The more efficient packaging the processes, the more sustainable their performance. In an interview with Stefan Knoth, Technical Support at Carl Kühne KG, you will find out how Schubert uses digital data and its GRIPS.world customer portal to optimise customer machines for sustainability. The family business ranks among the market leaders in the food industry and produces delicatessen products such as barbecue sauces and remoulades.
Big Data is the new currency – in the packaging industry as well as everywhere else. But storing machine data alone is not enough. If you really want to profit from sustainable packaging machines, you need a meaningful analysis of the important key figures and one-hundred-percent protection against attacks from the Internet. Schubert makes both possible: A GS.Gate is integrated into every new TLM line as an industrial gateway. This enables detailed evaluations of plant productivity to be called up. The results can be viewed either on the GRIPS.world customer platform or on the machine’s operating terminal. From this analysis, potentials and possibilities can then be derived as to how to improve the OEE (Overall Equipment Effectiveness) ratio of the line and therefore its added value.
Together with Schubert, delicatessen manufacturer Kühne is already evaluating the OEE key figures in two new robot-assisted Schubert packaging lines. The almost identical flexible lines pack glass bottles with sauces, vinaigrettes and remoulades in cartons. Schubert’s GS.Gate gateway collects all machine data and networks the Kühne plants with the GRIPS.world digital platform while adhering to the highest security standards. The Schubert experts can view the data via this customer platform, because the customer has allowed Schubert access to it. Based on the current production data and the automatically generated weekly reports, optimisation potential for the entire packaging process can be identified. For example, the targeted analysis of error messages increases machine availability. Stefan Knoth from Technical Support at Kühne reports on the results in an interview.
How had you been monitoring and analysing your machines until now?
Until now, we had used an OEE calculation program for our production meetings, which obtained part of its data from records from the machine operators on individual production lines. These records, however, do not consistently list the interruption times. This is because the elimination of a fault has priority over the documentation process for the machine operators – which results in certain inaccuracies in the documentation.
Why are you now using OEE evaluation with GRIPS.world?
Compared with our previous method, it is a real advantage that we now have a tool that automatically records the reasons for disruptions and downtimes. The weekly report provided by Schubert for this purpose provides an initial overview of the entire line’s performance. Detailed statements are possible with the program’s extensive analysis functions. Another highlight is the ECO dashboard for recording and evaluating power and compressed air consumption. This enables us to provide detailed data to our energy management system.
What were your requirements for the Schubert evaluation?
Shortly after the installation of the two new packaging machines, we approached Schubert’s system developers and expressed our wishes regarding the evaluation and presentation of the individual data. Together we succeeded in making it possible to evaluate the machine data by means of selection and filter functions – according to error messages, error classes or error status in number and/or duration. And this is done both layer- and article-related, in a graphic or tabular view.
What do you especially like about the solution?
A nice add-on is the possibility to export the processed data as a pdf file or into MS Excel and use it for further analysis. In the future, together with Schubert’s system development department, we intend to integrate further upstream and downstream machines into the system to process error messages from these systems as plain text in real time. As a result, we now have a powerful tool that provides us with excellent support in plant analysis and in increasing overall plant effectiveness.