A new order, a new product, a new format: the infeed and pick & place of the production line need to be changed, the packaging and palletizer remain untouched, but the outfeed module also needs to be changed. This is complicated, time-consuming and labor-intensive - for now. The Plug & Produce concept could soon ensure that the production line is quickly ready for use again - without a great deal of manual effort for configuration and programming.

Greater individualization of products means ever smaller batch sizes - and therefore more frequent retooling of production lines. It is not only the mechatronic modules of a machine or system that need to be replaced. Programming the control system, integrating it into the HMI, diagnostics and commissioning are further necessary work steps before production can be resumed. This means time and personnel costs for the end user. But the OEM also has to invest a lot, for example to implement the required connection options, provide different data or data formats and coordinate with suppliers of other modules.

Lenze, a specialist in machine automation, demonstrates that there is another way, using a fully functional showcase. This simulates the packaging of various products with different modules in the production line. The conversion of the production line follows the "Plug & Produce" concept - simply plug in and get started. The secret lies in the communication: open, manufacturer-independent standards enable the modules involved to automatically configure the production line and exchange data with each other, including full interaction during the production order. The production line therefore no longer needs to be programmed.

Using existing standards
The foundations of standardized communication include OPC UA and its Companion Specification PackML. Lenze was one of the first companies to use the asset administration shell to provide data for describing machine capabilities ("skills"). On this basis, the modules can couple automatically and organize the interaction in the production process. The Plug & Produce showcase is an example of the performance of the Lenze automation platform consisting of hardware and software in terms of openness, scalability, modularity and networking.

The manufacturer's aim is to create cross-manufacturer standards for this application. To this end, he is looking for allies in the industry and among OEMs and is involved in the standardization committees of the associations. This is the only way to achieve the goals of true Plug & Produce: openness in the selection of machine suppliers, in the adaptation of production lines and in product changes also means openness in the automation platform.

Advantages for OEMs ...
Mechanical engineering benefits from the Plug & Produce concept, as uniform interfaces and standards simplify the modularization of machines and systems. At the same time, the OEM's intellectual property is protected, as no core know-how needs to be disclosed to third parties in order to ensure smooth communication and networking. The integration and programming effort is reduced and the integration of visualization systems is also simplified - this reduces potential sources of error and provides more scope for the development of innovations. Better functionality with a shorter time-to-market and more effective use of personnel strengthens competitiveness.

... and end users
For users, Plug & Produce already pays off when designing a new production line: greater flexibility and adaptability, more openness in the selection of machines and suppliers and easier reusability of machine modules. Production can be adapted more quickly to changing market and customer requirements - with less integration effort and personnel deployment. End-to-end communication enables standardization of diagnostic and alarm management. In ongoing production, Plug & Produce enables more frequent product changes thanks to simpler, faster changeovers and higher system availability.

P. Brother/p