1. 2012 Line Information System Coca-Cola Refreshments
10/1/12
2012 Line Information System
Training
Coca-Cola Refreshments
April 2013
Posted on:
Information that is accessible, understandable, actionable, and visible.

2. Engineering LIS Utilization Team
Problem / Opportunity
With the rapid deployment of the LIS project, Engineering & OE lack the proper LIS training and are not utilizing effectively the LIS system for Diagnostic, Problem Solving & Performance Guaranty.
Main Goals:
Utilization of the LIS in more than 80% of the Machines Performance Guaranty
Utilization of the LIS in more than 50% of the Business Cases for the Lines / Machines replacement
Engineering LIS Utilization Team
Reliability Team
Rade Cavic
Ron Stockton
Brian Knuckles
Dan Huber
Dan Sullivan
SMEs
Mike Hiney
Howard Nugent
Transformation
Darren Ward
Train the Trainers:
The material to train the future trainers was developed
Basic
Advanced
Q&A and examples of Machines Performance Guaranty
Future Trainers: Engineering LIS Utilization Team members
Future Trainers activities / responsibilities - TBD
Report on performance
Monthly updates on the Performance Matrix
% of LIS utilization on the Machine Performance Guaranty
% of LIS utilization on the Business Cases for the Line / Machine replacement
% of Engineers with Advanced LIS training

3. Business Process Owners
Team
Project sponsor
Troy Ellis - SVP Manufacturing
Steering Committee
Troy Ellis-SVP Manufacturing
Chris Gaffney -SVP Strategy
Marc Katz – VP Engineering
Freager Sanders – VP NE & LIS SMEs Lead
Project Management
Ioan Batran
BIS Support
xx – Project Manager
xx – Field Operations
xx – Security
xx - Severs Support
xx - Network Specialist
xx - MII / SAP Specialist
Business Process Owners
Bryant Lewis – VP MW
John Byrne – Mngr. OE
Craig Hammer – Plant Manager Bismarck
Ioan Batran – Dir. Controls Engineering
Business Support
David Forte – Production Mngr. Vancouver
Iancu Benga – Production Mngr. Richmond
Sean O’dell – Production Mngr. Twinsburg
Norbert Galivan – Production Manager
Scott Miller – Dallas SOEL
Eduardo Mancilla – Production Mngr. Downey
Brett Lepak – Production Mngr. Milwaukee
Jeffrey Edwards
Customers
All Manufacturing Plants

4. LIS National Lead LIS Regional Lead CEG OE / TPM/L&D Productivity Team
Overall program management
Ensure functional alignment on initiative
Gatekeeper / Key POC to ELT for initiative updates
LIS Regional
Lead
CEG
OE / TPM/L&D
Productivity Team
Regional POC for LIS initiatives
System SME
Execution of routines / process improvements
Validate plants self assessment on LIS initiative in Maturity Matrix
Maintain / Upgrade the Management Routines and Maturity Matrix
Approve / Prioritize the requests for LIS new features
Support start up of new installations
Installation of hardware & software
Start up and system validation
System upgrades
Technical Support
First Level training of Plant Management, OE and Engineering
Maintain & Communicate Gantt Chart for timing of future installs & upgrades
Training Material development
Data analysis
RAW
Development and execution of Replication Package
Development of Management Routines
Development of LIS initiative Maturity Matrix with identified stages and gates
Data analysis
Prioritization of National RAW opportunities
- Confidential -

5. LIS & Management Routines Support
Productivity Team
Craig Hammer
Alignment with Productivity Team
Regional LIS SMEs
David Forte – Production Mngr. Vancouver
Iancu Benga – Production Mngr. Richmond
Sean O’dell – Production Mngr. Twinsburg
Norbert Galivan – Production Manager
Scott Miller – Dallas SOEL
Eduardo Mancilla – Production Mngr. Downey
Brett Lepak – Production Mngr. Milwaukee
Jeff Edwards – PCS Wilsonville
Overall Support
Ioan Batran
Controls Eng. Group
Bing Liu
New Machines
LIS Data Reliability
New Primary Packages
New Secondary Packages
Training
Controls Eng. Group
Tom Crynick
Rob Reyher
Ion Muresan
Pat Leach
David Avery
Kartik Madhani
David Bynum
Management Routines
LIS Implementation Schedule
Proposals for Improvements
LIS Maturity Matrix Assessment
Plant LIS Data Reliability Assessment
Overall Complains
Customers
LIS Plant Champion
LIS Plant Tech Support

