tecnomatix plant simulation

SummaryTecnomatix® Plant Simulation software enables the simulation and optimization of production systems and processes. Using Plant Simulation, you can optimize material flow, resource utilization and logistics for all levels of plant planning from global pro-duction facilities, through local plants, to specific lines.

In times of increasing cost and time pres-sures in production, along with ongoing globalization, logistics has become a key factor in the success of a company. The need to deliver JIT (just-in-time)/ JIS (just-in-sequence), introduce Kanban, plan and build new, sustainable production facilities, and manage global production networks (to name a few) requires objective decision criteria to help management evaluate and compare alternative approaches.

Plant Simulation helps create digital models of logistic systems (e.g., production) to explore the systems’ characteristics and to optimize their performance. The digital model enables users to run experiments and what-if scenarios without disturbing an

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existing production system or – when used in the planning process – long before the real system is installed. Extensive analysis tools, statistics and charts let users evalu-ate different manufacturing scenarios and make fast, reliable decisions in the early stages of production planning.

Plant Simulation helps users:

• Detect and eliminate problems that oth-erwise would require cost- and time-consuming corrective measures during production ramp-up

• Minimize the investment cost of produc-tion lines without jeopardizing required output

• Optimize the performance and energy usage of existing production systems by taking measures that have been verified in a simulation environment prior to implementation

Modeling manufacturing processesPlant Simulation enables you to create well-structured, hierarchical models of pro-duction facilities, lines and processes. This

Answers for industry.

Plant SimulationSimulation and optimization of production systems and processes

Benefits• Improve productivity of

existing facilities by as much as 20 percent

• Reduce investment in planning new facilities by as much as 20 percent

• Cut inventory and throughput time by as much as 60 percent

• Optimize system dimensions, including buffer sizes

• Reduce investment risks through early proof of concept

• Maximize use of manu-facturing resources

• Improve production line design and schedule

is achieved through powerful object-ori-ented architecture and modeling capabilities that enable you to create and maintain even highly complex systems, including advanced control mechanisms.

Plant Simulation’s user interface follows Microsoft Windows standards, making it easy to get familiar and productive quickly. Simulation models can be created quickly by using components from application object libraries dedicated to specific busi-ness processes, such as assembly or carbody manufacturing processes. Users can choose from predefined resources, order lists, operation plans and control rules. By extending the library with your own objects you can capture best-practice engineering experiences for further simula-tion studies.

Complex and detailed simulations can be handled, understood and maintained much better than in conventional simulation tools by using Plant Simulation architectural advantages like capsulation, inheritance and hierarchy.

Simulating and analyzing system performancePlant Simulation models are used to opti-mize throughput, relieve bottlenecks and minimize work-in-process. The simulation models take into consideration internal and external supply chains, production resources and business processes, allowing you to analyze the impact of different

Features• Optimize systems for

reduced energy usage• Simulation of complex

production systems and control strategies

• Object-oriented, hierarchical models encompassing business, logistics and production processes

• Dedicated application object libraries for fast and efficient system modeling

• Graphical outputs for analysis of throughput, resources and bottlenecks

• Automatic bottleneck detection, Sankey diagrams and Gantt charts

• 3D online visualization and animation

• Integrated neural networks and experiment handling

• Automated system optimization via genetic algorithms

• Value stream mapping and simulation

• Open system architecture supporting multiple interfaces and integration capacities (ActiveX, CAD, Oracle SQL, ODBC, XML, Socket, OPC, etc.)

production variations. Statistical analysis, graphs and charts display the utilization of buffers, machines and personnel. You can generate extensive statistics and charts to support dynamic analysis of performance parameters including line workload, break-downs, idle and repair time and proprietary key performance factors.

Model visualizationIn addition to the highly efficient 2D model view of Plant Simulation, models may be visualized in a 3D virtual environment using Plant Simulation’s included libraries or your own CAD data. The result is impressive 3D virtual models that are synchronized at all times with their 2D counterparts, allowing you the flexibility to choose the appropriate method of visualization without compro-mising simulation and analysis needs.

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ContactSiemens Industry SoftwareAmericas +1 314-264-8499 Europe +44 (0) 1276 413200 Asia-Pacific +852 2230 3308


© 2013 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Man-agement Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or ser-vice marks used herein are the property of their respective holders. Y3 7541 4/13 B

Tecnomatix Plant SimulationValue Stream Mapping


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Benefits• Increaseproductivityof

existingproductionfacilitiesbyasmuchas20percent

• Reduceinvestmentinplanningfornewproductionbyasmuchas20percent

• Reduceinventoriesandcycletimebyasmuchas60percent

• Optimizethesystemdimensions,includingbuffersizes

• Reduceinvestmentriskthroughearlyfeasibilityanalysis

• Increaseresourceutilization• Betterlineplanningand

allocation

Typicalquestionsforthesimulation:• Howcanweminimizethe

investmentcosts?• Istherequiredoutput

achieved?• Whathappenswhenquantity

changes?• Howcanstocksbereduced?

