Digitized by Kansas Correctional Industries

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Στην παρούσα διπλωματική εργασία παρουσιάζεται τμήμα ενός αυτοματισμού μιας βιομηχανικής διεργασίας. Πιο συγκεκριμένα, αφορά το γέμισμα φιαλών και την εποπτεία τους. Για τον έλεγχο του αυτοματισμού χρησιμοποιείται ένας προγραμματιζόμενος λογικός ελεγκτής (PLC) της σειράς SIMATIC S7 300 της Siemens, ενώ η εποπτεία θα γίνεται μέσω Ηλεκτρονικού Υπολογιστή και της εφαρμογής LABVIEW 2009 με την χρήση του NI OPC Servers της National Instruments. Για να ξεκινήσει η κάθε παρτίδα παραγωγής, ο χειριστής οφείλει να εκτελέσει τις εξής ενέργειες : 1) Να ελέγξει αν έχει στάθμη το tank. 2) Να τοποθετήσει φιάλες στο αστέρι. 3) Πιέζει το reset (μπλε μπουτόν), το μηχάνημα είναι έτοιμο και βρίσκεται σε κατάσταση standby. 4) Πιέζει το start (πράσινο μπουτόν), το μηχάνημα είναι ενεργοποιημένο και αρχίζει το γέμισμα. Στο πρώτο μέρος της γραπτής εργασίας, κεφάλαιο 1, κεφάλαιο 2, γίνεται μία εισαγωγή στα PLCs όσον αφορά την εγκατάσταση, διαμόρφωση, δομή, τον προγραμματισμό και τη λειτουργία τους. Οι βασικές αρχές που αναφέρονται ισχύουν σε γενικές γραμμές για όλα τα PLCs, αλλά οι αναφορές είναι στοχευμένες στη σειρά S7-300 της Siemens μια και αυτός είναι ο τύπος του PLC με το οποίο έχει υλοποιηθεί το πρακτικό μέρος της ειδικής επιστημονικής εργασίας. Στο δεύτερο μέρος, κεφάλαιο 3, κεφάλαιο 4, κεφάλαιο 5 γίνεται αναφορά στον προγραμματισμό και τη διαμόρφωση του PLC, μέσω του λογισμικού πακέτου STEP-7 – Simatic Manager. Στο τρίτο μέρος, κεφάλαιο 6, κεφάλαιο 7, κεφάλαιο 8 γίνεται αναφορά στον προγραμματισμό και τη διαμόρφωση του HMI, μέσω του λογισμικού πακέτου LABVIEW 2009 και την χρήση του NI OPC Servers της National Instruments. / In this thesis it is presented a part of an automatism of industrial process. More specifically it has to do with the filling of bottles and their supervision. For the test of the automatism it is used a programming logic control (PLC) of the series SIMATIC S7-300 of Siemens while the check will be done via both a PC and the application of Labview 2009 by the use of NI OPC servers of National Instrument. In order to begin every part of production , the operator has to carry out the following actions: 1) To check if the tank has the right level. 2) To put the bottles to the star. 3) To press the reset (the blue button) the machine is ready and is placed in the standby situation. 4) To press the start (green button), the machine is in function and the filling is starting. In the first part of this thesis, in unit 1, unit 2, is made an introduction for PLC as far as the installation is concerned, the formation, the structure the programming and their functions. The basic principles which are being referred are in force generally for the all PLC, but the references are aimed in the series S7-300 of Siemens, as this is the main type of PLC by which the practical part of this thesis has been created. In the second part, in unit 3, unit 4, unit 5, is made a mention the programming and the formation of PLC, through the software Step 7 Simatic Manager. In the third part, unit 6, unit 7, unit 8 is made a mention on the programming and the formation of HMI, through the software Labview 2009 and the use of NI OPC Servers of National Instruments.

The automation of industrial processes has been one of the greatest innovations in the industrial sector. It allows faster and accurate operations of production processes while producing more outputs than old manual production techniques. In the beverage industry, this innovation was also well embraced, especially to improve its bottling processes. However it has been proven that a continuous optimization of automation techniques using advanced and current trend of automation is the only way industrial companies will survive in a very competitive market. This becomes more challenging for small to medium scale enterprises (SMEs) which are not always keen in adopting new technologies by fear of overspending their little revenues. By doing so, SMEs are exposing themselves to limited growth and vulnerable lifecycle in this fast growing automation world. The main contribution of this study was to develop practical and affordable applications that will optimize the bottling process of a SME beverage plant by combining its existing production resources to basic principles of the current trend of automation, Industry 4.0 (I40). This research enabled the small beverage industry to achieve higher production rate, better delivery time and easy access of plant information through production forecast using linear regression, predictive maintenance using speed vibration sensor and decentralization of production monitoring via cloud applications. The existing plant Siemens S7-1200 programmable logic controller (PLC) and ZENON supervisory control and data acquisition (SCADA) system were used to program the optimized process with very few additional resources. This study also opened doors for automation in SMEs, in general, to use I40 in their production processes with available means and limited cost. / School of Computing / M.Tech (Engineering, Electrical)

