Customer requirements as the measure of all things
Achieving a customer-tailored solution with professional technical support
Peter Hoffmann* Customer requirements are the measure of all things – this summarizes the philosophy on which KHS technical support is based. As an international manufacturer of filling and packaging systems for the beverage, food and nonfood industries, KHS possesses a great deal of system/line expertise both for glass, PET, can and keg lines. Technical support procedures always start with the recording of customer requirements. KHS advises and plans, and customers check. The procedure is optimized until the system is designed precisely in accordance with customer specifications. This means for example that KHS also integrates requirements for sustainability during production, for connection to existing lines, for any future extensions and many other customer wishes into technical support. Every KHS line is customer-tailored and ensures the perfect interaction of individual system components. To start with, customer requirements are determined and recorded…. The KHS technical support is preceded by the recording of all requirements on which the new line must be oriented. Which products are to be processed? Which system performance has to be realized? Which bottles, cans or PET formats are to be used? Which types of label have been planned? What should the final packaging look like? Into which existing set-up must the system be connected? Which requirements have been specified with reference to energy and resource management? Answers to all these and numerous other questions will in the end assist in preparing the optimum concept. Here it is important to record the task in hand accurately. …and the general conditions are checked Once customer expectations of the new line have been precisely defined, it is time to check the general conditions. If there is already an accurate plan of the building into which the new system is to be integrated, KHS checks extremely carefully with the aid of this plan how the new system can best be planned, taking optimum accessibility and material supply/output of products into* Central Technical Support Division, KHS GmbH, Tel. 02 31/5 69 – 15 21 account. Here every single detail is thoroughly examined. This ensures, for example, that water supply and disposal, power supplies etc. are available at precisely the required places, and that they fully correspond to the requirements. 3D laser scanning for maximum accuracy Above all when accurate building plans are not available, or if special challenges have to be taken into account, such as columns or wall projections, KHS deploys 3D laser scanning prior to technical support. This instrument increases planning security twofold and then later contributes towards smooth incorporation of individual system components. Using 3D laser scanning, an extremely accurate 3D hall image is generated on the computer, into which the 3D representation of the entire planned lines can be directly integrated. Virtual tour of the system Usually, KHS offers the option of seeing each new planned line in 3D. The 3D presentation can either take place on the PC or on what is known as the "Powerwall". The advantage of the Powerwall 3D presentation is that the technical solution is represented in stereometry on a projection screen, and the layout is therefore particularly clear. In order to obtain the 3D effect, prospective customers wear special 3D glasses, just as for 3D cinema. An additional advantage of the KHS-style 3D system is that, using what is known as the "flight stick", observers can navigate themselves into the line and are able to look closely at every individual line element. Here a tour of the line on the ground is just as easy as gaining a moving bird's eye view of the line. A perfect solution: the innovative tracking system for control of the Powerwall enables customers to change the viewing angle simply by turning their heads as they walk through the virtual filling system. Quick variations are possible If the 3D observation of the line is carried out, all customer requirements voiced so far are completely integrated into this virtual system. In the event the customer changes his requirements, the new specifications can then be swiftly implemented in the 3D representation. Modifications to buffer sections, an alteration in accessibility, an additional labeling unit or additional processing of trays - everything can be flexibly planned. The adapted project planning is then represented immediately in virtual form, and also checked immediately for effects with reference to accessibility and supply/disposal on the line. This rapidity is possible amongst other reasons because KHS technical support is able to access a tried and tested "kit" of machines and components which ensure reliable functions whilst using the latest technological innovations. Future extensions taken into account Within the scope of KHS technical support, possible extensions to the lines are already taken into account during initial planning and have a high priority at this point also. If, for example, future plans include the positioning of a tray shrink packaging system in addition to the packaging of bottles into crates, it is possible even at this early stage to leave appropriate space for this future system - and this is of course also possible for the connection of further systems at a later date, or connection with logistical concepts. One additional service provided on special customer request by KHS is the integration of machines provided by other companies into the line. Here KHS also organizes the clarification of all interfaces. KHS technical support also for conversions Customers can also take advantage of KHS technical support for planned conversions or extensions of existing lines. Here too, the first step is always to record the actual situation accurately. In what condition is the existing line and in what condition are the machines which are to be replaced or converted? Which machine functions have been requested on the new machines, or what is to be achieved through the conversion? How large is the space planned for the new machine or the conversion measure? Everything is looked into extremely carefully. Based on the results, a new machine or conversion proposal is made which completely integrates the required general conditions. If conversions or supplements planned within an existing KHS line have already been planned in 3D, customers have a further advantage; namely 3D observation of their prospective line. New machines or conversions are simply incorporated into the existing KHS 3D planning, and the virtual tour of the line - as represented after successful modification - can begin. System simulation for determining efficiency One KHS technical support instrument which can be used for the planning of new systems as well as the integration of new machines into existing lines and for conversions is line simulation. The KHS line simulation system Innosim is a tool which can present the dynamic behavior of a line right down to the last detail. The preparation of each simulation model starts with the entry of general data into the simulation system, such as container and pack dimensions. Then the individual degrees of efficiency of machines along with the expected disturbance characteristics are communicated to the system. For example: on the shrink packer, a manual film reel change has to be carried out, or label material has to be replenished on the labeling machine after a certain service life. In these cases, the precise time span for which the shrink packer is expected to be shut down or which it generally takes the labeling machine to be replenished is incorporated into the simulation model. If automatic changeover procedures are planned, the respective reductions in speed required during the change have to be integrated into the simulation model. In this way, planning of the required