ImplementationThePlantSimulationValueStreamMappingLibrary(TN75096)isanoptionalextensiontothePlantSimulationStandardorProfessionallicense.

SummaryThePlantSimulationValueStreamMappinglibrarysupportstheuser,takingintoaccountthedynamicrelation-shipsofcomplexmanufacturingsequencestoincreasetheshareofvalue-addedpro-duction,variability,quality,speedandefficiencyforincreasedproduc-tion,whilereducinginventoryandcapi-talcommitment,andsecuringon-timedelivery.

Tecnomatix Plant SimulationPlantSimulationhelpsyoucreatemodelsoflogisticsystems(e.g.,pro-duction)toexplorethesystems’charac-teristicsandtooptimizetheirper-formance.Thedigitalmodelenablesuserstorunexperimentsand

Tecnomatix Plant SimulationValue Stream MappingVisualization,analysisandimprovementofdynamicvaluechains

what-ifscenarioswithoutdisturbinganexistingproductionsystemor–whenusedintheplanningprocess–longbeforetherealsystemisinstalled.PlantSimulationcontainspowerfulobject-orientedarchi-tectureandmodelingcapabilitiesthatenableyoutocreateandmaintainevenhighlycomplexsystems,includingadvancedcontrolmechanisms.PlantSimulation’suserinterfacefollowsMicrosoftWindowsstandards,makingiteasyforyoutoquicklybecomeproductive.Simulationmodelscanbecreatedquicklybyusingcomponentsfromapplicationobjectlibrariesdedicatedtospecificbusi-nessprocesses.Youcanextendthelibrarywithyourownobjectsthroughapowerfulprogrammingenvironmentforthefurther-ingofsimulationcapabilities.Toolsforautomaticoptimization,analysisofsimula-tionresultsand3Dvisualizationofsimulationmodelsarealsoavailable.Extensiveanalysistools,statisticsandchartsletusersevaluatedifferentmanu-facturingscenariosandmakefast,reliabledecisionsintheearlystagesofproductionplanning.

PlantSimulationhelpsusers:• Detectandeliminateproblemsthat

otherwisewouldrequirecost-andtime-consumingcorrectionmeasuresduringproductionramp-up

• Minimizetheinvestmentcostofproductionlineswithoutjeopardizingrequiredoutput

• Optimizetheperformanceofexistingproductionsystemsbytakingmeasuresthathavebeenverifiedinasimulationenvironmentpriortoimplementation

Tecnomatix Plant Simulation

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addedinmanufacturingandforidentify-ing,reducingandeliminatingnon-valueaddedprocessesandoperations.

ValueStreamMappingisamodernmethodofprocessoptimizationbasedonthemethodsofleanmanagement,asdescribedbythewell-knownToyotaProductionSystemandasappliedbytheSiemensProductionSystem.

Thegoalistoeasilyandquicklymapandbetterunderstandthevaluechainforthepurposeofoptimizingit.

Objectives and benefitsThetraditionalgoalsoftheValueStreamMappingprocessare:• Increaseproductionvariability• Increaseproductionquality• Increaseproductionrate• Increaseproductionefficiency

Theaimistooptimizeproductionresources,thelayoutofthecontrolsandthelotsizestoguaranteeasteadyflowofproductionwithoutbufferstockbuild-upwhilesimultaneouslymaintainingqualityoforderreceiptanddelivery.Source: Value Stream Mapping – The Road to Lean ManufacturingErlach, Klaus; Springer-Verlag, 2010

PlantSimulationallowsforthecreationofcomplexproductionsystemsandprocessesineasytounderstandcomputermodels.UsingPlantSimulation,materialflow,resourceutilizationandsupplychainsatalllevelsofcorporateplanningmaybeoptimized.

What is Value Stream Mapping?Valuestreammappingisanestablishedmethodforstudyingtheeconomicvalue

• EasytousethroughMicrosoftWindowsconformity

• Blocklibrariesforthefastandefficientmodelingoftypicalscenarios

• Graphsanddiagrams• Analysisofthroughput,

resourceutilizationandbottlenecks

Why perform value stream mapping in Plant Simulation?• Reductionofcostfordatacollectionby

reducingthenumberofobjectsdescribingtheprocessesthroughpre-definedlogicblocks

• Reductioninanalysiseffortthroughautomatedanalysismodules

Throughcomputersimulation,examinethedynamiceffectsofthevaluestream,whichremainhiddeninthestatic,paper-basedmappingofthevaluechain

ApproachTraditional:Depictionofproductionbymanual,graphicalsketchofthevaluestreamusingsymbolsonasheetofpapershowingtheconditions,suchasmaterialflow,informationflow,inventories,value-addedandnon-valueaddingactivities.Basedoncustomerdemand,inventoryandcycletimes,analysisofthecurrentstateofproductionisperformedasateam.Revisionandimprovementofthevaluestreamisthenderivedfromthiscurrentvaluestreammappingoftheproductionprocess.