Wine companies face two important challenges in their supply chain: the international shipping temperatures and their effect on the perceived quality of the wine and the optimization of the bottling schedule. The wine maker takes special care in producing the best quality product, which is then shipped to the importer/distributor or consumer, generally in non-refrigerated containers at the mercy of the prevailing environmental conditions. The contributions of this work is that it is the first to measure, for a significant period of time, the temperatures along the international wine supply chain and to link them to the specific supply chain processes. This is also the first work that analyzes the effect of shipping temperature on the perceived quality of the product by those who make the purchase decision for importers, restaurants and supermarkets. Results indicate that the wine is very likely to have been exposed to extreme temperatures during shipping. For white wines, tasters are able to detect differences in wines which have been exposed to shipping temperatures and show a preference towards them. For red wines, they are unable to detect differences. Our contribution to the second challenge was the development of a model that produces solutions for the wine bottling lot sizing and scheduling problem with sequence dependent setup times, in an adequate time-frame, which can be implemented by large wineries. We have developed a model and algorithm that produces fast, good and robust solutions for the winery lot sizing and scheduling problem with sequence dependent setup times. We implemented an effective decomposition algorithm that uses the structure of the problem, that can be applied to other families of sequence dependent scheduling and lot sizing problem. Results indicate that the model achieves reductions of 30\% in the total plan costs.

Oggigiorno diversi tipi di chiusure sono disponibili sul mercato e, tra queste, le chiusure a vite che sono molto diffuse nei paesi emergenti nel settore viti-vinicolo. L’uso dei tappi a vite, comunque, non è attualmente diffuso in relazione ai vini da invecchiamento o di alta qualità poiché a tale chiusura è associato un ambiente riducente che viene considerato poco idoneo alla conservazione di vini rossi da invecchiamento. Lo scopo di questo lavoro è stato quello di valutare, tramite analisi chimiche e sensoriali, l’evoluzione del vino tappato con diverse tipologie di chiusure a vite rispetto al sughero tradizionale e la bontà di diverse possibili condizioni di imbottigliamento. Nel corso dei tre anni di attività di dottorato sono state condotte diverse prove per testare capsule in fase di sperimentazione in confronto con chiusure a vite già impiegate in ambito enologico e con tappi sintetici e di sughero. Differenti tipologie di vino, associate a diverse tipologie di imbottigliamento e di tappi, sono state utilizzate. Alcune prove sono state condotte a termine nel breve periodo (9 mesi) mentre altre hanno richiesto tempi più lunghi. In linea generale, i risultati evidenziano, per tutti i vini, che il tempo di conservazione in bottiglia incide in maniera più significativa delle chiusure sull’evoluzione compositiva ed organolettica dei prodotti. Nel caso dei vini bianchi, il breve periodo di maturazione in bottiglia considerato non ha evidenziato differenze di composizione significative imputabili alla chiusura. Nel caso del Barbera Oltrepò Pavese i tempi lunghi di conservazione (36 mesi) hanno evidenziato che la chiusura esercita un effetto di separazione tra i vini. Quando la temperatura di stoccaggio è elevata (ad esempio 45°C) la shelf-life del prodotto si abbrevia in modo più evidente quando il prodotto è giovane. / Nowadays, there are different types of closures available on the market and, behind these, the screwcaps are very diffused in emerging enological countries. Screwcaps, however, are not used for premium or aged wines because their use is linked to a reductive environment in bottle, which is not useful for the maturation of aged red wines. The aim of this work was the evaluation, through chemical and sensorial analysis, of the evolution of wine, bottled with different types of closures and bottling conditions. During the PhD work time, different trails on experimental capsules and classical screwcaps, synthetic closures and cork closures were carried out. Several types of white and red wine, bottled in different conditions and with diverse kinds of closures, were studied. Some of the trials ended in a few months while others were longer. The results showed, for all wines, that the storage period had a significant influence on the wine evolution, more than the closure type had. The closures used for white wines in short periods of storage had no influence on the wine composition. For the Barbera Oltrepò Pavese wine, after the long storage period (36 months), the closure type exhibited a separation effect. The high storage temperature (e.g. 45°C) reduced the shelf-life of the product, particularly in case of young wines.

