COMPUTER SCIENCE SIX MONTHS INDUSTRIAL

TRAINING REPORT
AT

NESTLE INDIA LTD.

IN
I.T DEPARTMENT
On
AUTOMATION OF MILK COLLECTION DATA
SUBMITTED IN PARTIAL FULFILLMENT OF THE DEGREE OF
BACHELOR OF TECHNOLOGY
IN
ENGINEERING

Under the guidance of:-

Submitted By:

Name: Mr. V.S Chauhan

Designation: Manager
Department: I.T

Name: Aanchal Dhir

University Roll No.: 100250390868

MAY 2013

ACKNOWLEDGMENT

Training is an agglomeration of theoretical, practical and technical concepts, which enhances our
skills in the field of technology.
I would like to thank Mr. Daljeet for giving me this wonderful opportunity
to be a part of the Nestle team. Sir, I shall be ever grateful to you. My sincere gratitude towards
the team I worked with, in the I.T department, led by Mr. V.S Chauhan. I have learned a lot under
your guidance. Iwould like to thanks Mr. Naresh Dhir without whom I m not able to be here.
I am thankful to HR Manager Ms. Rupika Singh and HR Officer Ms.
Vineeta Tikoo who have always helped us.
Lastly Id like to thank DBIEM for embedding in me all the engineering
ethics and making me worth industrial Culture. I am proud to be a part of DBIEM .

Aanchal Dhir

PREFACE
It is a great pleasure for me to present the following report on my industrial training otherwise
one seldom gets the chance to go for the industrial training. It outlines the course of my
job details during my training period of 6 months at Nestle India Ltd. The training report
consists of various examples on ladder logic & my project details on Automation of Milk
Collection Data. Adequate layouts & diagrams have been provided for more descriptive
outlook & better clarity of understanding. All in I have tried to provide the best from me in
presenting this volume on my training at Nestle in a very precise manner. However any
suggestions & comments on this volume will be gratefully accepted.

TABLE OF CONTENTS

CHAPTER

TITLE

PAGE NO.

1.
1.1
1.2
1.3
1.4
1.5
2.
2.1
2.2

Introduction of Organisation
Nestle Story
Nestle History
Presence across India
Nestle Logo
Introduction to Moga factory
Introduction of AMCD
Automation of Milk Collection Data
EPOS collection Architecture

5-10

2.3
2.4

Milk collection process

Pos Terminal

13
15

2.5
2.6
3
3.1

Adding software in EPOS machine

EPOS Menu
AUTOMATION
Advantage & Disadvantage of Automation

22
24

3.2
3.3
3.4
3.5
3.6
3.7
4
5

P.L.C
Advantage & Disadvantage of PLC
Block Diagram of PLC
PLC Module
Ladder Logic
Human Machine Interface
Suggestions
Conclusions

28
29
30
33
35

References

42

6
7
8
9
10
11-25
11
12

26-39
27

39
40
41

CHAPTER 1
Introduction to Organization
COMPANY PROFILE

MR. HENRI NESTLE

HENRI NESTLE born Henrich Nestle (10 August 1814 - 7 July 1890) , was a
German confectioner and founder of Nestle, the worlds largest food and beverage
company, as well as the main creator of condensed milk.

1.1) NESTLE STORY

Nestl was founded in 1867 on the shores of Lake Geneva in Vevey, Switzerland
and its first product was Farine Lacte Nestl, an infant cereal specially formulated by
Henri

Nestl

to

provide

and

improve

infant

nutrition.

From

its

first

historic merger with the Anglo-Swiss Condensed Milk Company in 1905, Nestl
has grown to become the worlds largest and most diversified food Company, and
is about twice the size of its nearest competitor in the food and beverages sector.
Nestls trademark of birds in a nest, derived from Henri Nestls personal coat of
arms,

evokes

the values

upon which he founded His

Company.

