TECHNICAL NEWS AND TRENDS FROM PREVAS
#3 2015 innovation
case study
Are you the innovator of the year for 2016? Manufacturing and development services valued at SEK 1.25 million.
Arla is building Europe's largest dairy for cottage cheese. PAGE 6
case study
Orkla's factories are being interconnected with an ultra-modern follow-up solution for production. PAGE 8
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TR I N DU S
Y 4.0
eded e n 's t a – Wh oid the to av we n s ’ r emperos effect? clothe E 3 PAG
SANDVIK MINING
INVESTING IN AUTOMATION Prevas delivers. PAGE 4
PREVAS / TECH TRENDS
MORE EFFICIENCY? IN TODAY'S COMPETITIVE society, efficiency measurements
constitute one of the best tools for discovering untapped potential in factories. Measurements that provide business leaders with valuable insight and good input for making the right organizational decisions. On page 8 you can read about Orkla Foods and their investment in a modern OEE system for production follow-up that will give them overviews at more than 100 production plants. Sandvik Mining is also taking more control of their processes for cemented carbide in Västberga. In close collaboration with the client, Prevas has designed, installed and commissioned a new automated flow, complete with machines, robots and control systems. On the whole, it provides major efficiency gains at the same time as it improves the working environment for the operators, with a significant decrease in heavy lifting. See page 4 for more information. Demand for cottage cheese is behind a project conducted by Prevas for Arla. The production capacity at Arla's facility in Skövde was not keeping pace with consumers’ increasing demand for cottage cheese. On page 6 you can follow Arla’s rapid journey of change during which they moved to a new facility in Falkenberg, commissioned production systems and technical equipment, integrated new technology and started up production with new employees. During the year we welcomed our own “Prevas evangelist” Andreas Rosengren, who is spreading the message about Industry 4.0, currently the hottest topic in the manufacturing industries. The term Industry 4.0 was coined by German politicians for marketing digital communications to the manufacturing industries, and Andreas is one of Sweden's most prominent experts in what is still a vision. Sweden has good prerequisites for Industry 4.0 and Andreas believes that our knowledge of automation, IT and telecom is at least on par with Germany’s. The difficulty in digitalization is finding the right expertise, those who are knowledgeable of the interface between IT and automation. Prevas has historically put substantial resources into supporting innovation and skills provision. You can read about a few of the projects in this issue. Both the Prevas Student Embedded Award, which is an annually recurring award for students at Linköping University, as well as the competition Inission Innovation Award 2016 with the top innovator winning development and manufacturing services valued at SEK 1.25 million. We are collaborating here with Ny Teknik and ALMI. This is a slimmed issue of Tech Trends and I hope you will have time to read it and find inspiration in the midst of all the good things that the holiday season has to offer. I wish you all a relaxing and innovative Merry Christmas and a Happy New Year!
EDITORIAL
ARE YOU THE INNOVATOR OF THE YEAR FOR 2016? The Inission Innovation Award is a competition introduced by Inission and it has become a major success. There have been three winners since 2012 and an innovator will now once again be honored through this competition in entrepreneurship and innovation. Just as in previous years, the winner is offered industrialization and manufacturing services at a value of up to SEK 1 million, and thanks to Prevas being a new collaborating partner, the winner will also be offered development services valued at up to SEK 250,000. The final date for submitting entries is March 29, 2016. Read more at www.inission.com http://inission.com /inission-innovation-award2016-har-oppnat/
PREVAS STUDENT EMBEDDED AWARD 2015 Goes to Oskar Södergren with his Yggdrasil Home Automation System. It is an innovative and flexible solution for home automation, characterized by flexibility and simplicity, and with a major focus on cost. Congratulations! This is the second year that the prize is being awarded and it is an annually recurring award for students at Linköping University with a prize of SEK 10,000 for the best entry. The solution must incorporate advanced engineering, explore new ground and be usable.
Innovation for Growth CHR ISTER R A MEBÄCK Senior Vice President and Chief Operating Officer for Solutions, Prevas AB
2 / Innovation for Growth
Prevas has approximately 600 employees and is the primary supplier and development partner for many leading companies in the energy, automotive, defense, life science, telecom and manufacturing industries.