El objetivo general de este trabajo es mejorar la gestión mantenimiento de la máquina sopladora y llenadora de una línea de envasado de gaseosas en botellas plásticas, para ello, se ha planeado como objetivo puntual: reducir la cantidad de paradas de máquina por fallas o inconvenientes para incrementar la eficiencia máquina en 3.5% y mejorar la capacidad de producción. Debido a ello, el trabajo está enfocado en la implantación de la mejora del sistema de gestión de mantenimiento basado en la confiabilidad de la máquina. Asimismo, el trabajo comprende cuatro capítulos. El primero; describe la empresa y el marco teórico que sustenta el desarrollo de las propuestas de mejora que se van a implementar. El segundo; comprende el análisis de la situación actual, la descripción del proceso de soplado y llenado, análisis y determinación de la problemática. El tercero; comprende la definición de objetivos, la evaluación y elección de las alternativas de solución, el desarrollo e implementación de las propuestas de solución elegidas y su generación de valor para la empresa y, por último, se realizará la validación técnica, económica y de riesgos. / This research's general objective is improved the maintenance management of the blowing and filling machine for soft drink packaging line in plastic bottles. For this, it has been planned as a specific objective: to reduce the number of machine downtime due to failures or inconveniences to increase machine efficiency by 3.5% and so to improve production capacity. Due to this, the work is focused on the implementation of the improvement of the maintenance management system based on the reliability of the machine. Likewise, the work includes four chapters. First, describes the company and the conceptual framework that supports the development of the improvement proposals to be implemented. The second; It includes the analysis of the current situation, the description of the blowing and filling process, analysis, and determination of the problem. The third; It includes the definition of objectives, the evaluation and choice of solution alternatives, the development and implementation of the chosen solution proposals and their generation of value for the company and, finally, the technical, economic and risk validation will be carried out. / Trabajo de Suficiencia Profesional

El presente trabajo propone el desarrollo de un sistema de identificación de trazabilidad de paletas dentro de un almacén de una compañía embotelladora de bebidas en la ciudad de Lima. El uso de dispositivos IOT forma parte de la solución planteada para establecer parámetros de medición los cuales son el eje fundamental para determinar la distancia entre los equipos de etiquetado e identificación. Los parámetros serán usados en redes de área personal (WPAN) para establecer umbrales que pueden variar por la tecnología a emplear de Wifi en la banda de 2.4Ghz por el indicador de fuerza de la señal recibida (RSSI). El problema actual que presenta la compañía es un consumo de materiales no reutilizables dedicados a la identificación de paletas. El método de etiquetado actual produce un consumo anual de 1440 Kg de papel por cada línea de producción de las 11 que dispone la planta. El proceso de trazabilidad propuesto sigue los fundamentos del sistema de localización en tiempo real (RTLS) para sistemas de posicionamiento en interiores (IPS) el cual identificará los puntos clave para establecer la correcta comunicación entre los dispositivos de etiquetado e identificación. El dispositivo de etiquetado almacenara un código numérico que representa la etiqueta del proceso actual cuyos valores contienen información codificada del producto empaquetado sobre las paletas. Durante el proceso planteado los dispositivos de etiquetado harán uso de los dispositivos de identificación para determinar y enviar un conjunto de valores al sistema de monitoreo central para ser registrados, analizados y visualizados. En términos generales la solución propuesta tiene como objetivo reducir en más de un 80% el tiempo de identificación y más de un 60% el coste de mantenimiento del sistema de identificación de paletas. / The current job proposes the development of a pallet identification and traceability system within a warehouse of a beverage bottling company in the city of Lima. The use of IoT devices is part of the solution proposed to establish measurement parameters which are the fundamental axis to determine the distance between the labeling and identification equipment. The parameters will be used in personal area networks (WPAN) to establish thresholds that may vary by the technology to be used from Wi-Fi in the 2.4Ghz band by the received signal strength indicator (RSSI). The current problem of the company presents a consumption of non-reusable materials dedicated to the identification of pallets. The current labeling method produces an annual consumption of 1440 kg of paper for each production line of the 11 that the plant has. The proposed traceability process follows the fundamentals of the real-time location system (RTLS) for indoor positioning systems (IPS) which will identify the key points to establish the correct communication between the labeling and identification devices. The labeling device will store a numerical code that represents the current process label whose values contain encoded information of the packaged product on the pallets. During the proposed process, the labeling devices will make use of the identification devices to determine and send a set of values to the central monitoring system to be recorded, analyzed and visualized. In general terms, the proposed solution aims to reduce by 80% the palette identification time and by 60% the cost of maintenance of the identification system. / Tesis