Standardizedmethodbasedongenerallyacceptedsymbols

TecnomatixPlantSimulationispartofthePlantDesignandOptimizationsolutionofferingfromSiemensPLMSoftware.

Thesearecoordinatedsoftwarecomponentsthatenableyoutoplanthecompleteproductionofaplantbywayofacomputermodeltovisualizeandsimulatetheprocessesinproductionlines,warehousesandwork-shops,soastoquickly,easilyandsafelyachievetherequiredfindingsandresults.

Theextensiveportfolioallowsforanoptimizedmanufactur-ingprocessdesignlifecycle,includingplanning,factorylay-outdesign,andmanufacturingprocessesandfactorysimula-tion,enablingtheseamlessconnectionwithhigher-levelplanningsystems.

Thetraditional,staticvaluestreamanalysisisextendedtoincludethecriticaltimeele-mentforstockavailability.

Thus,youcandepictdynamicfluctuationsofthedailyproductionduetolotsizes,setupprocedures,productvariations,orotherdisturbances.

ThedynamicmaterialflowsimulationinTecnomatixPlantSimulationpermitsthereductionofthenumberofproductsinproductionandthusthecapitalinvestmentrequiredforrobustproduction,ensuringthatnaturalfluctuationsinproductiondonotimpairtheabilitytodeliver.

©2012SiemensProductLifecycleManagementSoftwareInc.Allrightsreserved.SiemensandtheSiemenslogoareregisteredtrademarksofSiemensAG.D-Cubed,Femap,Geolus,GOPLM,I-deas,Insight,JT,NX,Parasolid,SolidEdge,Teamcenter,TecnomatixandVelocitySeriesaretrademarksorregisteredtrademarksofSiemensProductLifecycleManagementSoftwareInc.oritssubsidiariesintheUnitedStatesandinothercountries.Allotherlogos,trademarks,registeredtrademarksorservicemarksusedhereinarethepropertyoftheirrespectiveholders.X3000007/12B

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ContactSiemensIndustrySoftwareAmericas +18004985351Europe +44(0)1276702000Asia-Pacific +85222303333

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Value Stream Mapping Library in Plant SimulationPredefinedsymbolsbasedonthegeneralstandard:• Quickandeasytolearn• Predefineddialogswithconfigurable

userobjects• Controllogics• Analysisobjects

ApplicationThePlantSimulationValueStreamMappingLibraryallowsuserstoquicklyandeasilymapandimprovetheirsupplychainswithrealdynamicbehavior.

ThePlantSimulationValueStreamMappingLibrarywasdevelopedincollabo-rationwithindustrypractitionersforusebyindustrypractitioners,providingthenecessaryobjects.

Predefinedcoreobjects:• Process• Supplier• Customer• Stock• Supermarket• Internalandexternal

transport• Predefinedcontrolsfor

mappingof:-Kanbanprocesses-HeijunkaBox-Compensationbox

Predefinedobjectsforanalysisandevaluationof:• Throughputtime• Loading/unloadingorwaiting

time• Value-addedtime• Analysisoftheprocess

utilization• Availabilityofresources

(timesensitive)

Moscow Domodedovo Airport is Russia’s largest airport. Handling 46 percent of air passengers in Moscow, the airport is used by 74 airlines and serves 228 destinations across the globe, with 91 destinations exclusive to the Moscow region. The airport works with 46 foreign and 28 domestic airlines. This includes 11 countries from the Commonwealth of Independent States (CIS). In 2009 Moscow Domodedovo Airport handled 18.7 million passengers.

The cooperation between Domodedovo and Siemens PLM Software began in 1999, when Moscow Domodedovo Airport implemented a major redevelopment program – among the largest European civil aviation investment projects of the decade – with a proposed series of airport infrastructure upgrades that required the development and evaluation of various designs.

Moscow Domodedovo Airport selected Siemens PLM Software as an instrumental technology provider for its reconstruction program.

To effectively plan for the airport renovation, qualitative and quantitative efficiency indicators needed to be set. In addition, the equipment, floor space and transport requirements needed to be determined. Moscow Domodedovo Airport’s experts used advanced computer-aided design (CAD) tools and some of the best practices of airports globally to address these requirements. Among Moscow Domodedovo Airport’s strategic tools for design and analysis is the Plant Simulation solution, part of Tecnomatix® software from Siemens PLM Software.