accumulations can be undertaken based on the individual degrees of efficiency of the machines and their individual disturbance characteristics, which then ensures an optimum degree of efficiency across the entire line. The increasing importance of system regulation and control The topic of system regulation and control is gaining in importance within the scope of technical support. This is already focused on when designing the system control with the integrated operating system. In order to ensure maximum operating convenience, KHS recently developed a new operator concept in collaboration with the Fraunhofer IAO Institute which has already received multiple awards - amongst others the "red dot: best of the best" and the "iF gold award". A clear advantage of the new KHS operator concept is that monitoring of the machines and entire production lines has been united into just one uniform interface. What were once many heterogeneous GUIs have now become a uniform system. The extremely user-friendly operator prompting works using simple buttons, colored figures, icons and interactive instructions. Even complex processes are depicted in a manner that is easy to understand. The new interface also allows user profiles to be accessed with an ID card, displaying relevant data to specific individual users. A Remote Diagnostic Service can be accessed online if required. Modular Manufacturing Execution System Innoline MES With its Innoline MES (Manufacturing Execution System), KHS is able to provide those requiring maximum transparency in filling and packaging technology with a modular production management system which is also capable of monitoring several lines if required and of working across several company locations. The basic version of the Innoline MES comes with the Line Monitoring module. This module records production data from filling, packaging and other filling-related processes and evaluates this information in accordance with the requirements of the Weihenstephan standard. The results can be called up online at the touch of a button. Those wanting more can extend the Innoline MES with numerous modules, on which they are comprehensively advised during KHS technical support. For example, the Order Execution module is focused on order management for filling and packaging lines. In addition, the Order Execution module visualizes a perfect representation of information on individual filling orders. Here processing times are assigned to each individual order with the utmost accuracy. The Order Scheduling module realizes the planning of orders in a Gantt chart-based planning board. At the same time, this module provides the option of automated order planning, taking set-up times into account. The Recipe Management is used for the central specification and monitoring of critical process parameters. The Order Material Tracking module uses scanners to accurately record all raw materials and supplies required for an order. This makes it possible to trace batches very precisely. The Production Analysis module concerns itself with the comprehensive evaluation of production data which serves to condense information and to provide the management with a quick overview of important key figures. Sustainability can also be planned Recently in particular, aspects of sustainability are more frequently becoming key factors for consideration when investing in new lines. KHS is well aware of this and has equipped itself accordingly. For this reason, many machines within the KHS portfolio can be optionally selected with an energy saving concept. For example, the shrink tunnel: here KHS offers, in addition to the classic shrink tunnel concept with electric heaters, the eco-shrink tunnel with gas heating. This realizes savings of up to 50 percent on energy costs in comparison to the classic shrink tunnel. Also possible is a reduction in energy consumption through intelligent system control. For example, it is possible to specify precisely on starting up a line via the MES system when the heating times for individual machines have to begin in order to ensure operational readiness as soon as the product is ready for processing. Reductions in packaging material can also be shown using the shrink tunnel. Here KHS has developed a concept for film-wrapped packs without shrinkage holes. The advantage of this is that the tray or pad supports required up to now for reasons of stability are no longer required if the new shrink packer option is selected. Furthermore, the aspect of sustainability plays a major role in new KHS developments. For example, the development of the InnoPET Blomax Series IV stretch blow molder, on which the heating time for the preform has been reduced to half in comparison with the previous generation of machines. This has been made possible through a newly-developed heater. Also worth mentioning is the clear reduction in the use of compressed air required in comparison to the InnoPET Blomax Series III by five to fifteen percent. Also the stretching process controlled via a servo motor on the InnoPET Blomax Series IV, which represents maximum process stability, allows optimization of the preforms right up to the last tenth of a gram of PET material. In comparison to the previous solution, for which an increased quantity of PET material was needed to maintain the required PET bottle quality, this represents not just increased production reliability, but also substantial savings in PET material and therefore reduced costs. Comprehensive advisory service on the use of newly-developed packaging material Within the beverage, food and non-food industries, more and more focus is being placed on the use of packaging which complies with ecological criteria. For example, many beverage companies are already switching to bottles which consist exclusively or partially of plant materials. One topic which has an influence on technical support is whether these newly-developed containers behave differently when guided through the line in comparison to standard glass or plastic bottles. As part of technical support, KHS always explicitly inspects packaging about which no detailed knowledge has been collected on its behavior in a system in collaboration with the respective KHS Competence Center. Based on laboratory analysis, for example, the friction behavior and the stability are determined, so that statements can be made on stackability or behavior during labeling. All of this is carried out with the objective of designing a system so that it is optimally equipped for the respective containers/packs to be processed. Armed for the future Even if KHS technical support already stands for perfectly designed lines planned right down to the last detail, KHS continuously questions its concepts. This is done in order to provide maximum KHS system competence even in the future. KHS is mainly planning developments in the field of technical support concerning further standardization - both for what are known as "stock" systems and for lines which only run a few products. For this reason, KHS is expanding its collection of approximately 50 templates to form a "kit" of standard solutions for common practical applications. The advantage for customers: KHS is then able to make use of tried and tested variations, which speeds up technical support and the provision of systems. The increased use of plug-and-produce systems and monoblock concepts also promise quick integration and implementation at customer sites. KHS products such as the InnoPET BloFill blow molder/filler monoblock or the compact CIP system Innopro CIP C that fits in a container for shipment and is designed according to the plug & produce principle, which have already been successfully placed on the market, represent already established examples. In summary: the future can come - KHS technical support is well-equipped for it and continues to pursue its clear aim of fulfilling customer requirements and providing KHS customers with a competitive advantage.