Namely,

the

values of security, maternity and affection, nature and nourishment, family and
tradition. Today, it is not only the central element of Nestls corporate identity
but serves to define the Companys products, responsibilities, business practices,
ethics and goals.
Now,

Nestl

had

around

2,32,000

employees

worldwide,

operated

523

factories in approx. 80 countries and offered over 8,000 products to millions of

consumers

universally.

The

Companys

transparent

business

practices,

pioneering

environment policy and respect for the fundamental values of different cultures
have earned it an enviable place in the countries it operates in. Nestls activities
contribute

to

and

nurture

the

sustainable

economic

development

of

people,

communities and nations. Above all, Nestl is dedicated to bringing the joy of

Good Food, Good Life to people throughout their lives, throughout the world.

1.2) NESTLE HISTORY

The Nestl Company was Henri Nestl's search for a healthy, economical alternative
to breastfeeding for mothers who could not feed their infants at the breast.

The Company formed by the 1905 merger was called the Nestl and Anglo-Swiss
Milk Company. The close of World War II marked the beginning of the most dynamic
phase of Nestl's history. Throughout this period, Nestl's growth was based on its
policy of diversifying within the foodsector to meet the needs of consumers.

In 1947, Nestl merged with Alimentana S.A., the manufacturer of Maggi

seasonings and soups, becoming Nestl Alimentana Company. After the
agreement with LOreal in 1974, Nestl's overall position changed rapidly.

Between 1975 and 1977, the price of coffee beans quadrupled, and the price of cocoa
tripled. Taking such a step in a time of increased competition and shrinking profit
margins required boldness and vision.

Nestl approached the 1980s with a renewed flexibility and determination to evolve.
Thus, between 1980 and 1984, the Company divested a number of non-strategic or
unprofitable businesses. Nestl managed to put an end to a serious controversy over
its marketing of infant formula.

Nestl opened the 20th century by merging with the Anglo-Swiss Condensed Milk
Company to broaden its product range and widen its geographical scope.
In the new millennium, Nestl is the undisputed leader in the food industry, with
more than 523 factories around the world. Nestl's existing products will grow through
innovation and renovation.

1.3) PRESENCE ACROSS INDIA

Processing units in India

After nearly a century-old association with the country, today, Nestl India has presence
across India with
8 manufacturing facilities and
4 branch offices spread across
the region. Nestl Indias first production facility, set up in 1961 at Moga (Punjab), was
followed soon after by its second plant, set up at Choladi (Tamil Nadu), in 1967. Consequently,
Nestl India set up factories in Nanjangud (Karnataka), in 1989, and Samalkha (Haryana), in
1993. This was succeeded by the commissioning of two more factories - at Ponda and
Bicholim, Goa, in 1995 and 1997 respectively. The seventh factory was set up at Pantnagar,
The 8th Factory was set up at Tahliwal, Himachal Pradesh, in 2012. The 4 branch offices in the
country help facilitate the sales and marketing of its products. They are in Delhi, Mumbai,
Chennai and Kolkata. The Nestl India head office is located in Gurgaon, Haryana.

1.4 NESTLE LOGO

The Nestl logo was launched by Henri Nestl in 1868 on the basis of the meaning
of his name in German, i.e. little nest, and of his family emblem (that you can see
here).

Henri obtained

15-year

French

patent

for

his

logo in

1868.

After he retired, it was registered in Vevey in 1875 by the new owners of his
company.

In 1938, the traditional nest design was combined with the "Nestl" name to form
what is called the combined mark.

In 1966 the design was simplified.

In 1988, the worm in the mother bird's beak was removed and the fledglings became
two instead of three. It is said that it was meant to better illustrate the activities of
the company, no longer active only in utrition, and to reflect the average modern
family of two children.