The first assignment for Tecnomatix was a cargo handling simulation project. The objective was to model the handling of incoming air cargo in order to identify bottlenecks and to improve overall efficiency. Within three weeks the model had been developed. Key information included the aircraft landing schedule, the

Business challenges

Plan for airport upgrade and passenger traffic increase

Keys to success

Use Tecnomatix Plant Simulation for modeling air cargo handling, passenger flows in the international terminal, as well as various terminal performance scenarios

Start with single application; with success, implement simulation across projects

Results

Bottlenecks identified at the design stage and timely corrections made

Investment risks reduced for reconstruction of the international terminal

Airport attained a leadership position in the Russian civil aviation market

Renovating Russia’s largest airport – virtuallyTecnomatix provides the tools to simulate optimum passenger and cargo handling workflows, helping airport become a leader in the Russian civil aviation market

MOSCOW DOMODEDOVO AIRPORT

Aerospace

TECNOMATIX



number and specifications of cargo handling transports, the storage capacity and timeline. The model provided an evaluation of both the cargo handling system “as is” and with several proposed upgrades, which led to the optimal solution for the air cargo terminal.

Next, using Tecnomatix, a series of joint projects were simultaneously implemented, including a simulation and evaluation of the international terminal’s reconstruction plan. Since the airport anticipated a sharp increase of international flights, it was important to make sure that the design solutions were correct. It was also essential that the investment risks related to the terminal’s reconstruction be minimized and controlled.

Using Plant Simulation, Moscow Domodedovo Airport produced a detailed model of passenger flows within the terminal. Airport experts were able to experiment with a variety of scenarios to evaluate and determine the optimal approach. For example, extensive parameters were entered to arrive at various solutions that depended on a range of anticipated passenger situations. Parameters included flight schedules and data, incoming passenger traffic, service regulations, passenger routes across the terminal, equipment for check-in, customs, security, luggage claim areas, the locations of stores, food outlets, and duty free zones.

Peak loads were a special concern, especially relative to the equipment needed to handle the high-traffic times. Plant Simulation accounted for different passenger flow patterns, considering both incoming and outbound flight schedules. Bottlenecks were readily revealed and corrective action taken.

“With such outstanding virtual planning, Tecnomatix Plant Simulation has significantly reduced the risks and uncertainty associated with our airport reconstruction planning,” says Helen Galanova, spokesperson for Moscow Domodedovo Airport. “Thanks to Tecnomatix, we have made considerable improvements to everyday airport workflows, including check-in planning, buses, gates, and boarding management.”

Galanova notes, “Using advanced technologies such as Tecnomatix, Moscow Domodedovo Airport has become a leader in the Russian civil aviation market.”

Solutions/Services

Tecnomatix www.siemens.com/tecnomatix

Client’s primary business

Moscow Domodedovo Airport is the largest Russian airport and holds the leading position among Moscow area airports in terms of passenger traffic. Located 22 kilometers southeast of Moscow, it is the first passenger airport terminal in Russia to be certified under ISO 9001:2000. www.domodedovo.ru/en/

Client location

Moscow Russia

“ Thanks to Tecnomatix, we have made considerable improvements to everyday airport workflows, including checkin planning, buses, gates, and boarding management.”

Helen Galanova Spokesperson Moscow Domodedovo Airport

Aerospace TECNOMATIx

© 2010 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, Nx, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. x9 22973 11/10 B


Contact Siemens PLM SoftwareAmericas 800 498 5351 Europe 44 (0) 1276 702000 Asia-Pacific 852 2230 3333

www.domodedovo.ru/en/

IndustrySemiconductor equipment Industrial machinery

Business challenges Deliver new and innovative machinesShorten machine delivery cycleAdjust production capacity to market conditions, while maintaining cost control

Keys to successSimulate new production lines before they are commissionedAnalyze production scenarios and recommend best alternativesOptimize the sequencing of production processes

ResultsCreated a pilot in which real-world results were compared against simulation models created using Tecnomatix, proving that actual production performance/metrics can be accurately imitated

A leading provider of lithography systems for the semiconductor industry uses Plant Simulation to optimize production scenarios

Innovative consumer and industrial electronics products require state-of-the-art microchipsASML is one of the world’s leading provid-ers of lithography systems for the semi-conductor industry, manufacturing complex machines that are critical to the production of integrated circuits and microchips. These advanced systems help ASML’s customers, the chipmakers, to reduce the size and increase the function-ality of microchips within consumer elec-tronics equipment. As a result, ASML helps to create more powerful electronics systems for consumers and industry professionals.