6. QUESTIONS?
Return

7. Definitions and Formulas
10/1/12
Machine Centers
Machine Efficiency = (Availability – Down Time) / Availability
Availability = Machine is not in Lack and not on Backup (during Production Time)
Down Time = Machine was stopped for internal reasons (something happened to the machine other than Lack or Backup)
Minor Stops = Machine was stopped for Internal Reasons for < 10 Minutes
Break Downs = Machine was stopped for Internal Reasons for => 10 Minutes
Average Maximum Speed = Average Set up Speed for the machine (example)
MTBF = Machine Running Time / Frequency Down
MTTR = Machine Down Time / Frequency Down
Machine in “Commissioning” mode: the machine will NOT be penalized for things like “Lack of Caps”, “Lack of Syrup”, or “Discharge Jam” (Fillers)
Machine in “Production” mode: the machine will be penalized each time it goes down from an Internal Fault
(i.e. not in Lack or Backup, but not running) TPM Interface
Process Stop - When a machine stops for more than 10 minutes but it is not a Breakdown Example: human error, lack of raw materials, quality issues, external influences, etc.
Unplanned Down Time – Break Downs and Process Stops
Failure Factor (Root Cause) must be filled out for Break Downs or Process Stop
Failure Prevention will be filled out case by case: AM Task, Update PMs, SPL (Single Point Lesson, SOP, Poke Yoke (error Proof), Review Design, Record for Tracking

8. Line Configuration 1 4 3 2 USLE H&L Set up for Color Coding
X Reasons Visible 4
To allow the data Entry
for Minor Stops
In “Production” mode, a machine will be penalized
each time it goes down from an Internal Fault
(i.e. not in Lack or Backup, but not running) 3
In “Commissioning” mode, a machine will NOT be
penalized for things like “Lack of Caps”,
“Lack of Syrup”, or “Discharge Jam” (Fillers) 2

9. Line Layout 1
Machine Status
Color Code 2
Machine
KPIs

10. Filler Today 1 2 Machine KPIs Accepted by Industry Overview before
and after the Filler

11. Filler Historical The same KPIs as for Today but from a
historical perspective

12. Filler First Shift Historical
The historical KPIs
for a shift (to allow
comparison among
shifts)

13. Filler Speed Trend 2 1 3 Select the Start Time And the Duration
The Chart will display
Real time speed
Average Max Speed
Reason for Machine Stop 3
The arrows at the bottom of the trend change the time frame in the window.

14. Filler Status 4 3 2 1 Overlap the Red Vertical Line and the Machine
Status Event and Click
Event Description (For
Any Additional DT) 3
Select the Start Time
and the Duration
The arrows at the bottom of the trend change the time frame in the window. 2
The most important events are
displayed on the Y axis. In this example
the filler had an Internal Fault between
6:25 pm and 6:33 pm 1
This Chart shows the
Machine Status (events
type and Date /Time)

15. Filler Efficiency Trend by Hour2
Select the Start Time
And the Duration 1
Machine Efficiency
by Hour Trend 3
The arrows at the bottom of the trend change the time frame in the window.

16. QUESTIONS?
Return

17. Performance Guaranty using the LIS
10/1/12
Let the Supplier know that the LIS will be used for Performance Guaranty. Please refer to CCR Electrical Specifications: “CCR will utilize electronic data collection via a Line Information System (LIS) as a means of verifying machine efficiency for Performance Acceptance Test (PAT) validation. Manual verification shall be used for PAT validation where Line Information System are not in use.
Let the Control Engineering Group (CEG) know at least three weeks in advance about the intention of using LIS for the Performance Guaranty
CEG will verify the LIS data reliability and make sure that the additional signals, which are “a must” for the Performance Guaranty, exist and function properly. Example of a additional signals which are “a must” for the Performance Guaranty: Down Container at the infeed & Lack of Cartoon (Packer), Lack of empty pallets (Palletizer), etc.
Project Managers, SMEs and SOEL will decide who will be on site at the time of the Performance Guaranty. CEG will support the initiative remotely (through GoToMyPC).
During the Performance Guaranty the Machine will be put in “Commissioning Mode”; this way the machine will not be penalized unfairly. Example: the Packer will not be penalize for down containers or lack of carton.
During the Performance Guaranty, the LIS data may be subject to interpretation by the Project Manager / SME. As an example, the machine may be down for internal reasons for 10 minutes but if the operator would be present (or properly train) the stop would be only 2 minutes. The Project Manager / SME can manually change the down time from 10 minutes to 2 minutes.