1.5) INTRODUCTION TO MOGA FACTORY

When Nestl India set up its first manufacturing plant in Moga in 1961, the local milk economy
was virtually nonexistent. On the first day, we collected only 511 kgs of milk from 180
farmers. Since then, Nestl has set up milk collection centers that ensures prompt collection and
pays fair prices, transforming Moga into a prosperous and vibrant milk district. By supplying
milk to Nestl, farmers are benefited from the assurance that our collection centres will
purchase their entire quantity of milk, however big or small, as long as it meets Nestls
stringent quality standards. Furthermore farmers are paid monthly, guaranteeing them a regular
income that would not be possible with seasonal crops. Since there is continuous demand from
Nestl for milk throughout the year, their occupations are stable ones, assuring them of long
term relationships and fair prices. In addition to collecting milk, Nestl has embarked on a
number of other initiatives to support the development of dairy farmers in India. Our
relationships are based on the understanding that our investments must result in long term
sustainable growth and economic and social progress for the community as well. Thus in
addition to collecting milk and implementing our milk district model successfully to
ensure a stable livelihood for local dairy farmers, we also support the sustainable development
of our farmers by assisting them to increase milk productivity and expand their herds via
Financial assistance
Technical assistance regarding feeding practices, breeding, mechanisation of dairy
farms and making veterinary services available through our team of 35 veterinarians
Promotion of sustainable agricultural practices
Farmer training and education
Today, Nestl works with over 110,000 milk farmers and collects over 300 million kilograms
of high quality milk every year across the States of Punjab, Haryana and Rajasthan. Even
during the blackout days of the Indian-Pakistani war in 1971, Nestl continued to reach out to
the farmers. Nestl developed the farmers, teaching them how to look after their cattle and
handle the milk. If it wasnt for Nestl, the Moga region would not have
progressed to the extent it has today

10

2. INTRODUCTION OF AMCD
Automation of Milk Collection Data (AMCD) is developed for automate the milk
collection process and reporting to factory. It utilizes GPRS enabled hand held terminal for
remote data collection and provides foolproof capture and validation of milk collection and
dispatch details.

It has the following features:

Electronic data capture of milk collection details with foolproof validation
Automated generation and cross-referencing of receipt/dispatch note and tally
sheet
Instant communication of transaction details to server
Data query and monitoring tool on handheld device
Robust scalable data communication technology with fault tolerance at
application level
Electronic data archival
On-demand querying and reporting tool
Automated update application through server

The complete system consists of following two components:

EPOS handheld terminal: The handheld terminal is preloaded with

application software and will be provided to collection agencies and tankers.
No other IT resource is required at the agency except consumables like
thermal paper.

AMCD Server: The server software is installed on a dedicated server

located at the IT Centre of Nestle Moga Factory. This server software
handles transactions with the remote handheld terminals via GPRS. It is also
integrated with Nestles RMPS server for sending collection data for
payment processing.
11

2.2) EPOS COLLECTION ARCHITECTURE

12

2.4) POS TERMINAL

POS terminal is a handheld device where we insert the various application to perform
multiple functioning like entering Milk Collection Details, Personal details of Farmer and
various Side Agencies & PACKO.
VISIONTEK 92 POS is built on ARM9 processor and comes with thermal printer powered
by in-built battery & external adaptor. It accepts magnetic swipe cards & ISO Compliance
Smart Card Reader.
This smart transaction terminal completes transactions instantly with rapid online and offline
authorizations. The terminal supports a wide range of applications viz. Cash Collection,
Electronic Voucher Distribution, Ticketing, mobile payments etc.,

13

a) VISIONTEK 92POS SPECIFICATIONS

Processor

ARM9 32-bit Core CPU @ 400MHz

Memory

RAM : 128 MB (DDR)

Flash : 256 MB
External Flash Memory : Micro SD Card Reader

Operating System

LINUX Operating System (Ver 2.6)

Display

128 x 64 pixel Graphic-FSTN LCD with LED backlight

Keypad

19 Keys keypad including 4 Function keys and 3 Command keys with

backlighting

Printer

Thermal graphic printer

8 dots/mm resolution
57 mm (2.25 in) wide paper

Peripheral Ports

1x RS-232
1x USB Slave
1x USB Master

Communication
Modules

GSM / GPRS, (Quad band) (SMA female antenna connection)