www.prevas.se
TREND
INDUSTRY 4.0
The emperor’s new clothes? Andreas Rosengren is a man with a mission. As Prevas’ “Industry 4.0 evangelist” Andreas is one of Sweden's most prominent experts in what is still a vision. The term Industry 4.0 was coined by German politicians for marketing digital communications to the manufacturing industries. Read about Andreas’ take on where we are today, what we should do so that the vision won't just become a case of the emperor's new clothes and which advances the new digital vision can bring. describe the factory. This makes it much easier for example, to add machinery and is nothing more than a paradigm shift, a configure systems. The system will adjust shift that can be seen as the Fourth Indusitself, and there are major efficiency gains trial Revolution, following in the tracks with the flexibility. of industrial mechanization in the 1800s, The model for today’s industrial IT electrification in the 1900s and computersolutions in factories entails that a process ization in the 2000s. What is really behind is firmly bound to a particular system that the concept Industry 4.0 and supports that specific process. how does the German initiaWhen the data is not bound tive affect industrial developto systems it becomes easier ment for Nordic industry? to make changes in factories Industry 4.0 entails because the data is sufficiently an entirely different way free that you can relate it of looking at informato any given moment. My tion. Industrialization and absolute vision when it comes computerization have become to the industrial Internet of so complex that a need has Things is that we will be able Andreas Rosengren arisen for simplifying comde-computerize communications to the point that the basic munications. The big difference with 4.0 is that data is components – the things – can handled in a much less restrictive manner. talk with each other in plain language. But Traditional industrial automation is based this requires that the thing internals are simplified and rid of unnecessary inforon hard-coded interfaces, with definitions mation, because the things today commade in advance that you want “this clump municate a multitude of superfluous data of data, on this occasion.” With the new without context. With 4.0 context data is technology, you can take any data you want put into perspective with other events. and say “I want to use it like this.” This is Because it is important to establish the a direct opposite, and for industry, it is a level from which we communicate, 4.0 revolutionary approach. is not expected to replace automation’s With Industry 4.0 you do not need a control levels. We often speak of four finished model of your factory. You can levels in the system structure consisting deploy a system that gathers information of machines, integration, MES and ERP. from the facility openly and freely without Much of that I relate to is on levels one needing to hard-code it. For as soon as and two with machines and equipment, hard-coding is necessary, time is required in other words pure automation and then and above all, you have to guess in advance infrastructure to tie them together. A lot how the data will be handled in the future. will happen on the MES level. Above all it Instead you can now receive data continuously about so many “events” that only will have significance for the “thing” that the patterns from these events emerge to is on the lower level and that spouts out THE DIGITALIZATION PROCESS THAT IS JUST OVER THE HORIZON FOR MANY companies
“A major challenge in implementing 4.0 is skills provision.”
the information that is handled on a higher level. Today’s automation technology is very complicated and system integration in a factory consumes many hours of engineering. With modern interfaces you do not need to be as knowledgeable of the details and you can more easily choose systems from different suppliers. The virtual factory will become the master. You want to avoid a multitude of IT solutions in a factory because automation equipment is made to be simple and idiot-proof. A technical solution can have a service life of up to 20 years. In principle you never need to touch the equipment during this time and the machine builders are the best experts. No standard computers work in this way and this is why communications interfaces must be simplified. It should not be important what this “stuff” consists of, but rather that the way in which it communicates is simple. We then have to step away from the approach of fixed structures.
CONTINUED ON PAGE 8
Andreas Rosengren and Torbjörn Johansson from Prevas.
Innovation for Growth /
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CASE STUDY
SANDVIK MINING INVESTING IN AUTOMATION Sandvik Mining in Västberga is expanding capacity and streamlining many of its processes. Prevas has delivered and commissioned a new production line with robots as well as a complete automation system that has been integrated with machinery and a new high bay warehouse. 4 / Innovation for Growth
“HERE IN VÄSTBERGA we've worked with cemented carbide since the 1950s and there is considerable knowledge of how the material should be handled,” says Daniel Lindqvist, technical manager at Sandvik Mining in Västberga. “The investment has been made possible thanks to gains in efficiency, but at the same time we have the capability to improve the working environment for operators and reduce our impact on the external environment.” Sandvik manufactures cemented carbine rotary cutters for the mining industry. With the new automated facility, Sandvik Mining is upgrading the final steps of the process. ROBOT SERVICE AND SELF-DRIVING FORKLIFTS
Prevas has designed, installed and commissioned a new automated flow, complete with machines, robots and control systems. The project began in January 2014 and
delivery was underway throughout the year. The new production line includes several concepts developed in collaboration between Sandvik and Prevas during the course of the project. In the original layout for example, each of three machines were served by a separate lift. “By adjusting the location of the machines, the three lifts could be replaced by a single robot,” says Lars-Erik Forsberg, sales manager for system solutions at Prevas and responsible for the delivery to Sandvik Mining. “To create a better working environment for the operators, primarily with regard to noise, the machines and robot were placed in a separate room in the facility.” Another solution that has turned out well is material transports with AGVs, Automated Guided Vehicles. From the beginning, the idea was for the material to be transported in the facility on transport
PREVAS / TECH TRENDS
An industrial robot packs boxes with cemented carbide cutters for the automated high bay warehouse.
