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1、Unlock the value of connectivity.Industry 4.0 Technical thought leadership paperProduction flexibilityHow to deliver what you need,when you need it.This paper explains how Industry 4.0 is helping manufacturers respond to the need to be more flexible.It explains the fundamentals and shows how Tetra P
2、ak is helping customers improve their forecasting,develop more responsive production plans and execute customers orders faster with fewer mistakes.Part of a series,this paper will be of interest to anyone with a stake in the food and beverage industry and especially those who are looking for ways to
3、 respond to the increasing pressures resulting from changing business realities.2/Industry 4.0 Technical thought leadership paperIndustry 4.0Industrial practice has evolved by adopting new technologies and innovation since the Industrial Revolution over three hundred years ago.The term Industry 4.0
4、was coined to describe the fourth great leap in technology since the dawn of the industrial age.Industry 1.0Mechanical productionEnabler:SteamIndustry 2.0Mass productionEnabler:Electricity and division of labourIndustry 3.0Automated production Enabler:Electronics and ITIndustry 4.0Digitalphysical pr
5、oduction Enabler:Robotics,sensors,AI,cloud computing and blockchainIndustry 4.0 The face of grocery retailing is changing.Consumers want more ways than ever before to satify their demand for convenience,performance,sustainability and personalisation,and traditional retailers are facing increasing co
6、mpetition from online competitors(the so called,“etailers”)for the purchase of food products.This is putting pressure on food and beverage manufacturers to be more flexible.They need to find ways to respond to demands for shorter delivery times,smaller batch sizes and calls for mixedproduct pallets,
7、as well as even faster to changes in consumer demands.And they need to do all this without increasing their costs.Industry 4.0 the revolution in manufacturing made possible by the advances in automation,data collection and analytics offers the tools needed to address these challenges.Drawing on unri
8、valled industry expertise and global experience stretching back over six decades,Tetra Pak can help manufacturers improve their production flexibility.This is achieved by implement an Industry 4.0 solution that will improve demand forecasting,develop more responsive production plans and facilitate c
9、ollaboration across the entire supply chain so they can execute customers orders faster and with fewer mistakes.3/Industry 4.0 Technical thought leadership paper Fig.2:Connect,Collect and Compare.the three Cs at the heart of an Industry 4.0 solutionIndustry 4.0 is about smart manufacturing.It charac
10、terises a factory where,as shown in fig.2,all the equipment is connected and data is collected,integrated and then compared against the required standards to make sure the production process is stable and producing highquality products.Smart manufacturingSmart factoryIn a smart factory,the manufactu
11、rer benefits from insights that emerge from combining operational and business data.Operational data collected from equipment and operational systems such as the Manufacturing Execution System(MES),Quality Management System(QMS),Laboratory Information Management System(LIMS)and Warehouse Management
12、System(WMS)should be linked to the business management systems,such as the Enterprise Resource Planning(ERP)system.CollectCompareConnectConnectProcessing AreaPackaging LinesOutbound LogisticsInbound Supply Chain4/Industry 4.0 Technical thought leadership paperThe advances of food and beverage manufa
13、cturing are made possible by Industry 4.0,which relies on nine foundational technologies,as shown in fig.3.The following,in addition to system integration,have the most impact of efforts to improve flexibility:Big data and analytics.Manufacturers already have access to a lot of data about their oper
14、ation.However,by gathering even more from across their organisation and feeding it into a single system,they can gain powerful insights into their operations.When this is integrated with information about where they have product throughout the distribution network and linked to realtime sales data f
15、rom retailers and raw material stocks from their suppliers,they are able to develop a neverbefore possible view of their current status that can be used to maximise their production flexibility.Advanced robotics.Robotic systems have a long history of use in manufacturing where they have been used to
16、 take on complex or hazardous assignments.In the food and beverage industry,robotic systems are already being used in a range of palletising and warehousing applications,some of which are described later in this paper.Simulations.Simulations are used to build virtual models of the real world so diff
17、erent scenarios can be explored.Today,most manufacturers rely on experienced staff and simple,spreadsheetbased solutions to simulate the impact of changes to their manufacturing operations.However,by using advanced modelling software coupled with the wealth of information collected from their operat