CDMA 1X2000; SMA female antenna connection

Power Adaptor

AC input 100 - 240V, 50/60Hz DC output 9V, 2.2A

14

b) Accessories of 92POS
KEYPAD

FUNCTION KEYS
F1 : Performs Go, Back or No operations on respective screen
F2: Scroll up
F3: Scroll Down
F4: To continue

OTHER ACCESSORIES

15

c) Installation of POS terminal

Charging the POS terminal

switch on the terminal

16

Loading the thermal paper roll

1). Unlock the printer cover, rotate the cover toward top side & open it.
2). Place a roll of thermal paper (20 mtr.)
3). Hold the extreme end of paper roll by keeping a few centimetre of thermal paper
out of paper roller of printer cover , ensure paper is at proper place & close printer cover
4). Lock the printer cover.

Battery installation

17

Antenna Installation

Sim Card Installation

18

d) Precautions to be taken while using POS

Avoid using the terminal during lightning storms.

Do not use liquid or aerosol cleanser .

Do not disassemble or modify POS terminal in absence of Technical Guide.

Do not open the cover of POS terminal during its operation.

Do not expose terminal to metal particle.

Do not pull the power plug by wet hands.

Do not try to charge the battery with other chargers.

Turn off the device when not in use , it may cause interference with other
device.

Always place it on dry and cool place. Do not place near dusty places.
Sometimes dust stick on its internal parts and block its functioning.

e) APPLICATION AREAS
Electronic Voucher Distribution
Money Transfers
Tax Collection
Medical & Healthcare
Cash and Tax Collection
Lottery / Gaming

19

2.5) ADDING SOFTWARE IN EPOS MACHINE

Every machine or device require a special software alter than its hardware for its proper
functioning , that is called Operating System. We can use different type of applications for
multi-functioning purpose. That applications are in the form of Image file format. We can
perform many operations as per our requirement. The feature we want to operate can be
added by modifying the applications image file.
Now we need an interface to insert the application file into EPOS. So there is a special tool
which is used for inserting the applications into device called

EPOS Download

Application.

First connect the EPOS device to desktop via serial interface with RS232 cable.

Select Drive (COM 1).

Connect the device.

Console should always be Enable.

Select Flash Type 16 Mb.

Give both Terminal and Serial name is 1.

Now select Terminal Type which is our EPOS 92.

Select the File Type which can be:

AGENCY

i.

Kernel

ii.

RAM disc

iii.

Application

PACKO

NESTLE_TDN (Tanker)

Now browse location where the image file of application is saved and select the
desired image file.
Click on send button and on the EPOS.

20

21

22

CHAPTER 3
AUTOMATION
Automation is the use of machines, control systems and information technologies to optimize
productivity in the production of goods and delivery of services. The correct incentive for
applying automation is to increase productivity, and/or quality beyond that possible with
current human labor levels so as to realize economies of scale, and/or realize predictable
quality levels. In the scope of industrialization, automation is a step beyond mechanization.
Whereas mechanization provides human operators with machinery to assist them with the
muscular requirements of work, automation greatly decreases the need for human sensory
and mental requirements while increasing load capacity, speed, and repeatability. Automation
plays an increasingly important role in the world economy and in daily experience.
Automation has had a notable impact in a wide range of industries beyond manufacturing
(where it began). Once-ubiquitous telephone operators have been replaced largely by
automated telephone switchboards and answering machines. Medical processes such as
primary screening in electrocardiography or radiography and laboratory analysis of human
genes, sera, cells, and tissues are carried out at much greater speed and accuracy by
automated systems. Automated teller machines have reduced the need for bank visits to
obtain cash and carry out transactions. In general, automation has been responsible for the
shift in the world economy from industrial jobs to service jobs in the 20th and 21st centuries.
The term automation, inspired by the earlier word automatic (coming from automaton), was
not widely used before 1947, when General Motors established the automation department.
At that time automation technologies were electrical, mechanical, hydraulic and pneumatic.
Between 1957 and 1964 factory output nearly doubled while the number of blue collar
workers started to decline

23

3.1) Advantages and disadvantages

The main advantages of automation are:

Increased throughput or productivity.

