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　娃哈哈的煩惱
　　飲料的生產要經歷水處理、配料、制蓋、制瓶、吹瓶、灌裝、套標，裹包和碼垛等多道工序。在娃哈哈杭州下沙第二生產基地內一條長達百米的水汽生產線上，一瓶瓶純凈水和含氣飲料快速而有序地飛過，生產速度達到每小時54000瓶。
　　雖然這樣的生產效率已是業內領先，但娃哈哈的工程師們卻有一個不小的煩惱。水汽線上每臺設備都處在單機自動控制的狀態，只知“埋頭苦干”，“兩耳不聞周圍事”。這樣一來，工廠不僅無法通過整線協調達到效率最大化，一旦生產線出現故障，原因也難以快速排查。
　　在娃哈哈遍布全國的飲料工廠里，80%至90%的設備已通過西門子的可編程邏輯控制器(PLC)實現了自動化。在進一步實現數字化和智能化升級改造的過程中，西門子為娃哈哈細致規劃并提供了包括S7-1500系列控制器、工業服務器和人機界面(HMI)等在內的自動化設備、全集成自動化平臺(TIA Portal)、WinCC系統、B.Data能源管理系統和Profinet工業網絡等在內的完整SIMATIC解決方案，幫助這條水汽線實現了設備的互聯互通和中央監控，達到柔性生產的要求，并優化了產線能源管理，也通過產品質量追溯，保障了食品安全。
　從“單兵作戰”到互聯互通、中央監控
　　實現生產線數字化與智能化的核心是設備的互聯互通和中央監控。有了西門子的解決方案，水汽線的生產設備從“單兵作戰”的狀態中解脫出來，形成了高效的“團隊”，而散落在工廠各處的數據也形成了閉環，在生產線上高效流轉。
　　以前，娃哈哈集團總部到各個分廠的企業資源計劃(ERP)系統雖已實現互聯，但工廠到車間內各設備的數據卻沒有打通。現在，情況發生了徹底的改變�？偛靠梢酝ㄟ^ERP系統將銷售訂單發送到工廠的制造執行系統(MES)中。接下來，MES會根據庫存等情況將銷售訂單拆分為不同的生產訂單并發送到西門子WinCC系統上，由它對生產訂單進行分解，生成具體的生產方案并下發至不同的生產設備。
　而在底層，西門子的PLC等自動化設備覆蓋整條生產線�；�于Profinet工業網絡，生產設備遵照統一的OMAC數據接口標準實現了互聯互通。生成的數據將由WinCC系統采集，并返回給MES系統。操作員可以利用TIA Portal進行統一的數據管理、通訊、組態和編程，實現自動化設備與系統的無縫連接。
　　西門子WinCC系統與PLC等自動化設備組成了高效的中央監控系統。借助西門子SIMATIC解決方案，娃哈哈打破了各個設備的信息孤島，讓從設備層到管理層的全部數據徹底貫通，成功實現了對整條生產線的數字化管控。
　　設備的互聯互通和對生產線的中央監控為生產線的運行帶來了革命性的變化。
　　借助西門子SIMATIC解決方案，所有物料供給過程都可以由系統自動控制。以前，在飲料行業中，由于沒有實現設備的中央控制與互聯互通，操作員每次生產都需要根據訂單情況手動控制物料供給。
　　如今，試點線上所有物料供給都可以由系統根據訂單信息和實際生產進程自動完成精準控制。例如，如果一批產品中包含8000瓶飲料，當系統計算出已經通過裹包機的成品為7500瓶，而生產線上剩下的500瓶產品也即將進入裹包階段時，系統就可以自動停止前道工序供料，保證訂單的準確執行。
　　如今，故障排查也變得更加便捷、及時。現在，中央監控系統與分布在產線各處的攝像頭實現了聯動。一旦設備報警，監控系統就會指揮攝像頭自動切換畫面，快速定位報警點，以便操作人員及時處理故障，縮短停機時間。
　　此外，中央監控系統也大大方便了娃哈哈的管理人員對車間進行整體維護和管理�，F在，操作員和管理人員可以通過WinCC系統輕松查看整條生產線的運行狀況。
　　杭州娃哈哈集團有限公司設備工程部部長邵金榮切身感受到了生產透明化帶來的改變：“現在，我只要坐在辦公室里就能實時了解整條產線的運行狀況。這對管理層決策有很大幫助�！�

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