18、ions in realtime,they are able to improve production flexibility.Smart manufacturingBig data&analyticsArtificial intelligenceAdvanced roboticsAugmented realitySystem integrationIndustrial IoTSimulationAdditive manufacturingCyber securityFig.3:Nine technologies underpin Industry 4.0.(Manufacturuers a
19、re using simulations to optimise machine settings for the next product a customer in the production schedule and to work out the best way to minimise run before the physical changeover,model different ways to cater for a rush order from the disruption caused by an unplanned machine stop.)5/Industry
20、4.0 Technical thought leadership paperBetter forecasting.Traditionally,food and beverage manufacturers forecast demand and plan their production using historic data using manual or relatively simple,spreadsheet based systems.They aim to process and pack products in long production runs and minimise
21、the frequency of line stoppages for product changeovers so they can maximise machine utility and efficiency.However,this means they need to overstock raw material and tie up working capital by holding finished goods in warehouses so they can respond to customer orders quickly.By connecting and integ
22、rating the manufacturers production forecasting system with their customers order intake and demand management systems,a manufacturer can develop a dynamic production forecast that will meet actual demand with the optimal number of product changes,without needing to hold excessive raw material or fi
23、nished goods stocks.The ability to build and analyse the data sets required to create these forecasts demands the use of advanced data analysis and simulation systems,as it would not be possible to manage the required analysis manually.An added advantage is the ability to publish updated schedules a
24、cross the organisation and,if appropriate,with customers and suppliers so everyone can play their part in optimising production in real time.How can production flexibility be improved?6/Industry 4.0 Technical thought leadership paperBetter planning.Disruption to a production plan caused by a retaile
25、r placing a rush order or a critical piece of machinery breaking down is inevitable in even the very best managed organisation.When this happens,it is important that the manufacturing team can adjust their plans quickly so they can manage the situation with as little disruption as possible.This mini
26、mises the impact on their delivery commitments and any ensuing consequences.Planning can be improved by using advanced simulation tools,integrating plans across the entire organisation and,if possible,by connecting the manufacturers systems with their customers and suppliers networks.The resulting p
27、lan can be modified at short notice to accommodate changes in a customers priorities which is especially important for online retailers who hold low or even no quantities of finished goods stock.An Industry 4.0 solution that can collect,manage and analyse the huge volumes of data needed to create a
28、dynamic production plan extremely quickly,also allows the production team to model the impact of an unscheduled machine stoppage and find a way to minimise the disruption it will cause.Augmented reality and handheld devices with realtime data are increasingly being used to guide operators through pr
29、oduct changes and to support engineers making repairs by offering them detailed instructions or advice from equipment experts at other locations.How can production flexibility be improved?7/Industry 4.0 Technical thought leadership paperBetter execution.Today,order handling is typically a manual pro
30、cess that involves multiple steps and considerable interaction between systems and people.This adds to the time and cost required to process an order and risks mistakes being made at one of the multiple data entry or processing points.By integrating the different internal systems and connecting them
31、 with both the customers and suppliers systems,an automatic order handling solution can be developed.If this is then connected with the forecasting,planning and production control systems,a manufacturer can develop a flexible,endtoend manufacturing solution.The technologies enabled by Industry 4.0 a
32、lso offer further opportunities to improve the execution of the production plan.They include:Recipe and batch execution systems that allow the production team to complete product changeovers quickly and accurately.Advanced warehouse management systems with smart decision-making capabilities.These gu
33、ide a forklift driver or a selfguided vehicle to collect raw materials and deliver them to the production line.They can also load pallets of finished product onto a truck for shipment to retail customers.Advanced robotics able to take product from several production lines or operate in the warehouse
