Line Management System
Schubert's packaging machines consist of various units. An entire packaging line can be monitored and controlled via a line management system developed by SCS.
-
Initial situation
A packaging line consists of individual system components, each with a local control system. A higher-level line management system must coordinate the individual machines - so that they start and stop in an orderly fashion. In the event of a format change, the individual system components must be reconfigured in the correct sequence.
-
SCS solution
SCS developed a line management system (LMS) for Schubert that communicates with the control systems of the individual plant components via OPC UA and MQTT. The LMS also communicates between the higher-level systems, such as SAP, and the plant. This allows production batches to be started, serial numbers to be managed and production to be documented in general.
-
Added value
The customised software programmed for Schubert covers the requirements exactly. The graphical user interface on the line control station facilitates work in production and during format changeovers, which can now be initiated via the central line control station. The line management system guarantees consistent track & trace of the packaged products.
Packing
Schubert specialises in packaging machines for piece goods in the food and pharmaceutical sectors. The packaging lines consist of individual system components that prepare the piece goods (separating, aligning), prepare the packaging (folding the carton, inserting the blister), fill it with the piece goods, seal it and label it. The individual packages are then often filled into larger cartons and palletised for dispatch.
Line Management System
Each individual part of the packaging line is controlled by a local control system. To coordinate the entire packaging line, Schubert uses a Line Management System (LMS) developed by SCS. This can be used to set up a packaging line, for example: Each part of the line receives information on which format and which product it is to pack. The packaging line can then be started via the LMS: a production batch is recorded with the necessary information. For medicines, an area with serial numbers is assigned. Here it is essential that it is possible to trace which product was produced and packaged when and where at any time – see also the section on Track&Trace.
Plant control centre
Employees can control and monitor the packaging line via a graphical user interface (GUI) at the system control centre. This is where they start and stop the line. When starting, the line management system sends all the necessary parameters, from the format of the packaging to the serial number to be printed, to the control systems of the individual parts of the line. When stopping, the line control centre guides the machines to a safe state before production is stopped.
OPC UA and MQTT
The LMS exchanges individual values and messages with the local controllers via OPC UA. If larger data volumes such as serial numbers are involved, MQTT is used, which is asynchronous and slower, but can handle larger data volumes. The LMS can also be connected to a higher-level production system, typically the company’s SAP.
Track & Trace
In order to be able to trace the manufacture of a product at any time, various information such as batch and serial numbers are managed by the LMS. The LMS receives the valid serial numbers from the higher-level production system, which are usually applied to the packaging using a printed label. The system monitors whether the labels are printed and affixed correctly. The serial numbers are then returned to the production system as “produced”. If something is wrong, they are reported back as “rejected”.
For quality control purposes, the operating personnel can display the images that the system is currently producing on the system control centre. This gives the staff a good overview and helps with problems in production.
Audit Trail
In the pharmaceutical industry, it is important to document what has been done and by whom at all times. The LMS documents all steps in detail, for example user actions and configuration changes. User management can be used to define exactly who has which rights at the plant control centre. User management is often automatically synchronised with the plant operator’s MS Active Directory.
Reliable operation
For Schubert’s customers, it is important that the systems work reliably. For example, that they restart reliably after an emergency stop or power failure. To achieve this, the line management system was equipped with a small emergency power supply, among other things. The software recognises a power failure.
Equally important is robust software and IT security. SCS has been working with Schubert since 2007. Long-standing employees on both sides share their expertise, which has grown over the years. This keeps distances short and co-operation efficient.
.Net and Angular
The server application of the line management system was written in C#/.NET and stores the data in an SQL database. The GUI on the system control centre is programmed in Angular. In addition, SCS has created a project configurator that allows the extensive configuration options of the LMS to be used conveniently. The production line can thus be graphically displayed on the control centre.
