Arla Foods:
A Software Standardization Case Study
How Arla Foods leveraged software standardization to reduce commissioning time by 50%
Arla Foods
Arla Foods is a large food and beverage manufacturing company that works with OEMs on a global scale
Company Profile:
Machine Integration
Arla Foods does not have a technology centre - they purchase machines from many suppliers around the world and integrate them into a production/packaging line system.
Their challenge is to work with OEMs to create machines which can be integrated into lines easier and faster.
Packaging Line Example
A typical packaging line at Arla Foods is made up of 9 machines from 7 suppliers located in 4 countries.
All of these machines have to be integrated into a production line horizontally and vertically using special purpose interfaces for each OEM.
Challenges
Arla Foods frequently faced these challenges when integrating machines into their lines
There was no consistency in the automation software of different machines. This includes different machines provided by the same OEM.
Each machine had a bespoke horizontal and vertical interface. This made it difficult to integrate new machines in a line.
Each machine had a unique operating and reporting concept. This meant that operator and technician training had to be provided for each machine.
Software Standardization Saves the Day
Arla Foods worked with OEMs to create a standard software architecture and machine interface.
This interface is based on PackML for the interface between machines and the SCADA system and Make2Pack for the automation software architecture.
The benefits reported by Arla Foods and their OEMs are remarkable.
End User Benefits of Standardization
4x Reduction in Integration Costs
The standardized interface is easy to test with a pre-defined and reusable test plan.
5x Reduction in Specification Costs
Use case and technical specifications can be reused reducing the workload involved in creating specifications for new machines.
50% Less Commissioning Time
Standardized architecture is easy to troubleshoot and software quality increased thanks to the standard architecture.
OEM Benefits of Standardization
Value Added Machines
Machines which are PackML and Make2Pack compliant are more valuable to end users, increasing revenue
Faster Development Time
Standard software architecture means less bespoke programming is required for each machine
Greater Reusability
Code modules are reusable across machines leading to increased quality and decreased cost
Fewer Custom Interfaces
Interfaces don't have to be defined per client when everyone is using a standard interface
Reduced Training
Standardized training material can be used to train end users in operating and maintaining machines
Easier Debugging
Standardized software is easier to navigate and understand while troubleshooting and debugging
What Can Standardization Do for You?
By standardizing your machines and interfaces, you can increase the quality of your machines and your capacity to deliver machines to your customers.
At KB Controls, we have more than 5 years experience of standardizing our clients' solutions. With Vanderlande, we defined the standard modules that were used to deliver large material handling systems to clients around the world. These standard modules have been used by more than 30 engineers in 3 countries to deliver 7 large projects valued at more than 200 million euros in record time.
Are you ready to save time and money on your automation projects? Use the form below to organize a free consultation call with one of our automation consultants to learn how we can help your business.
References
This case study is made up of data from the following sources