved around in the plant. - Plant Management has real-time insight into actual and historical performance rates of production lines (Overall Equipment Effectiveness) and performance bottlenecks.
- Optimized material utilization and waste reduction: Warehouse transfer clerks are assisted by picking and staging the right pallets for consumption at the lines. Automated “Material Stock Requests” generate transport orders for raw materials to ensure that input materials are replenished at the production line before it runs out of material, ensuring continuous production.
- Production personnel are supported while preventing contamination of intermediate materials through smart moveable container management.
Systems & Tools
- Siemens SIMATIC IT Production Suite
- Siemens SIMATIC IT Process Libraries
- Siemens SIMATIC NET OPC server
The Results
Increased visibility into production operations as operators have real-time insight into production status anywhere in the plant.
Real-time inventory levels of Raw Materials and Finished Goods.
Reduced paperwork (digital data collection).
Transparency about causes for downtimes.
Streamlined warehouse material movements.
Optimized material utilization and waste reduction.
Better equipment utilization and less downtime
Reduced cost of ownership: Storing all production data together in single database instead of in different (Excel) spreadsheets helped to improve the value of the generated reports.