Improved quality or increased predictability of quality.

Improved robustness (consistency), of processes or product.

Increased consistency of output.

Reduced direct human labour costs and expenses.

The following methods are often employed to improve productivity, quality, or robustness.

Install automation in operations to reduce cycle time.

Install automation where a high degree of accuracy is required.

Replacing human operators in tasks that involve hard physical or monotonous work.

Replacing humans in tasks done in dangerous environments (i.e. fire, space,

volcanoes, nuclear facilities, underwater, etc.)

Performing tasks that are beyond human capabilities of size, weight, speed,
endurance, etc.

Reduces operation time and work handling time significantly.

Frees up workers to take on other roles.

Provides higher level jobs in the development, deployment, maintenance and running
of the automated processes.

The main disadvantages of automation are:

Security Threats/Vulnerability: An automated system may have a limited level of

intelligence, and is therefore more susceptible to committing errors outside of its
immediate scope of knowledge (e.g., it is typically unable to apply the rules of simple
logic to general propositions).

Unpredictable/excessive development costs: The research and development cost of

automating a process may exceed the cost saved by the automation itself.

High initial cost: The automation of a new product or plant typically requires a very
large initial investment in comparison with the unit cost of the product, although the
cost of automation may be spread among many products and over time.
24

3.2) PROGRAMMABLE LOGIC CONTROLLER (PLC)

Programmable logic control or PLC is the most commonly used industrial automation
technique in the world. It is universally applied for factory automation, process control and
manufacturing systems. Programmable logic control originated from the creation of
computerized versions of relay control systems used to control manufacturing and chemical
process systems. The programming is done using a special technique called ladder logic,
which allows sequences of logical actions to be set up, inter-linked and timed. A standard
task in logic control is batch control and sequencing in a process system.
Introduction
A PLC or Programmable Logic Controller is a user friendly, microprocessor specialized
computer that carries out control functions of many types and levels of complexity. Its
purpose is to monitor crucial process parameters and adjust process operations accordingly. It
can be programmed, controlled and operated by a person unskilled in operating computers.
Essentially, a PLC's operator draws the lines and devices of ladder diagrams with a keyboard
onto a display screen. The resulting drawing is converted into computer machine language
and run as a user program.
PLC will operate any system that has output devices that go on and off (Discrete, or Digital,
outputs). It can also operate any system with variable (analog) outputs. The Programmable
Logic Control can be operated on the input side by ON/OFF devices or by variable (analog)
input devices.
Control engineering has evolved over time. In the past humans was the main method for
controlling a system. More recently electricity has been used for control and early electrical
control was based on relays. These relays allow power to be switched on and off without a
mechanical switch. It is common to use relays to make simple logical control decisions. The
development of low cost computer has brought the most recent revolution, the Programmable
Logic Controller (PLC). The advent of the PLC began in the 1970s, and has become the most
common choice for manufacturing controls.

25

3.3) Advantages of PLC

Flexibility: One single Programmable Logic Controller can easily run many
machines.

Correcting Errors: In old days, with wired relay-type panels, any program
alterations required time for rewiring of panels and devices. With PLC control any
change in circuit design or sequence is as simple as retyping the logic. Correcting
errors in PLC is extremely short and cost effective.

Space Efficient: Today's Programmable Logic Control memory is getting bigger and
bigger this means that we can generate more and more contacts, coils, timers,
sequencers, counters and so on. We can have thousands of contact timers and counters
in a single PLC. Imagine what it would be like to have so many things in one panel.

Low Cost: Prices of Programmable Logic Controllers vary from few hundreds to few
thousands. This is nothing compared to the prices of the contact and coils and timers
that you would pay to match the same things. Add to that the installation cost, the
shipping cost and so on.