18. Project Steps & Milestones
Decide on the Plants which will have LIS in 2013
CAR Approval
Generate the POs
Choose the LIS Plant Champion & LIS Plant Support
Assess the Controls Infrastructure to support the LIS implementation
Propose the location of the kiosks and Large Display
Choose the LIS electrical installer
Generate the SOW for the LIS electrical Installation
Site Meeting - CEG will Present the LIS Project
Agreement on the Project Steps & Schedule
Hardware & Software Shipment
Basic & Advanced LIS training for the Plant Management (Live Meeting)
Deliver the CD with the LIS Training for Managers, Supervisors, and Operators to the LIS Plant Champion
Deliver the Materials for the "Management Routines" to the LIS Plant Champion
Upgrade the PLCs to support LIS
Install the networks (DH+ or Ethernet) to bring the data from Production PLCs to LIS Data Concentrator
Install the LIS Ethernet Network for LIS Office Stations & Plant Floor Kiosks / Stations
Electrical Installation - Sign Off
Implement the LIS code in the Production PLCs (Filler, Packer, etc.)
LIS Data Validation - Verify the LIS Data Accuracy - using the Statistical Analysis
LIS Data Validation - Create Lacks, Backup, Internal Stops for each machines (at least 3 times)
LIS Data Validation - For the machines with an excessive number of internal stops, observe the machine
LIS Data Validation - Check the Machines speeds
LIS Data Validation - The operators will fill out a form with all the machines internal faults (2 shifts)
LIS Data Validation - Sigh off
LIS Support
Management Routines Training for the LIS Plant Champion
Management Routines Training for the Plant Personnel
LIS Management Routines - Sign off
Project Success Metrics Questionnaire (end of project) - Data Reliability & Management Routines
Legend
Milestones – RED
Plant Involvement - BLUE

19. LIS Set up to maintain data integrity
10/1/12
Set up Production Schedule - Supervisor Today & Tomorrow Screen
Manually Enter Planned Downtime – Manual Entry Planned Downtime Screen
If a Machine is out of Service, press the Pause PB (to avoid decreasing the machine efficiency and penalizing the machine for stopping the line) – “Machine x – Line x” Today Screen
Set up the Filler / Line speed correctly for each Primary Package – Config. Max Speed Screen
If the Line Layout display “Comm Error” take action; most likely is caused by a different PLC being downloaded
Let the machine stop in a natural way through Lack and Backup vs. Stopping the machine in anticipation of a lack or backup; the LIS will memorize the first event until the machine will run again
If the Production Day finish earlier, hit “End Data Collection” PB; if the Production Day finish late, extend the duration of the last shift – Supervisor Today Screen
The plant will let know the CEG (three weeks in advance) if there is a new Primary or Secondary Package or new / upgraded Machine
Choose the Reason, Flavor and Secondary Package – Config DT Reasons
LIS Machine Data Reliability check: create Lack, Backup & Internal Stops and check if LIS capture correctly the events.

20. QUESTIONS?
Return

21. Engineering LIS Utilization Team
Problem / Opportunity
With the rapid deployment of the LIS project, Engineering & OE lack the proper LIS training and are not utilizing effectively the LIS system for Diagnostic, Problem Solving & Performance Guaranty.
Main Goals:
Utilization of the LIS in more than 80% of the Machines Performance Guaranty
Utilization of the LIS in more than 50% of the Business Cases for the Lines / Machines replacement
Engineering LIS Utilization Team
Reliability Team
Rade Cavic
Ron Stockton
Brian Knuckles
Dan Huber
Dan Sullivan
SMEs
Mike Hiney
Howard Nugent
Transformation
Darren Ward
Train the Trainers:
The material to train the future trainers was developed
Basic
Advanced
Q&A and examples of Machines Performance Guaranty
Future Trainers: Engineering LIS Utilization Team members
Future Trainers activities / responsibilities - TBD
Report on performance
Monthly updates on the Performance Matrix
% of LIS utilization on the Machine Performance Guaranty
% of LIS utilization on the Business Cases for the Line / Machine replacement
% of Engineers with Advanced LIS training

22. Next Steps
10/1/12
Agree on the frequency and date / time of the conference call - Done
Agree on Goals - Done
Agree on the Reporting the Team Performance - Done
Define the RACI Chart; potential stakeholders: Project Managers, SMEs, Transformation Team, SOEL, Controls Engineers, LIS SMEs, Procurement, TPM / OE, Maintenance Managers, etc.
Decide on the Start Time for the 2 Main Goals -
Decide on the type of training for the “Train the Trainers” and the Training Materials for the New Trainers (2- 3 volunteers) - we have volunteers
Decide on the Machine Performance Guaranty Process (2 – 3 volunteers) – we have volunteers

