Sonoco Products implemented FactoryTalk Metrics across 33 tube and core plants to increase visibility and boost efficiency. The standardized solution increased uptime by an average of 30% and reduced changeover times by 20%, allowing Sonoco to increase capacity by 3% while only requiring a 15% increase in resources. Integration with Oracle also provided a direct link between production data and financial reporting. Overall, the project delivered a repeatable and cost-effective approach to capturing real-time machine data for driving continuous improvement efforts.
4. Presenter – Tod Easterling
• Supply Chain Commercial Services Manager
• Education
• Bachelor of Science Accounting and Marketing
• 25 Years working with Manufacturing Information
Technology Solutions
• 17 years with Sonoco Products
• Data Collection
• HMI input and Oracle Integration of production data
5. Presenter – Wendy Armel
• Principal MES Analyst, Stone Technologies
• Education
• BSBA Computer Information Systems
• MBA
• 17 years in manufacturing
• Data acquisition and reporting
• Discrete event simulation
• Deep knowledge of FactoryTalk® Metrics
• Design OEE solutions in many industries
6. Audience
• How Many
• End Users
• System Integrators
• Rockwell automation
• Distributors
• Other
• Experience with
• FactoryTalk® Metrics
• FactoryTalk Transaction Manager
7. What is FactoryTalk® Metrics?
OEE and Downtime Tracking (Typical Applications)
• Overall equipment effectiveness (OEE) can provide you with critical insight into how well
you are managing your production operations.
• Downtime - identify specific causes of inefficiency, including sophisticated methods of
analysis that allow you to measure or compare the performance of plants, lines, machines or
even individual production teams.
Sonoco Unique Application
• Oracle Integration using FactoryTalk Transaction Manager
• Scrap Tracking
10. Company Overview
• Sonoco leads the packaging sector on Fortune’s 2018 list of Most Admired
Companies, ranking first in the industry for several key attributes like Global
Competitiveness, Financial Soundness and Social Responsibility.
Sonoco Markets
Food and Beverage Frozen Foods Adhesives and Sealants
Dairy Snacks Ink
Produce Infants and Toddlers Automotive
Deli Construction
Seasonings and Spices Pharmaceuticals
Coffee Other Sports and Nutrition
14. Project Goals
Initial Goals
• Provide real time, accurate machine data to enable zero loss corporate
productivity initiative
• Feed all data to a corporate data repository for plant to plant, line to line
comparisons
• Simple, Standard Solution – One size fits all…
Expanded Goals
• Integrate automated data collection with Oracle jobs data
• Transition from Data Collection to Smart Manufacturing via integration with
Oracle and other supporting systems/processes
15. Business Challenges
• Standardize on a single, simplified solution that is repeatable
• Provide automated data that is easily used by operations
• Alignment of loss buckets across the division
• Ability to capture production within a continuous process
• Culture Change
• Tribal Knowledge automated system (FactoryTalk ® Metrics)
• Data Accountability – Integrated into daily plant standard work
• Data ownership – work to define an owner at each location that would be actively engaged in
the reliability of the data
16. Technology – FactoryTalk ® Metrics and Transaction
Manager
• Sonoco’s needs
• Allen-Bradley PLCs at plants and wanted to stay within the Rockwell Automation platform
• Leverage existing trusted partnership with EESCO (local Rockwell distributor)
• Flexibility to use the engine of FactoryTalk Transaction Manager to incorporate non OEE data
back to Oracle
• Provided machine level detail to support corporate productivity initiative
• Open end data structure allows Sonoco to pull the necessary data from FactoryTalk Metrics
and Oracle to a central data repository for high level reporting
• FactoryTalk is flexible and able to grow with the company
18. Project Specifics – Project Approach
• Consulting Engagement with Stone Technologies to create a design
• Defined a small set of simple effective custom reports for the plant level
• Defined a structured methodology that was repeatable
• Resulted in small pilot - one plant/one line
• Refined pilot for base configuration
• Expanded base configuration to 33 Tube and Core plants
implemented on a global footprint
19. Project Specifics – Pilot Project
• Standard, Simple, limited scope design to capture loss data for
continuous improvement initiative
• Machine States – Running or Down
• Speed – How fast it is running when producing goods parts
• If down, what is the reason
• Account for every minute of machine time
• Implemented solution on one machine
• Created 4 reports to be used within the plant
• Dashboard Report
• Downtime Reasons
• Uptime
• Average Speed
26. Corporate Reporting
• Sonoco has created reports that allow divisional management to see KPIs across
multiple plants that focus in the following areas:
• Monthly Downtime Costing
• Changeover
• Scrap losses (Yield)
30. Tubes and Cores - Expansion
• Global Division standard was rolled out to 33 plants over the course of 4 years
• Currently increasing our global footprint with addition plants are added as scheduled
• Standardized on the Oracle integration at all sites active using Oracle
• Standardized on a set of downtime reasons
• Standardized on a set of scrap reasons
• Standardized on a set of reports to be implemented at all sites
31. Unexpected Results
• Shortened recovery for plant production changes
• Data provides immediate machine performance feedback for product/mix changes
• Provides the data foundation for eliminating overtime/reducing shifts
• Set targets in uptime and speed to increase throughput to reduce overall hours
• Integration with Oracle gives direct link to P&L
32. Management’s Perspective
• FactoryTalk ® Metrics is a valuable resource to quantify and identify daily
throughput improvement opportunities
• The solution provides a standard way to compare plants/lines across the division
• The near real-time data allows plant management to make timely decisions
• Increased overall efficiencies
• Increased plant capacities
• Integration between FactoryTalk and Oracle provides the foundation for “Smart
Manufacturing” and Plant Network Optimization
33. Realized Results
• Increased uptime an average of 30%
• Reduced change over time by 20%
• Provided timely feedback for improvement efforts
34. Next Steps
• Creating a corporate standard to be piloted on one line in the Plastics Division
• Implementing data driven HMI and downtime reasons across all Tier 1 plants
• Creating a smart PLC layer that will flex based on each location and their specific assets and
data needs
• Expect to implement the standard solution at 81 facilities, 300+ lines
35. Benefits
• Standard solution
• Easy to explain to new project team members
• TIME – a standardized solution shortens implementation time
• RESOURCES – a standard solution allows alignment and utilization of key
resources
• MONEY
• Software cost
• Hardware needed to support a standard solution
• Possible network modifications/upgrades
• Ongoing support
• Integration
36. Lessons Learned
• Keep it simple
• Data accuracy
• Prior to implementation ~50%
• Automated solution 95% accuracy (durations of time is 100% accurate)
• Must be part of a managed process – Estimated savings continuum below:
37. Summary
• Goals
• Define what you are trying to solve.
• Get a new data acquisition solution up and running quickly and efficiently
• Keep the solution cost effective
• Approach
• Do a proper design before implementing a solution
• Stick to a standard configuration as much as possible
• Integrate with a productivity improvement process for management buy in
• Results
• Streamlined, repeatable solution that provides valuable data to multiple levels of the
organization