Testing: A Programmable Logic Control program can be tested and evaluated in a

lab. The program can be tested, validated and corrected saving very valuable time.

Visual observation: When running a PLC program a visual operation can be seen on
the screen. Hence troubleshooting a circuit is really quick, easy and simple.

Disadvantages of PLC

Newer technology: It is difficult to change the thinking of some personnel from

ladders and relays to the PLC computer concept.

Fixed program applications: Some applications are single function applications. It

does not pay to use a PLC that includes multiple programming capabilities if they are
not needed.

Environmental considerations: Certain process environments, such as high heat and

vibration, interface with the electronic devices in PLCs, which limit their use.

Fixed circuit operation: If the circuit in operation is never altered, a fixed control
system (such as mechanical drum) might be less costly than a PLC. The PLC is most
effective when periodic changes in operation are made

26

3.4) Block Diagram of PLC

Components of PLC
1. Central Processing Unit or Processor
It is the brain of the system. The CPU, or processor, constitutes the motor or the
master of ceremonies of the Controller. It is the CPU that:

Reads the sensors value

Executes the program with the data contained in memory

Writes the output connected to the actuators

2. Memory
The controller memory contains the program to be executed, but also the data used by
27

the program (timer values, mono-stable values, counter values, etc.) This is where all the data
contained in the Controller is stored. The Controller cannot operate without memory.
Memory section of the processor consists of hundreds or thousands of locations where
information is stored. It is divided into two parts, user and storage. The user memory is for
storage of the user program, which contains the ladder logic, or instructions that control the
driven equipment. The storage memory is used to store information such as input/output
status, timer or preset / accumulated values and internal control relays etc. that are necessary
for the processor to control equipment.
The memory chips used in the processor can be separated into two distinct groups:

Volatile: That losses its stored information when power is removed.

Non-volatile: It has the ability to retain stored information when power is removed,
accidentally or intentionally.

Back-up batteries included in the processor power supply protect volatile memory. The
battery may be D sized dry cells re-chargeable nickel cadmium or non-rechargeable alkaline,
lithium types.
Memory types:
1.

Random Access Memory (RAM)

2.

Read Only Memory (ROM)

3.

Programmable Read Only Memory (PROM)

4.

UVPROM-EPROM

5.

Electrically alterable read only memory (EAROM)

6.

Electrically erasable programmable read only memory (EEPROM)

3. Bus:
It enables all parts to communicate with each other. It is the internal dialogue tool of the
programmable controller.
4. Actuator:
It allows actions to be performed in the system. In other words we can say it is an output
terminal through the operation is seen to be performed

28

5. Sensors:
Sensors are basic input elements through which the controller senses an input signal. There
are various types of sensors used in the field but basic are mentioned below:

Level Sensor

Temperature Sensor (Thermometer)

Motion Sensor (Techno meter, Auto meter), etc.

E.g. to detect an automobile at a highway toll booth, photoelectric sensor is used.

6. Communication Module :
This transfers the data from computer to controller or controller to computer.
7. Controller Cycle :
As soon as we launch the execution of the program, the controller will carry out three
phases cyclically:
Phase 1: snapshot of the status of its inputs
Phase 2: program execution
Phase 3: output activation or deactivation
At the end of the phase 3, the controller returns to phase 1, and so on.

29

3.5) PLC Modules

PLC I/O Modules (input/output)
The Input module has terminals into which outside process electrical signals, generated by
sensors or transducers are entered.

Racks and Chassis: The rack on which the Programmable Logic Control is mounted.

Input and Output Modules: We get information in and out of the PLC through the
use of input and output modules. The input module terminals receive signals from
wires connected to input sensors and transducers. The output module terminals
provide output voltages to energize actuators. There are typically 4,8,12,16 and 32
terminals per module.

