Fill + Pack | IGZ

Fill + Pack® - Automated filling and packaging lines with SAP MES

Direct connection of filling and packaging lines

For the area of Consumer Products, IGZ provides SAP MII (SAP Manufacturing Integration and Intelligence) Best Practice Fill + Pack, a solution for efficient filling and packaging processes for liquid products or bulk.

Based on SAP MII, IGZ provides modular best practice solutions that enable the creation of transparent processes in automated filling and packaging within the shortest possible time of the plant and company.

Overview of Fill + Pack®

Online key figures
Identification and presentation of performance metrics (e.g., OEE, efficiency, ...) at the order, shift, and line levels to validate the effectiveness of actions.

Order fine control
Transparency of pending, current and processed orders with graphical rescheduling function.

Control room functionality
Monitoring of the conditions of machines within a line and control of the order progress. Identification of weaknesses and initiation of measures.

Machine data acquisition / production data acquisition
Direct online connection of the shop floor for the specification of order parameters and automatic entry of process values for the order. Easy-to-use and easy-to-expand touch-screen interface for convenient capture of manual operating data.

Traceability
Batch traceability from goods receipt through production to goods issue.

Overview of functions
Fill + Pack​ – Master Data | IGZ

Allows configuration of complex filling and packaging lines, which are not shown in SAP ERP (SAP Enterprise Resource Planning).

  • Individual configuration of separate machines and production lines
  • Flexible tool for self-adaption
  • Definition of order areas for order changes within a line
  • Consideration of special features, such as “shared” and “exclusive resources”
  • Automatic transfer of the system configuration to the line control station
Fill + Pack​ – Control Center | IGZ

Provides central visualization capabilities and a quick overview of the production.

  • Line control station with online display of system states, line and machine parameters
  • Proactive line control through information at a glance
  • Realistic system layout with display of operating states, data points and key figures
  • Display and control of order data
  • Presentation of current sturgeon situations
Fill + Pack​ – Order Cockpit | IGZ

Creates complete transparency about outgoing, upcoming and processed orders.

  • High order transparency for rapid introduction of measures
  • Detailed planning and fine control by line managers or shift masters are compatible via graphical planning board
  • Order buffering for self-sufficient production, even if the connection is interrupted to ERP
  • Cost reduction of deadlines by enforcing production planning
  • Easy integration with SAP PP (SAP Production Planning) and SAP APO (SAP Advanced Planning and Optimization)
Fill + Pack​ - Overall Equipment Effectiveness | IGZ

Serves to identify and present effectiveness metrics.

  • Determination of the total plant availability for the targeted introduction of measures
  • Waterfall model for the representation of performance indicators and losses
  • Systematic reporting in shift reports for evaluations
  • Support of the Weihenstephaner standard for machine integration
Fill + Pack​ – Machine data acquisition | IGZ

Allows the direct connection to the automation level without additional IT subsystems.

  • Direct parameterization of the machine level
  • Read of machine data (e.g. quantities, times, errors, etc.) for visualization and ERP feedback
  • Support of popular communication technologies (e.g. TCP/IP, OPC, etc.)
  • Connection of various machine types, e.g. Bizerba, Tetra Pack, …
Fill + Pack​ – Operational data collection | IGZ

Ensures the safe and comfortable recording of all manually entered operating data.

  • Manual entry of order backlog and error messages for effective controlling
  • Collect quantities, times, and states for multi-layered evaluations in SAP ERP (SAP Enterprise Resource Planning)
  • Ergonomic dialogue via data radio or stationary terminals
Fill + Pack​ – Shop Floor Connection | IGZ​

Realizes the direct integration of simple, technical production components.

  • Connection of e.g. label printers, RFID writing and reading equipment, scanners and sensor technology (e.g. light barriers)
  • No further IT systems required for connection
  • Similar process logic for different production plants

Key Facts

  • Order fine control / grouping
  • Paperless, system supported worker guidance
  • Machine / production data acquisition (MDE, BDE)
  • Benchmarking, reporting, dashboards (OEE, KPI)

Use

  • Optimal process integration and task distribution of the ERP and MES level
  • Future-proofing through release-capable SAP standard software
  • Uniform system support and key figures independent from system suppliers
  • Simple realization of customized extensions and adjustments
  • Based on proven and well-known SAP standard technology
  • Maintenance-friendly system landscape by eliminating non-SAP systems and interfaces
  • High stability, scalability and performance due to homogenous SAP solution

SAP MII
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