The “digital revolution” has been realized by the semiconductor industry and indi-rectly by lithography: the process responsi-ble for imaging smaller features on silicon wafers and continuing “Moore’s Law,” which predicts that technology will double the number of transistors on a microchip at regular intervals. Thanks to lithography, ever-shrinking microchips have brought better, more affordable and energy-effi-cient electronics and services to everyone, improving mobility, connectivity, safety and digital entertainment.

Tecnomatix • NX • Teamcenter

www.siemens.com/plm

ASML Digital manufacturing tools support a world leader in a growing market

Amid the global financial crisis of 2009, chipmakers sharply reduced capital expen-ditures. Halfway through the year, the semiconductor industry was among the first to recover, and orders picked up, lead-ing to two subsequent years of record sales for ASML. Sales in 2010 were nearly three times those of 2009, followed by another sales increase in 2011. During this strong rebound, ASML had to ensure that it would continue to deliver its machines on time and in accord with the highest quality standards.

Evolving high-productivity TWINSCAN NXT platform, manufactured by ASML.

As demand in the semiconductor industry is cyclical, ASML must continuously adjust its production capacity to meet the requirements of the market. This is a sophisticated process that involves fore-casting demand, setting detailed output plans and aligning with a large and complex supply chain. This process also involves the use of the Plant Simulation solution in the Tecnomatix® portfolio.

Bridging the gap between product design and manufacturingASML uses several Siemens PLM Software solutions, including Teamcenter® software for digital lifecycle management and NX™ software for product design. Recently, the Industrial Engineering department of ASML began using Plant Simulation, a discrete-event simulation tool.

“The Industrial Engineering team functions in between D&E (Development and Engineering) and M&L (Manufacturing and Logistics),” explains Andreas Schoenwaldt, Industrial Specification

Management (ISM) team manager at ASML. “The production simulations that we develop using Plant Simulation support building a bridge between these groups. We have to make many decisions regard-ing the establishment of new production facilities, or improving existing ones. Plant Simulation helps us make these decisions after simulating what-if production scenar-ios. Our machines have to perform to high standards; they need to print very small features on silicon wafers, printing 30-40 layers exactly on top of each other, and do it extremely fast. Precision is measured in nanometers. A relentless drive to innovate is part of the ASML culture, and has allowed us to meet this challenge. In this context, we had the need for a discrete-event software simulation tool to simulate and optimize our production.”

Results (continued) Optimized a production line configuration that supports the needed throughput and reduces the investment in production resources for a new EUV machineBoosted production capacity for a new design by using two positioning module qualifica-tion toolsCreated library of simulation objects, e.g. an optimization algorithm object that identifies the most efficient sequencing of manufacturing stepsImplemented Plant Simulation as part of the company’s pro-duction process approach that enables continuous delivery of the most innovative and cost-effective solution to customers

Production of the new EUV machine in a clean room.

“Maintaining world leader-ship is a tough task. You must be innovative and cost-effective. Plant Simulation will be part of our engineering decision-making process. A lot of production scenarios will be simulated virtually using Plant Simulation, before we will actually commission the production line.”

Andreas Schoenwaldt Industrial Specification Management Team Manager ASML

Creating a Plant Simulation model for the production phase, with a target of shortening machine lead timeMachine testing is the production phase that requires the longest duration, even significantly longer than the final assembly phase. ASML is constantly striving to shorten lead times, increase production capacity and lower costs in order to increase its appeal as a go-to supplier. In studying these challenges, data analysis showed that one source of delays is the late delivery of processed wafers. Joris Bonsel, an industrial engineer on the Industrial Specification Management (ISM) team at ASML, notes, “These wafers are produced in our process lab, mainly for the purpose of machine testing. We used data from a five-month period of actual wafer orders requested by the test department, combined with the corresponding actual delivery times. We then created a Plant Simulation model that delivered the same results that were collected, reflecting a surprisingly high level of accuracy.

“Once we knew that we had a simulation model that reflected reality, we started to do the industrial engineering analysis. It was clear that adding more manpower in the lab would improve delivery perfor-mance, but we were able to simulate the actual production, and proved that there is a clear financial benefit to adding one employee to the process lab, rather than invest, for example, in a new track. Just to prove that this result is not trivial, we sim-ulated and showed that adding a second employee was not cost beneficial. This analysis was previously done based on gut feeling, rather than a simulation, and therefore it was difficult to argue with the simulation recommendation.” Bonsel notes, “This was actually the project we used to pilot Plant Simulation, and we

were impressed when we realized that with Plant Simulation, we can build a model that will accurately imitate the per-formance of a physical production line.”