IEC 61131-3 standard

IEC 1131-3 is the international standard for programmable controller programming
languages. The following is a list of programming languages specified by this standard:

Ladder diagram (LD)

Sequential Function Charts (SFC)

Function Block Diagram (FBD)

Structured Text (ST)

Instruction List (IL)

One of the primary benefits of the standard is that it allows multiple languages to be used
within the same programmable controller. This allows the program developer to select the
language best suited to each particular task.

Ladder Logic
Ladder logic is the main programming method used for PLC's. As mentioned before, ladder
logic has been developed to mimic relay logic. The decision to use the relay logic diagrams

30

was a strategic one. By selecting ladder logic as the main programming method, the amount
of retraining needed for engineers and trades people was greatly reduced.
The first PLC was programmed with a technique that was based on relay logic wiring
schematics. This eliminated the need to teach the electricians, technicians and engineers how
to program - so this programming method has stuck and it is the most common technique for
programming in today's PLC.

Mnemonic Instruction
There are other methods to program PLCs. One of the earliest techniques involved mnemonic
instructions. These instructions can be derived directly from the ladder logic diagrams and
entered into the PLC through a simple programming terminal.
Sequential Function Charts (SFC)
SFC have been developed to accommodate the programming of more advanced systems.
These are similar to flowcharts, but much more powerful. This method is much different from
flowcharts because it does not have to follow a single path through the flowchart.
Structured Text (ST)
Programming has been developed as a more modern programming language. It is quite
similar to languages such as BASIC and Pascal.
Structured Text (ST) is a high level textual language that is a Pascal like language. It is very
flexible and intuitive for writing control algorithms.
Function Block Diagram (FBD)
FBD is another graphical programming language. The main concept is the data flow that start
from inputs and passes in block(s) and generate the output.

31

3.6) INTRODUCTION TO BASIC LADDER LOGIC INSTRUCTION

Introduction
In this section we will cover some of the basic instructions used in PLC programming. These
instructions are some of the most used instructions in PLC programming. Once we explain in
detail the instructions then we will have a look at how we can implement and used those
instructions in real life application.

Definition
The following is a list of the basic instructions in SLC 500:

XIC - Examine if Closed

XIO - Examine if Open

OTE - Output Energize

OTL - Output Latch

OTU- Output Unlatch

OSR - One-Shot Rising

XIC Examine if Closed

Symbol

Definition

Examines a bit for an On condition

Use the XIC instruction in your ladder logic to determine if a bit is ON.

0 = False

1 = True

32

Devices

Start/Stop push buttons

Selectors

Limit switch

Proximity switch

Light

Internal bit

XIO Examine if Open

Symbol

Definition

Examines a bit for an off condition.

Use an XIO instruction in your ladder logic to determine if a bit if off.

1 = True

0 = False

Devices

Start/Stop push buttons

Selectors

Limit switch

Proximity switch

Light

Internal bit

33

OTE Output Energize

Symbol

Definition

Turns a bit on or off

Use OTE instruction in your ladder logic to turn on a bit when rung condition is
evaluated as true.

Devices

Light

Motor run signal

Internal bits

OTL Output Latch

Usually we latch a signal with a condition and then unlatch it when a different condition
becomes true. Most of time the Latch / Unlatch go together.
Symbol

Definition

Turns a bit on when the rung is executed, and this bit retains its state when the rung is
not executed or a power cycle power occurs.

OTL is a retentive output instruction. OTL can only turn on a bit. This instruction is
usually used with OTU with both OTL and OTU addressing the same bit.

Ladder logic can examine a bit controlled by OTL as often as necessary.

When you assign an address to the OTL instruction that corresponds to the address of
a physical output, the output device wired to the screw terminal is energized when the
34

bit is set. When rung conditions become false, the bit remains set and the
corresponding output device remains energized.

Actuating the latch input turns the function on or causes it to change state. The
function then stays on even if the latch input is turned off. To turn the function off,
another input must unlatch which turns the function off.

OTU Output Unlatch

Symbol

Definition

Turns a bit off when the rung is executed, and this bit retains its state when the rung is
not executed or when power cycle occurs.