Daniel Lindqvist and Fredrik Tallbom showing the new production line at Sandvik Mining in Västberga. Smart but nonetheless simple and robust automation solutions have been developed and implemented in close collaboration with Prevas.
conveyors, but with self-driving forklifts a more open and pleasanter layout could be attained. “Self-driving forklifts provide a flexible solution that can be adapted to our future needs and prioritizations,” says Daniel Lindqvist. “Moreover, we found that conveyors would actually cost significantly more.” The initiative for self-driving forklifts came from tool designer Fredrik Tallbom at Sandvik Mining. Prevas could provide an interface that made the solution possible, both mechanically and for communications. “We designed the technical solutions, such as the forklifts being able to safely pick up and drop off materials at the various stations,” says Lars-Erik Forsberg. “Thanks to our open collaboration, with regular meetings and discussions, we achieved very good results.”
SIMPLE, ROBUST SOLUTIONS
A number of experts from Prevas participated in the project – project managers, mechanical engineers, electrical engineers, installation technicians as well as robot, cell computer and PLC programmers. Much of the work was also carried out at Prevas’ shop in Västerås. “To facilitate installation and speed commissioning, we utilized a good portion of our shop resources in testing communications and functions before we delivered to Västberga,” says Lars-Erik Forsber. The project has required many special adaptations and methods of problem solving, but at the same time, Daniel Lindqvist emphasizes that Sandvik Mining has constantly strived for implementing solutions that are as simple and robust as possible.
“Together with Prevas we carefully simulated the flows and then built up the production line with a straightforward approach and low complexity,” Daniel Lindqvist explains. “Our production is fairly simple, with conventional robots that lift materials in and out, so there was no reason to make things complicated.” Despite there still being work to be done with fine tuning the flow and increasing the flexibility of the facility, Daniel Lindqvist is very optimistic about the future. “Installation and commissioning have gone smoothly and we're also very satisfied with the assistance and support we've received from Prevas now that we've begun testing the facility. We're happy to be able to invest here in Västberga and we're looking forward to continued development of our production and operations,” says Daniel Lindqvist in closing. × Innovation for Growth /
5
CASE STUDY
Arla building Europe's
LARGEST DAIRY PLANT for cottage cheese
The demand for KESO® has dramatically increased in recent years. Limited capacity in the old dairy plant and an opportunity to streamline production led to the decision to move all operations to an unused plant in Falkenberg. Prevas has delivered and commissioned a scalable and future-safe production system. “SALES OF COTTAGE CHEESE – with Arla’s KESO® brand being best known among consumers – has increased by about 25 percent each of the past five years,” says Owe Jarlö, dairy manager at the Falkenberg plant. “The products are good for the health, tasty and the production process is very efficient in making use of the raw materials, which means that the development is welcomed by both Swedish dairy farmers and us at Arla.” Arla has previously produced various cottage cheese products at the Skövde dairy, also under the supervision of Owe Jarlö who has worked nearly 45 years in various positions at the company. The capacity in Skövde was limited however – the dairy is in the downtown area and as the city Dairy manager Owe Jarlö.
grew and became more densely developed, there were no longer opportunities for expanding operations. “Production in Skövde had just maxed out,” says Owe Jarlö. “With limited production capacity we can't reach out to new markets, such as Norway, Germany and Great Britain. It had gone so far that in 2013, we were rationing cottage cheese to retailers because production just couldn’t meet the demand.” At about the same time as cottage cheese production was running at full capacity, Arla phased out hard cheese production in Falkenberg and the plant was no longer in use. Arla saw an opportunity here to build up a new, adapted dairy plant for cottage cheese, with high capacity and close to the many milk-producing farms in the Halland district. PREVAS DELIVERS PRODUCTION SYSTEM
Work was begun in 2014 with the new production lines in Falkenberg and during 2015 the machinery and equipment from the Skövde plant were moved to Falkenberg and installed. Deltatec has been the lead contractor for this very extensive
6 / Innovation for Growth
project and Prevas was engaged to adapt and commission the new production system. “With a tight schedule, the most important challenge has been in getting all of the equipment in place in a structured manner without compromising quality,” says Lars Sandberg, sales manager for Prevas Industrial Systems in western Sweden. “To ensure the delivery we strengthened project management and even tried to be on site in Falkenberg as much as possible.” Prevas has involved a wide range of expertise and functions – project management, testing, development, support and maintenance. All have worked side by side with Arla’s personnel. The MES (Manufacturing Execution System), which constitutes Prevas’ primary delivery in the project, gathers and analyzes production data to optimize production with regard to, for example, energy consumption and utilization of various resources. HIGHER CAPACITY AND MORE EFFICIENT PRODUCTION
Arla previously produced 20,000 metric tons of cottage cheese each year, which was insufficient for the growing market. The
The flagship of Arla’s cottage cheese products is KESO ®, a brand that was first registered back in 1958. Shown by production manager Tintin Mattsson.
