industrie 4.0 – digitalization strategy · management production planning production engineering...

Unrestricted © Siemens AG 20152015-06-17 Siemens PLM Software

Industrie 4.0 – Digitalization Strategy2015 Plant Simulation Worldwide User Conference – Dr. Ulrich Rossgoderer


Virtual world Real world

T I ATotally IntegratedAutomation

PLMProduct LifecycleManagement

Productionplanning

Productionengineering

Productionexecution

Productdesign

Digital Enterprise Platform

The Digital Enterprise Platform merges sophisticated PLM Softwareand powerful automation technologies, optimizing the entire value chain.


Organization

Customer Services

Product LifecycleManagement

FactoryAutomation

ControlProducts

eCar PowertrainSystems

MotionControl

Integrated product portfolio paves the way for the Digital Enterprise.

Digital Factory Division


Digital “Factories of the Future”Public/Private Partnerships

Realizing next-generation product/production processes

DIGITAL MANUFACTURING ANDDESIGN INNOVATION INSTITUTE


Roadmap towards Industrie 4.0:Evolution, not Revolution

Introduction of electronicsand IT to further automateproduction

Integration and optimizationof the entire productdevelopment process

Industrie 4.0 –Self-optimization ofcyber-physical systems(CPS)

On the way to Industrie 4.0

1960 2010 2030


Cyber-physical systemshave all the information as a digital model

ServicesProductionexecution

Productionplanning

Productdesign


The digital model is always up-to-date and is extendedover the entire lifecycle

• Software / Informatics• Mechanics,• Electrics, Electronics• Automation, HMI• Safety, security• Maintenance

Cyber-physical system (CPS)

Physical production facility Digital model

• Location,identity…

• Status• SW version• Interfaces• …

Contains all the information on …

+


Digitalization is Transforming the Manufacturing Industry

Smart ModelThe product model sets the objectives needed to produceitself

Digital TwinFull digital product definition that simulates reality

Optimized, Distributed ProductionAutonomous production with embedded intelligence.


Our Digitalization Portfolio


Siemens Integrated Product/ProductionDigital Factory HW and SW Portfolio

PLMTECNOMATIX

DigitalManufacturing

TEAMCENTERCollaborative

PDM

NXProduct

Development

SIMATICHMI

SIMATICControllers

SIMATIC IDENTIndustrial

Identification

SIMATICDistributed I/O

SINAMICSDrive Systems

SIMATIC WinCCSCADA System

SIMATIC NETIndustrial

Communication SIRIUSIndustrialControls

SINUMERIKCNC

SIMOTIONMotion Control

TIA PORTALEngineering

Framework forAutomation

Tasks

SIMATIC ITProduction

Suite

SIMATIC ITIntelligence

Suite

Field Level

Control Level

Enterprise Level

Management Level

Operator Level

ERP PLM

MES

SCADA


Siemens PLM Software Integrated Product/Production

Design/ManufacturingCollaboration

Plant planningand feedback

IntegratedPlanning and

Simulation

Process andLayout

Collaboration

Ramp-up support

Global Production and Supplier Collaboration

JT – 3D Collaboration on ISO Standard

Teamcenter – Integrated Product/Production Platform

Product

Data

Plant

Data

Resource

Data

Process

Data

Collaboration through a common platform


The Future of Manufacturing1. Faster development of product design through PLM software

Productdesign

Productionplanning


ProductionService

12

3 4 5

Virtual Development &Planning with PLM Software

Reduced development times


Product Design- Product Planning -

Program Management Product Data/Change Management

Requirements/System/Functional Definition Global Collaboration

ProductDesign

Productionplanning

Productionengineering Production Service


Product Design- Product Development -

Concept Layout and Styling Multi-discipline Design

Analysis and Simulation Computer-aided Manufacturing

Text

ProductDesign

Productionplanning



Product Development DemonstrationRequirements Driven Product Development

Roof opening requirement

Roof openingobstruction requirement

Increase apertureopeningrequirement

Requirement:Open/ close time to meet marketexpectation

Criteria:Overall cycle - 7.6 sec.Retract target - 6.5 sec.Tilt target - .9 sec.

Requirement:During closure roof must reverseif obstructed

Criteria:Maximum pressure onobstruction not to exceed 40N

Requirement:Customer forum - Sun roofaperture needs to increase

Criteria:Increase runner to maximum sizemeeting roof crush properties


Today’s Product Challenges areMore Difficult Than Ever Before…

Landing on Marsis one of the hardestjobs on Earth.

On August 5, the Mars rover Curiosity landed successfully on thesurface of Mars. There was only one chance to get it right. For thisunprecedented challenge, NASA employed Siemens PLM softwaresolutions. The development team at NASA’s Jet PropulsionLaboratory digitally designed, tested, assembled, and simulated theentire Mars rover before a single physical prototype was created.