OTU is a retentive output instruction. OTU can only turn off a bit. This instruction is
usually used with OTL with both OTL and OTU addressing the same bit.

Ladder logic can examine a bit controlled by OTU as often as necessary.

When you assign an address to the OTU instruction that corresponds to the address of
a physical output, the output device wired to the screw terminal is de-energized when
the bit is cleared.

The unlatch instruction tells the controller to turn off the addressed bit. Thereafter, the
bit remains off, regardless of the rung condition, until it is turned on.

35

3.7) Human Machine Interface

Human Machine Interface aim at a better Human-machine interaction. Any automation
system is said to be blind without HMI. HMI gives the ability to the operator, and the
management to view the plant in real time. Add to that the ability to have alarm management
that can warn the operator of a problem. It cam even log and print all the alarms in real time,
which can help the management to improve the production and efficiency.
Today there exists many Human Machine Interface software that could be used to monitor,
supervise and control process. What we are presenting here is just an overview of what could
be achieved with most of these software.
So what are the main functionalities of an HMI. Well the HMI's main functionality is to
monitor, supervise, and control processes. This could be used in a variety of industries such
as food processing, sawmills, bottling, semiconductors, oil and gas, automotive, chemical,
pharmaceutical, pulp and paper, transportation, utilities, and more. HMI software provides
the process knowledge and control needed to perfect the products companies make and the
processes they manage. It is said that a control without an HMI is a blind control.
Human Machine Interface can display texts, pictures, bar graphs, bitmap and animated
pictures. More importantly it can also display System messages, reports, alarms, trends and
manipulate string values and calculate Boolean operations and more complex math
operations. This flexibility reduces the task that the PLC
More and more manufacturing designers are recognizing the benefits of using Human
Machine Interface to control and to operate their controls.

Typical Applications

Machine monitoring and control

Supervisory Control and Data Acquisition (SCADA)

Control Centre Monitoring, Tracking, and Control

Building Automation and Security

Electrical Substation Monitoring

Pipeline Monitoring and Control

36

SUGGESTION
After having an experience of six months of training in the I.T Deptt.

few of

the points that came into my consideration which could improve the efficiency of
system.

Sometimes PACKO agents or Tanker Person interrupt the service engineer when they
are troubleshooting machines. They should not be allowed to personally meet them
until their is a big problem in their EPOS device. They can communicate personally to
service engineer via mobile phone.

Their must be facility of give token number to agents, so that all work will complete
turn by turn.

There should be separate room for service engineer, so that their work efficiency will
increase.

37

CONCULASION
I did my six months training at the Nestle India Limited, Moga factory- one of the esteemed
multinational. During this whole period I come to how to deal with the various types of the
persons and how to tackle the problems. I come to know about the various types of the
machines and their working principles. Nestle is a totally principle based company and they
are maintaining the standards to do any kind of the work. During this training I put my
theoretical approach in to the practical format to do the jobs assigned to me. I come to know
about the Field work in Automation of milk collection data, learn basics of PLC
programming and practical working on the PLC trainer kit. It will beneficial for me and helps
me throughout my career. I feel myself lucky to be a part of the Nestle for the six months
The advancement brings a change in all over in the world. All this occurs
due to the continuous efforts of the scientists, analysts and of course engineers.
The hard work with time definitely pays and that is what we see all around us.
The engineers play a key role in all this development and to bring this modern era
of the technology. During these new inventions and discoveries the conductor
gets a very good knowledge about that and in this way improving his practical
skills. The engineers in the same way, gets a knowledge from the job they are
performing and improves their skills by bringing their theoretical approach in to a
practical format.

38

REFRENCES
1). http://en.wikipedia.org/wiki/Nestl%C3%A9
2). http://www.visiontek.co.in/transaction-terminals/92pos.html
3). http://en.wikipedia.org/wiki/Ladder_logic
4). https://en.wikipedia.org/wiki/Programmable_logic_controller
5). http://www.youtube.com/user/thegeterrdone

39

40