34、 to build pallets of mixed products/multiple SKUs(the so called“rainbow pallets”)to meet specific orders exactly.End-to-end supply chain systems that show,in real time,exactly where a product is located in the delivery network so,if needed,the delivery route can be changed to match the demand from t
35、raditional or online retailers.Together,these advances offer a manufacturer a distinct competitive advantage as they will improve their responsiveness and increase the flexibility of the service they offer their customers.How can production flexibility be improved?8/Industry 4.0 Technical thought le
36、adership paperCustomerA producer of milk and wheybased powder ingredients in Central Europe,with a huge range of products,some of which have a complex production process.ChallengeThe customer needed more flexibility both to handle variation in incoming raw materials and to meet the rapidly changing
37、demands of its dynamic product market while also ensuring traceability.At the same time they needed to increase production throughput and capacity.SolutionWe commissioned the largest processing plant we have ever created in our long history,with a single point of control in the control room.All the
38、equipment is fully integrated and automated,and fully traceable from raw material intake to finished and packaged products:100 tanks,19 filters,13 pasteurizers,heaters UHT,2 CPS evaporators,3 CPS dryers,a Tema dryer,a powder system,and 3 CIP stations,as well as mixing equipment and a reception syste
39、m.Full traceability even covers equipment from thirdparty suppliers.ResultA new fully integrated,automated,and highcapacity production site with builtin flexibility and traceability,and seamless and efficient handling of all product types.The customer has gone from struggling with an old site that w
40、as small and rigid,to a spacious,fully automated,and very flexible plant.With full paperless traceability,they produce lactose and whey products including lactose,as well as milk and whey protein concentrates.They can easily adapt to market and customer demands,by quickly and easily changing product
41、ion based on their raw materials.Increase flexibility and capacity with Tetra Pak PlantMasterCase study9/Industry 4.0 Technical thought leadership paperThe food and beverage industry has,in general,been slower than some others to adopt an Industry 4.0 mindset and to date has made limited use of the
42、foundational technologies.Tetra Pak is changing the game.By leveraging our decades of global food and beverage industry experience,our unrivalled expertise in supply chain management and our investment in digitalisation,we are able to partner with food manufacturers of any size,and in virtually any
43、corner of the world,to plot a path to realise the benefits that Industry 4.0 offers.Tetra Pak has developed our unrivalled expertise and reputation for manufacturing operation management by working with leading food and beverage manufacturers all around the world.By embracing Industry 4.0 we are tak
44、ing this to another,higher level.Join us to start your journey to a more flexible future.From theory to practice.Our approach starts with a workshop led by Tetra Pak experts and joined by your production,maintenance and business leaders.Together we will identify the key challenges and agree on the k
45、ey objectives for an improvement strategy.To make sure the workshop is able to achieve this,Tetra Pak experts will visit your site before the meeting to make a preliminary review.They will review your current performance and,by referring to best practice and drawing on experience gained by helping c
46、ustomers all around the world to increase flexibility,identify the vital few areas where an Industry 4.0 solution will add value.Following the workshop,a joint team will be formed to finalise the long-term strategic goals,agree on the short-to-medium priorities and start developing a detailed implem
47、entation plan for the first steps.12310/Industry 4.0 Technical thought leadership paperAnders AndrnProduct Manager,Plant Automation and Integration I have worked at Tetra Pak for 30 years,gaining extensive experience across the global food and beverage industry by helping customers improve their ope
48、rations.I have managed different parts of the Services portfolio and delivered numerous TPM and WCM programs that have reduced operational cost and minimised time losses in customer operations.I currently manage our Plant Automation and Integration portfolio and,by working with a portfolio of end of
49、 line,intralogistics and our Industry 4.0 innovations,I help customers develop fitforpurpose automation and digitalisation strategies.Please contact Anders if you would like to discuss any aspect of this paper or would like to arrange to take the first steps on your Industry 4.0 journey with Tetra P
50、ak.Author biographies.Notes For a comprehensive review of the opportunities connectivity offers the food and beverage industry,visit https:/ 4.0 Technical thought leadership paper Tetra Pak International S.A.Read more at https:/ reserve the right to introduce design modifications.Tetra Pak,PROTECTS WHATS GOOD are trademarks belonging to the Tetra Pak G