new dairy plant in Falkenberg has initially been dimensioned for an annual capacity of 29,000 metric tons. Depending on how the market develops in coming years, however, annual production can be scaled up to all of 44, 000 metric tons. “We’ll initially be at about the same production volume as in Skövde,” says Tintin Mattsson, production manager at the Falkenberg plant. “The big difference is that with low investments in equipment and a small increase in personnel, we can dramatically increase the production volume.” An arrangement that permits adjusting production to meet market needs is also entirely in line with how Prevas works. “The only thing we know about the future is that our customers’ operations are constantly under development, and won't be the same in five years as they are now,” says Lars Sandberg. “This why we always strive to build scalable and flexible solutions.” WITH THE SIGHTS SET ON “BUSINESS AS USUAL”
During the autumn Arla has worked with its suppliers to stabilize production and settle into routine production. Prevas
is among those helping to optimize the processes and to check off the last items on the to-do list. “Prevas has had an important role in the project, with overall responsibility for coordinating and integrating the various suppliers’ control systems,” says Tintin Mattsson. “Support has worked well and they're now helping us to understand and clear up the remaining issues.” Production of cottage cheese in Skövde came to an end in late September. The move to Falkenberg has been made without any significant decreases in production. Countless tests have been run alongside ordinary dairy operations and an entirely new production organization is in place. “We've lived with constant change for nearly a year and a half now,” says Tintin Mattsson. “We've moved and commissioned systems and technical equipment, integrated new technology and started up production with new employees who in many cases lack previous experience in cottage cheese production. Implementation of the project has been fantastic and both our suppliers and personnel have made major contributions.” × Innovation for Growth /
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CASE STUDY
ORKLA’S MORE THAN 100 PRODUCTION PLANTS ARE BEING BROUGHT TOGETHER WITH AN ULTRA-MODERN OEE SOLUTION In their strivings for higher production efficiency, Orkla – a leading supplier of branded consumer goods and concept solutions to the grocery sector and large households – has entered a framework agreement with Prevas for delivery of an ultra-modern system for production follow-up. THE DELIVERY IS BASED ON THE highly praised OEE system (Overall Equipment Effectiveness) RS Production from Swedish Good Solutions. Prevas’ efforts and the product RS Production give Orkla's more than 100 factories a standardized process for performance control and help the organization to harmonize important measurement figures on all levels. The system for production followup provides Orkla with overviews of its production performance – both at individual factories and on the group level. Efficiency measurement as a tool for detecting untapped potential in production is a decisive competitive factor for all our customers. Through valuable insight, help is obtained in making the right organizational decisions, both locally and globally.
“Orkla’s competiveness is being strengthened by gaining an easy-to-use and efficient tool for accelerating processes for continuous improvements,” says Christer Ramebäck, Senior Vice President and Chief Operating Officer for Solutions at Prevas. Prevas and Good Solutions have closely collaborated for many years, with the Orkla assignment being the most important undertaking to date. Implementation of the new system for production follow-up has already begun and the process is scheduled for completion by the end of 2017. This entails an extensive commitment for Prevas. The large number of simultaneous projects has required a special multinational deployment team for implementing the system in Scandinavia and the Baltic countries. ×
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Innovation for Growth
8 INNOVATION FOR GROWTH
Continued from page 3
Industry 4.0 The emperor’s new clothes? Industry is not quite yet ready for changes. It is still the Excel spreadsheet that is the reigning “MES” and data is gathered in a rather old-fashion way. But it is high time for industry to begin considering its infrastructure. Because the cornerstone of Industry 4.0 is Ethernet-based digital communications, it must be made possible to apply it. If you are aware of your communications channels it is very easy to then lift in things via these channels. My best advice is therefore to ensure construction of industrial networks, to set up a structure and to make sure that your company has a true global standard for industrial Ethernet. Formulate questions such as: How does the internal network topology look? How should our machine park be so that we can to switch towards 4.0? If you invest in the wrong technology it will be difficult and expensive to converge. A major challenge in implementing 4.0 is skills provision. The entire industry is mobilizing. Automation and IT have been moving closer together for quite some time, but it is easier to find personnel who work with automation and teach them IT rather than the opposite. IT development is moving so quickly that you never really have time to become an expert at anything. People are needed who understand the interface between automation and IT, but they are extremely difficult to find. With our collective knowledge, Prevas has the requisite specialist expertise for helping clients to be clear in specifying requirements. Sweden has come far in automation technology and telecom. We have major domestic companies such as ABB, and the reason why the Automation Region was founded in Sweden’s Mälardalen in particular is because this is where a large portion of the world's automation technology was born. It is not more expensive to invest in new technology – what is missing is the courage. That is why we at Prevas consider it our mission to help companies to initiate a new automation strategy. ×
www.prevas.se