A new generation of lithography systemsASML has developed a new generation of lithography systems that uses extreme ultraviolet (EUV) light and will allow chip-makers to continue to shrink feature sizes on chips. The first systems intended

The NXE:3300B.

The Plant Simulation process lab model.

for volume manufacturing, dubbed NXE:3300B, will ship in 2012, and the engineering teams had to plan production facilities to support the rollout. Maurice Schrooten, an industrial engineer on the ISM team at ASML, explains: “One of the main questions was: ‘Which production resources were needed for manufacturing the MBMM (main body mid module), one of the major modules of this machine?’ Naturally, we were looking for the most cost-effective investment, and therefore we have used Plant Simulation to analyze the implications of three different alterna-tives on clean room space consumption, throughput variation, and labor and hard-ware investment. The three alternatives were: 1) cloning the current production line, 2) outsourcing, called HLQB (high-level qualified buy), some of the produc-tion and, 3) using a new production line methodology, which splits the assembly work between three different work areas. The simulation showed that the cloning alternative required a higher investment in equipment, so we abandoned it. Out of the other two alternatives, which were largely equal, we selected the one with the lowest risk for ASML. The Plant Simulation result is an optimized produc-tion line configuration that supports the needed throughput and reduces the investment in production resources.”

Plant Simulation result chart: comparison of investment in three production line alternatives.

Higher throughput through simulationOne of the key modules of the TWINSCAN NXT:1950i machine is the positioning module (PM). As ASML was considering how to boost production capacity for a new design, the team wanted to know how many qualification tools, that is, posi-tioning module qualification tools (PMQTs) would be needed, and how could the tool utilization be maximized. The team also planned to compare deployment of two parallel workstations with the same tasks versus two serial workstations, each with half of the tasks. Ron Clauwers, an indus-trial engineer on the ISM team at ASML, notes: “To deliver the highest throughput, four scenarios were compared with each other, and the Plant Simulation results showed that we should use two identical PMQTs in a flexible (not fixed) manner, in other words, each PMQT can accommo-date any needed production step, com-bined with priority rules, and use parallel workstations (rather than serial worksta-tions), in front of the PMQTs.”

Plant Simulation result box plot: the time (in weeks) needed to produce a specific volume of PMs is shown. The highest throughput is obtained with two tools, flexible utilization and parallel workstations.

“We were impressed when we realized that with Plant Simulation, we can build a model that will accurately imitate the performance of a physical production line.”

Joris Bonsel Industrial Engineer Industrial Specification Management ASML

“The Plant Simulation result is an optimized production line configura-tion that supports the needed throughput and reduces the investment in production resources.”

Maurice Schrooten Industrial Engineer Industrial Specification Management ASML

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. TWINSCAN NXT, TWINSCAN NXT:1950i, and NXE:3300B are trademarks of ASML Netherlands BV. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z13 29753 4/12 Awww.siemens.com/plm

Solutions/ServicesTecnomatix www.siemens.com/tecnomatixNX www.siemens.com/nxTeamcenter www.siemens.com/teamcenter

Customer’s primary businessASML, one of the world’s leading manufacturers of chipmaking equipment and a key supplier to the chip industry, designs, develops, integrates and services advanced systems to produce semiconductors. The company has manufacturing, customer support centers and training facilities in more than 15 countries. www.asml.com

Customer locationVeldhoven Netherlands

Partnercards PLM Solutions B.V.

Siemens Industry Software

Americas +1 800 498 5351 Europe +44 (0) 1276 702000 Asia-Pacific +852 2230 3333

Plant Simulation becomes part of the decision-making tool kit“One of the strengths of Plant Simulation is the ability to create a library of objects with certain logic, and re-use these objects in different models,” says Schrooten. “We worked closely with the Siemens PLM Software deployment partner, cards PLM Solutions B.V., and they have provided us with an initial, useful library of objects. For example, we created the genetic algorithm (GA) optimization object in our object library. When we simulate a manu-facturing process, we define a lot of constraints between the manufacturing steps, such as the precedence constraint, which defines which step should be done prior to another step; time constraint, which defines waiting time that is some-times needed after executing some of the manufacturing steps; and constraints that are related to physical aspects, for instance, two steps that can’t be done simultaneously, as they are done on the same physical area of the machine.

“The GA optimization object uses the genetic algorithm capability of Plant Simulation to recommend a sequence of process steps, taking into account all the constraints, and to assign the steps to the required production personnel.

Another useful capability of Plant Simulation we are using is the experiment manager. With this, we run simulations of several scenarios, and can very easily com-pare the results of different alternatives.”

Schoenwaldt concludes, “Maintaining world leadership is a tough task. You must be innovative and cost-effective.” He notes, “Plant Simulation will be part of our engineering decision-making process. A lot of production scenarios will be simulated virtually using Plant Simulation, before we will actually commission the production line.”