23. Draft1 - Structure to Support the “Engineering LIS Utilization Team” Goals
10/1/12
When?
Training “Machine Performance Guaranty” – Date:
Training “Machine Replacement Business Case” – Date:
Develop the “Machine Performance Guaranty Methodology / Process” – Date:
Starting Date for the “Machine Performance Guaranty”
Starting Date for the “Machine Replacement Business Case”
What Machines?
Only New Machines
Depal, Filler, Labeler, Packer, Palletizer, Wrapper
Who is managing the “Machine Performance Guaranty Process” (MPGP)?
Project Manager will manage the “Overall Machine Performance Guaranty”
SOEL will manage the “Local Machine Performance Guaranty Process”
Conditions:
There is a LIS in place and the data is reliable
Visibility and Requirement in PMM (Caitlyn) for the MPGP
Project Manager to know about “Machine Performance Guaranty” at least four months in advance
SOEL is trained on the “Machine Performance Guaranty” and available
Project Manager responsibilities:
Communicate with the Regional Controls Engineer one month in advance
Communicate with the procurement three months in advance
Communicate with the SOEL two months in advance
SOEL Responsibilities
Attend the training “Machine Performance Guaranty for SOEL”
Implement the “Machine Performance Guaranty” process
Communicate with the Maintenance Manager, Project Manager, Vendor, and Regional Controls Engineer

24. QUESTIONS?
Return

25. Who Needs Information VP Manufacturing Plant Management
10/1/12
VP Manufacturing
Control and visibility to all aspects production for all plants globally
Use common KPIs to benchmark plants to drive performance improvement & productivity
Plant Management
Control and visibility to all aspects of production environment: Production, Quality, Maintenance
Increase collaboration between departments
Reduce and better control of costs (mfg, labor, maintenance, & inventory)
Project Managers
Significantly reduce the time for the machines observation during PG
Hold the Suppliers accountable for the machine performance
Maintenance Team
Use MTTR & MTBF to improve operations
Top ten hitter report on demand
Focus the resources to the activities with the biggest impact
TPM & OE Team
Mini Kaizen
Foundation for TPM initiatives
Foundation for continuous improvement projects
Production and Line Supervisors
Production and Quality reporting by shift
Efficiency and production counting
Quality
Reduce and track scrap thru early warning
Variable Conformance Analysis
Operators
Improve engagement
Allow fast response to Down Time events & incorrect machine speeds setup
“Are we winning?” KPI

26. LIS Activities & Support Structure
10/1/12
LIS Activities & Support Structure
With RED color – Who is Responsible
CEG – Control Engineering Group
LIS Plant Champion – Production / Operation Manager
LIS Tool Training:
Plant Management - CEG
Production Supervisors / Operators – LIS Plant Champion
Maintenance Supervisors / Mechanics – Maintenance Manager
TPM team - CEG
OEE Team - CEG
Diagnostic Team - CEG
ROEL - CEG
LIS Management Routines Training
LIS Plant Champion – Regional Productivity Team
Production Supervisors / Operators – LIS Plant Champion
Maintenance Supervisors / Mechanics – LIS Plant Champion
New LIS Features:
Propose – Productivity Team, LIS Plant Champion, TPM / OEE
Approve / Prioritize (twice / year) – RVPs / Productivity Team
Execute - CEG
LIS Management Routines Changes:
Propose – LIS Plant Champion, Productivity Team
Approve / Prioritize – Productivity Team
Execute – Productivity Team
LIS Project:
Plants Choice – RVPs
Business case, RFA, PO, Invoices - CEG
Upgrade the control infrastructure - CEG
LIS Implementation & Schedule - CEG
Communication with:
Regional VPs – Productivity Team
TPM, OEE, Diagnostic Teams – CEG, Productivity Team
Productivity Team (Monthly LIS Support status) – CEG
Productivity Team (Monthly LIS Installation Status) - CEG
Drive USLE Improvements:
Operations Manager / Production Manager / SOEL
TPM / OEE Teams
Diagnostic Team
Assessments:
Training needs – LIS Plant Champion, Productivity Team
Proper use of LIS & Management Routines – Productivity Team
Proper Support from CEG – LIS Plant Champion, Productivity Team

27. LIS - How to Improve USLE
10/1/12
Line Pareto Chart allows to focus on a few things that matter. Machine Efficiency should be >95% (for the machines which have the biggest impact on the Line Downtime). Engineering Group & Vendors can help; if not, Control Engineering Group can help with the Business Case for the Machine replacement.
Stimulate the competition among shifts; a machine can be bad, but why the machine efficiency is different among shifts?
Remote access allows access to the machines’ KPIs from anywhere. Compare the same type of machine among plants (efficiency, MTBF, MTTR); if the machine’s KPIs are different, why?
Focus on reducing the Minor Stops (down container, jams, etc.); are considered to be “low hanging fruits”
LIS Real Time information allows faster reaction to downtime events
Is the Machines’ Speed V-Graph “acceptable”? ; if not, act.
Monitor the Machines setup speed (mainly Filler, Labeler & Packer); if below setup speed adjust.
Focus on Planned DT; reduce the variation and the target
Utilize the LIS for new Machines and Lines Performance Guaranty
Utilize the Planned DT and Machines Lacks / Backups for the AM.