Digital ModelLeverage Hybrid Machining for Replacement Parts


Digital Model (https://www.youtube.com/watch?v=s9IdZ2pI5dA)Leverage Hybrid Machining for Replacement Parts

https://www.youtube.com/watch?v=s9IdZ2pI5dA


The Future of Manufacturing2. Simulation of production planning reduces time to market

Productdesign

Productionplanning


ProductionService

12

3 4 5

Complete Simulation &Optimized Production

Up to 50% reducedtime to market


Smart Models in Production PlanningExample: Energy Efficiency


Problem Statement

Not only the CO2 emission during use of a product isrelevant but also the CO2 emission spent duringmanufacturing

Therefore manufacturing companies are giving moreand more attention to energy efficiency of theirfactories

Besides using more smart and more energy efficientequipment, the manufacturing processes themselvescan be optimized for energy efficiency as well

Digital Models should help analyzing various energysaving scenarios without disrupting runningproduction


Green Carbody Technology Research Project

INDUSTRYROBOTS

INDUSTRYROBOTS

LOGISTICSMATERIAL FLOW

LOGISTICSMATERIAL FLOW


SustainabilityPROFIenergy Profile

Plant Simulation supportsthe creation of simulationmodels testing the effectsof PROFIenergy relatedenergy control strategiesfor manufacturingequipment.


Case Study

Saving 1.66 Mio kWh per year through“start-stop” control strategy for machines

Measurement did match simulationprediction

Additional 1.4 Mio kWh saving throughturning of high-pressure pumps for coolinglubricants in case of idling machines

Positive side-effect: noise reduction


Energy Simulation in Tecnomatix Process Simulate


Tecnomatix Process SimulateRobot – Human Interaction


Digital Twin in Production Planning


Problem Statement

Most planning projects are dealing with “brown-fieldplanning”

Can I use my current production line for a new ormodified product?

Can I fit another piece of equipment into my currentproduction line?

I would love to do this in a digital model withoutdisturbing running production, but:• Do I have a complete enough digital model?• Can I be sure that my digital model matches reality?


• Verify plant installation 3D-CADgeometry and point cloud

• Plant items designed in CAD will beverified against actual scans

• Integrate factory design with PLM• Re-use of point cloud data with

Bentley .POD format• Change Management between

process and layout engineering

• Visualize the assembly process inthe real plant context

• Adjust simulation layout accordingto “as built” plant

Usage of Point Clouds in Digital Manufacturing

Planning in factory context* Visualization of point clouddata and planning data

Simulation and verification


Hannover fair Siemens boothLaser scanning workflow

Survey andScan

Registration& Pre-

processing

Referencescan inProcessPlanning

model

Simulationand

Validation


Hannover fair 2014 – Laser scanning of Siemens Future ForumLaser Scanning process and pre-processing


Hannover fair 2014 – Laser scanning of Siemens bothTecnomatix Process Simulate - Reference scan in Process Planning model


3D Scan Use-Case Material FlowSiemens Stuttgart


Digital TwinDynamic Human Motion – Record and Analyze


The Future of Manufacturing3. Cost savings through highest efficiency in production engineering

Productdesign

Productionplanning


ProductionService

12

3 4 5

Smooth Communicationof all components

Integration of all Automation Functions


Operation

Typical Engineering and Commissioning

Mechanical Engineering

Physical

Commissioning

Testand

Debug

Job 1

Automation Engineering


Operation

New Engineering and Commissioning

Virtual

Comm.

Testand

Debug

Physical

Comm.

Job 1MechanicalEngineering

AutomationEngineering

Job 1


Team

cent

er

From Planning to Virtual Commissioning On All Levels

Planning, Validation, Commissioning


Process SimulateVirtual Commissioning


The Future of Manufacturing4. Efficient Production based on one high performance network technology

Productdesign

Productionplanning


ProductionService

12

3 4 5

Fully integratedProduct & System Portfolio

Data integration fromshop-floor to top-floor


ProductionDigital Twin – Plant Behavior

Customer Value:• Analyze impact and demand for manufacturing

changes• Determine production system parameters based on

actual order look-ahead

Our approach:• Maintain a precise behavior model of your factory• Leverage data from MES and Order systems to

feed the model• Allow for on-demand simulations, where the model

represents the current real production to the bestpossible level

ProductDesign

Productionplanning



Production

Manufacturing

Quality SolutionsIntegrating Design, Manufacturing and Production

Design

Continuous improvement through a PLM Platform


Overlaying Production Measurement with Virtual Planning


Big Data for DPV in ProductionParsing 1.6 million data files a month

Data Load Verification and Transformation:Automatically extract translate & load plant floormeasurement data to Teamcenter:• Real time data flow from 360+ data drops around

the world.• ~.8 GB of measurement database inserts a day.

Advanced Analysis:SSAS Cube – multidimensional statisticalaggregations:• Automating multiple complex quality metric

calculations for monthly, weekly and daily basis.• ~.6 GB of stored statistical calculations a day


Digitalization is Transforming the Manufacturing Industry

Smart ModelThe product model sets the objectives needed to produceitself

Digital TwinFull digital product definition that simulates reality

Optimized, Distributed ProductionAutonomous production with embedded intelligence.


Visit us online today and get in on the conversation:

Tecnomatix Manufacturing Discussion Forum

www.siemens.com/plm/community/tecnomatix

World Wide Web

www.siemens.com/tecnomatix

www.siemens.com/plm

[email protected]

Thank You

http://www.siemens.com/plm/community/tecnomatix

http://www.siemens.com/tecnomatix

http://www.siemens.com/plm

mailto:[email protected]

industrie 4.0 – digitalization strategy · management production planning production engineering...

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