IndustryProcessing technology

Business challenges Increase completeness of the solution offered to customersDeliver a cost-effective solution for unloading shipsIncrease effectiveness of food production equipment operation

Keys to SuccessProvide field engineers and sales with a cutting-edge software to demonstrate solution superiorityAnalyze different ship unloading solutionsSelect the optimal production sequence

ResultsCut cost of unloading ships by embedding proprietary algorithm in a simulation modelReduced operational cost of mixing plants by using optimal production sequence

Plant Simulation enables the delivery of complete solutions

Innovative automation solutions delivered with Swiss accuracyDid you know that 65 percent of the chocolate and 40 percent of the pasta manufactured globally is done so with the machines of the Swiss company Bühler Group? Bühler is a specialist and global technology partner for plant, equipment and services for processing foods and manufacturing advanced materials. The organization holds leading market positions worldwide in the fields of technology, such as processes for transforming grain into flour and animal feeds, producing pasta and chocolate, and manufacturing die-cast components.

Tecnomatix

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Bühler Leading process technology partner uses advanced tools to increase value for its customers

Bühler’s core technologies are in the areas of mechanical and thermal process engineering. With its expertise and over 150 years of experience, Bühler enables its customers to succeed by consistently rolling out unique and innovative solutions. Over the years, Bühler has acquired a reputation as a reliable partner, thanks to its global presence and commitment to customer value.

Bühler operates in over 140 countries, and has a global payroll of over 10,000 employees.

To increase its operational efficiency, Bühler uses product lifecycle management (PLM) solutions from Siemens PLM Software: NX™ software, and the Plant Simulation solution in the Tecnomatix® portfolio.

A Bühler chocolate production line.

http://www.siemens.com/tecnomatix

Ship unloading solution validated with Plant SimulationAs part of its grain handling products, Bühler delivers ship unloading solutions to its customers. The unloading process for a ship requires many hours, and every hour the ship is in the port is very expensive. As a result, there is a high motivation to unload the ship as safely and quickly as possible.

During the unloading process, the ship’s center of gravity shifts and the ship tilts. Any tilt above the allowed tilting angle during unloading might break up the ship. Therefore, the sequence of unloading the different compartments of a ship is very important. Moreover, there is a need to balance the unloading of neighboring compartments.

“We are very pleased with our usage of Plant Simulation, as it allows us to easily test different scenarios with little effort, and embed it in the simula-tion of our own algorithms”.

“When quantifying the expected improvements into an economical benefit, we found an impressive cost reduction enabled by the usage of Plant Simulation for the production sequence determination.”

Dr. Mukul Agarwal Expert for Intelligent Process Operation Corporate Technology Bühler

When a company is interested in acquiring a new ship unloading solution or modify-ing an existing system, it must consider the number and type of unloaders that will be needed. Naturally, there is a compro-mise between the number of unloaders, the type and the unloading time. This compromise can be optimized by analyz-ing different scenarios.

Bühler field engineers and sales represen-tatives had challenged the Bühler Corporate Technology department with finding a solution that would help pros-pects resolve this complex decision. Such a solution should enable a customer to easily define an unloading scenario for a specific ship, simulate different scenarios and compare them.

Bühler ship unloading solutions.

“We analyzed several potential solutions and realized that an event simulation tool would be the most suitable for this task,” says Dr. Mukul Agarwal, expert for Intelligent Process Operation, Corporate Technology at Bühler. “Since we were already using Plant Simulation, we decided to use it for the ship unloading scenarios analysis. So we created a simulation model and embedded in it an unloading algorithm that we developed. We are very pleased with our usage of Plant Simulation, as it allows us to easily test different scenarios with little effort, and embed it in the simulation of our own algorithms.”

Mixing production equipment operation optimized with Plant SimulationBühler delivers a complete mixing solution, including process definition, plant engi-neering, process automation, manufactur-ing, installation and start-up, as well as customer service. An example of a mixing application would be the blending done by flour mills, which mix different types of flour and sometimes add additional ingredients.

In its drive to increase its competiveness and the completeness of the solution it delivers to its mixing production equip-ment customers, Bühler decided to check the feasibility of also offering a software tool which would enable it to test differ-ent production scenarios. Therefore, it cre-ated a model using Plant Simulation that is easy to use and identifies the recom-mended production sequence.

A Bühler mixing production line.

“When implementing the suggested sequence identi-fied using Plant Simulation, we found there was a signifi-cant reduction in the overall production time and the number of delayed order deliveries was minimized.”

Dr. Mukul Agarwal Expert for Intelligent Process Operation Corporate Technology Bühler

Ship unloading simulation with Plant Simulation.

