Carlsberg Autoware IoT partnership | Automation World
Based 172 years in the past, Carlsberg is a Danish brewing firm with a world presence that’s among the many world leaders within the brewing trade. With over 140 brewed drinks, together with core beers, specialty and craft beers, non-alcoholic beers and native manufacturers from quite a few international locations, Carlsberg has a various and globalized beer portfolio.
Carlsberg has grown by means of a number of acquisitions and confronted some challenges widespread to producers situated in numerous areas of the world. There was little consistency in how completely different websites tracked manufacturing information. Consequently, the shortage of constant information and outdated strategies meant they might not totally optimize machine efficiency, leading to unplanned downtime, longer lead instances, increased prices and diminished throughput – all of which negatively impacted total gear effectiveness (OEE).
Though Carlsberg had a full Manufacturing Execution System (MES) in 10 factories, they knew they wanted a leaner answer that will scale shortly and simply and that will assist them standardize information assortment throughout their international amenities to fulfill the wants of the trade to enhance manufacturing efficiency.
Carlsberg companions with Autoware to leverage IoT options and enhance OEE
Carlsberg turned to Autoware, an Italian software program firm targeted on enabling digital transformation within the manufacturing sector, as a know-how associate to assist them enhance their information assortment and processes. To this finish, Autoware leveraged PTC’s know-how to develop an IoT-based software for real-time efficiency monitoring. The appliance might be utilized by machine operators to simply assess manufacturing efficiency in numerous amenities utilizing real-time information and alerts.
To develop the applying, Autoware used Kepware, software program that routinely pulls information from quite a lot of automation units and software program functions and aggregates it right into a unified information mannequin. As well as, Autoware leveraged ThingWorx, an end-to-end industrial IoT platform that gives perception into manufacturing and asset well being with real-time information analytics and quite a lot of insights and manufacturing experiences. Collectively, the applied sciences allowed Carlsberg to watch machine information and undertaking it onto dashboards.
The information offers operators a transparent understanding of how the road is performing in opposition to targets, whereas real-time alerts assist them shortly determine and resolve manufacturing points. Equally, some floor operators have tablets outfitted with an app that makes use of ThingWorx information to trace a selected machine’s downtime and recommend the rationale in actual time; The operator can then affirm the subsequent motion to be taken, even from a distant location within the facility.
Autoware’s answer helps Carlsberg standardize and scale effectively
Carlsberg had already laid a lot of the groundwork for cross-site standardization, however their new answer would higher fill the gaps left by legacy gear and variations in information assortment, structure, and software program. Importantly, standardizing information and metrics would enable Carlsberg to benchmark machine efficiency and productiveness in opposition to different factories. After launching in simply three months, it will additionally assist meet the necessity to scale quickly throughout a number of amenities.
Specifically, Kepware was key to creating worth and dealing in a centrally configured information atmosphere. It allowed them to import and export configuration data and simply modify a given setup’s variances to fulfill the applying’s information requirements. Kepware collects information from the PLCs on the regional websites, and ThingWorx takes the information from Kepware and visualizes it for real-time monitoring and diagnostics at every website.
The staff selected a cloud-based structure for the brand new answer, which provided some important benefits over the earlier on-premise answer at their different amenities. A cloud-based answer makes it simpler to additional develop the system and add new capabilities. Any updates to the applying solely should be deployed as soon as, and the cloud-based structure makes the identical modifications immediately out there to any location. On the identical time, they will make some site-specific options solely out there to sure websites and later deploy them to others.
This flexibility to configure the answer as wanted – and subsequently extra environment friendly and time-saving – considerably improves the full price of possession. “The footprint of the brand new answer is way smaller than the footprint of an on-premise answer – it requires fewer sources to handle,” says Marco Faltracco, Technical Lead at Autoware. “The structure permits them to scale to so many extra belongings, and now they’re contemplating additional enlargement as a result of it is simple,” he continues. “When it comes to complete price of possession, they are much decrease than an on-premise answer.”
Carlsberg achieves improved efficiency and productiveness whereas planning for a extra sustainable future
Thus far, the applying has been rolled out at 28 Carlsberg amenities. Lastly, implementation within the remaining breweries is on the agenda. Whereas Carlsberg’s digital transformation journey continues to be ongoing, the corporate has already seen clear advantages of real-time efficiency monitoring throughout its group. First, they’ve seen improved operations and better high quality merchandise, in addition to fewer manufacturing line disruptions with higher visibility. As well as, Carlsberg has seen much less gear downtime thanks to higher preventative upkeep. One other optimistic result’s the discount of waste, which contributes positively to the corporate’s objectives by way of carbon emissions and sustainability.
Specifically, the ability of the partnership has been instrumental in Carlsberg’s skill to roll out its answer with confidence and effectivity, which can solely profit all events in the long term.
For Carlsberg, advancing their digital journey has been an affirmation of the corporate’s strong place within the brewing trade, not simply as an innovator, however as an organization dedicated to creating a greater, extra sustainable future – and so they stay up for continued partnership with Autoware for fulfillment.