Driving Operational Performance by building Manufacturing Capability one

Driving Operational Performance by building Manufacturing Capability one step at a time…. . Phillip Terlesk

Agenda Opportunity Questions Customer Use Case Present State For Many Manufactur es Collaborate to

Global population will exceed 7 billion BEST IN CLASS DEMANDS More than 70 million will enter the middle class Middle class adding $8 US trillion to consumer spend Operating Excellence Compliance Dynamic Value $8 Creation Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 3

Growth Matrix – Wine is a STAR! Copyright © 2013 Rockwell Automation, Inc. All

Growth Matrix – Infant Formula Copyright © 2013 Rockwell Automation, Inc. All rights reserved.

Infant Formula / Nutritional Powders Copyright © 2013 Rockwell Automation, Inc. All rights reserved.

Value Add will drive growth Copyright © 2013 Rockwell Automation, Inc. All rights reserved.

Adding Value will build export $$ Copyright © 2013 Rockwell Automation, Inc. All rights

Dynamic Value Creation Succeeding in a Changing Market Place Capability To Bring Profitable Products to Market Faster v Product Innovation Raw Materials Time People Chemical / Energy MANUFACTURING OPERATIONS CAPABILITY Process Innovatio Market Data Reduce Waste Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 9 9 9

Questions We Face On a Daily Basis ? Did we stay within range on all Quality parameters during Fermentation Did we meet the CIP targets during the cleaning cycle? • Temp • Time Have I completed & signed off all the preflight checks before starting the new batch? Are our labels and packaging material correct & serialised Have we set up our coders correctly Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 11

Business, IT & Automation Investment may not be 100% Aligned Laboratory Information Management Systems Manufacturin g Operations Management Other Database s Alarms/Events Quality Systems HMIs Control Systems Production Historians Performance Management Computerized Maintenance Management Systems Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 12

Building Capability one investment at a time ERP Manufacturing Operations Management Standard Operating & Procedures Change & Asset Management Manufacturing Intelligence Process Optimisation Process, Packaging & Safety Automatio n Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 13

Deliver the correct Information Plant Mgmt. For the Executive § § Production Quality Engineering Operator Costs, schedules, production output Financial indicators, sustainability For the Production Manager § Schedule, track production activity § Way production is running, ways to improve For the Quality Manager § How product was made, ensure compliance § Ways to improve product and yield For the Engineering / Maintenance Manager § Keeping plant running § Predicative maintenance, asset optimization For the Operators § Monitoring process to keep production running § Identifying relationships to optimize the process Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 14

Collaborate to Prioritise Objectives & Align Capability Line & Site Specific Reports & KPI’s Performance Focus High level Business Objectives People Quality / Yield Processes Throughput Business Drivers Align Capability Execution Innovation Compliance Material Energy Equipment xxx $$$ xxx Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 16

Agenda Opportunity Questions Custome r Use Case Present State For Many Manufacture s Collaborate

APC & Industry Use - Case Phillip Terlesk Sales Executive

Rockwell Improves Manufacturing Processes Enhance Profitability through: - Improve Product Quality Minimize variability Reduce deviation from specifications - Increase Production Unlock capacity Maximize throughput - Reduce Manufacturing Costs Use less energy per unit of output Maximize yield MPC Goal – High ROI, robust, operator friendly solutions that deliver long-term value Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 19

Model-based Applications Approach Analysis A Hybrid Model explains or emulates the behavior of a process. Soft Sensors Prediction Optimization Control Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 20

Pavilion 8 Model Predictive Controller executes at 5 sec to 1 min intervals Copyright

Soft Sensors (Virtual Online Analyzers or VOA) Neural Networks § Replace sparse, or infrequent, feedback from Lab or analyzer Proces s Data Lab Data VOA Calcs Product Quality Process Parameter artificial neuron with weight parameters Heat and Material Balances outpu t … neural networks can fit general non-linear relationships Traditional Empirical Correlations input A input B Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 22

How APC Enables Operational Objectives Minimize operational variance DV Reduce Variability 30 – 50% CV Achieves Uplift - closer to spec or performance limit whilst managing the process within constraints and safety margins Transition effectively Follow operational plan CV KEY TARGET CV SPECIFICATION OR LIMIT BEFORE MODEL PREDICTIVE CONTROL BENEFIT $ WITH MODEL PREDICTIVE CONTROL AND OPTIMIZATION The Business Value is Achieved by “raising the bar” Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 23 23

Operator Interaction with a Standard Regulatory Control System ? !? !? Step A, D,

Operator interaction with a. Model Predictive Control System Production Target Pavilion 8 Soft Sensor MPC PID Lab PID PLC/DCS Process Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 25 25

Milk Powder Processing • Farm Cows • Tankers / Rail • Raw Milk Silo Storage • Separation into skim milk and cream • Standardization to specifications by combining skim milk, cream, and lactose or permeate • Falling Film Evaporation • Spray Drying • Powder Packing Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 26 26

Dairy Solution Production Landscape Future Automation Landscape ERP Evaporation / Drying / Fluidbed Packaging /Logistics/Mass Serialisation Utilities Quality Milk Separation into Skim Milk & Cream Standardization to specifications by combining skim milk, cream, and lactose or permeate / Milk Treatment Rockwell FT Historian - Reporting and Tools Receiving Area & Raw Milk Silos CPGSuite Pavilion Fat / Protein Optimisation Pavilion Moisture Optimisation CPG Suite Labeling / Serialisation Plant Pax Visualisation Plant Pax - Logix ERP MO M Milk Treatment Powder Drying Packaging SCAD A Controls & Safety Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 27

Scope for both Protein & Fat Optimisation & Pavilion 8 Dryer & Evap MPC Butter Processing Permeat Rockwell - Protein & Fat Optimisation e/ Solution Cream Lactose etc Pavilion 8 Protein & Fat Optimisation Analysis – this overview Wholemilk Separation Pasteurization Standardizing Streams Rockwell’s MPC Solution-Dryer & Evap Optimization Product In 8 -15% solids Standardized buffer Storage Proces. Scan™ FT Hot Air Product Out 45 -55% solids Solids Pavilion 8 MPC Dryer &In. Evap Optimisation Hot Air Cold Air HP Pumping Powder Out Drying Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 28 28

Dairy Standardisation Solution • Rockwell’s Pavilion 8 Model Predictive Control (MPC) platform provides a closed loop standardising solution with superior targeting of final powder Fat and Protein composition. • Minimising giveaway of protein and fat in the standardisation process optimises yield providing substantial financial benefit. Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 29 29

Dairy Standardisation Solution Performance and Visability Copyright © 2013 Rockwell Automation, Inc. All rights

Visualisation: Performance Metrics Accepted moisture lab value against specification limit and controller target Moisture benefits, control performance & how hard moisture is pushed Distribution curve comparison (mean & standard deviation) against baseline Standard deviation improvement against baseline Downloadable & accepted moisture lab values report Cp – how good is distribution within limits: Cpk – how centre is the distribution within limits A key Differentiator 31 Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 31

Dairy Standardisation Solution Benefits • Composition variability reduction of 50% or greater • Tight compositional control allows fat and protein targets to be driven to the specification minimums. • Superior final powder compositional targeting. • Performance visualisation facilitates proactive decisions Copyright © 2013 Rockwell Automation, Inc. All rights reserved. 32 32

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