© 2013 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z8 32120 1/13 Asiemens.com/plm

Solutions/ServicesTecnomatix siemens.com/tecnomatixPlant SimulationNX siemens.com/nx

Client’s primary businessBühler is the specialist and technology partner for plant, equipment and services for processing foods and for manufacturing advanced materials. www.buhlergroup.com

Client locationUzwil Switzerland

“Offering a Plant Simulation model and methodology as a means to optimize the operation of the equipment our customers are buying from us is an important step in increasing our competiveness and the completeness of our solution.”

Klaus-Jochen Lisner head of Intelligent Process Control Corporate Technology Bühler



Buhler conducted several pilots to validate the benefit of this simulation model. “We analyzed the performance of an exist-ing line, and compared the production sequence that was used with an optimized production sequence suggested by the analysis done with Plant Simulation,” notes Dr. Agarwal. “When implementing the sug-gested sequence identified using Plant Simulation, we found there was a signifi-cant reduction in the overall production time and the number of delayed order deliveries was minimized. When quantify-ing the expected improvements into an economical benefit, we found an impres-sive cost reduction benefit as well.”

“Offering a Plant Simulation model and methodology as a means to optimize the operation of the equipment our customers are buying from us is an important step in increasing our competiveness and the completeness of our solution,” says Klaus-Jochen Lisner, head of Intelligent Process Control, Corporate Technology at Bühler. “It directly supports our slogan, ‘Engineering Customer Success.’”

Food production simulation with Plant Simulation.


http://www.siemens.com/nx

http://www.buhlergroup.com

IndustryIndustrial machinery and equipment

Business challengesAcquire both domestic and foreign automotive manufac-turing customersSupport accelerated growthExpand to new areas such as aerospace

Keys to successUse Tecnomatix process plan-ning and simulation tools to validate production lines Leverage global knowledge and engineering methodologiesUse Process Designer and Process Simulate to generate quotations

ResultsTremendous growth – an average of 50 percent annu-ally in a span of ten yearsOne of the biggest and most talented 3D simulation teams in China

Comau (Shanghai) simulates more production scenarios in less time using Tecnomatix

Expanding innovative automation solutions to ChinaComau (Shanghai) Engineering Co., Ltd. [Comau (Shanghai)] is a wholly owned subsidiary of the Italian-based company Comau S.p.A, a Fiat Group affiliate. Comau (Shanghai) was established in 1997 as Comau (Shanghai) Automotive Equipment Co. Ltd. but after 15 years in operation, the company is no longer confined to the automotive industry. Having expanded its advanced automation technology into other areas of industrial manufacturing, the company officially changed its name to Comau (Shanghai) Engineering Co., Ltd. in 2010.

Comau (Shanghai) employs more than 900 people at several facilities in China. In the Chinese auto market, Comau (Shanghai) is a major supplier of body welding and powertrain assembly and machining equip ment. The company started manufacturing robots in 2011 and has developed a well-balanced portfolio of customers, including joint ventures of global brands. The company’s five business units are Body Welding, Powertrain Systems, Robotics, Aerospace, and Adaptive Solutions.

Strategic decision to use the best In building production lines for automotive original equipment manufacturers (OEMs),

Tecnomatix


Comau (Shanghai)Digital manufacturing tools support rapid growth

Comau (Shanghai) is often required by customers to deliver line and workcell simulations. For simplicity, the company typically uses the same planning and simu-lation system used by its customers.

Comau (Shanghai) technicians setting up a production line in its Shanghai facility.

“Most of our customers require us to use tools in the Tecnomatix portfolio, such as Robcad, Process Designer and Process Simulate,” explains Riccardo Piegaia, pro-cess engineering manager in the Comau (Shanghai) Mechanical Engineering Department. “But even for those few customers who use other tools, we have taken the strategic decision to use only the Tecnomatix tool set. Why? Because we believe Tecnomatix is the best tool set for the 3D simulation of robotized workcells.

Results (continued)Delivered complete turnkey automotive body welding lines to leading automotive OEMsImproved proposal writingMore efficient resource utilization

“Using the Tecnomatix tools, we are able to simulate more production scenarios in less time.”

Piegaia, who relocated from Italy, brought to China his experience using the Tecnomatix® portfolio from Siemens PLM Software. When he started with Comau (Shanghai), he was the only person using 3D simulation, but as the company was awarded more and more projects, he trained other engineers and significantly increased the size of the team.

A physical, commissioned welding station delivered to Fiat, and the virtual workcell simulated using Tecnomatix.

“The Tecnomatix tools not only help us provide best-in-class production lines to our customers, but also elimi-nate waste within our organization by saving engi-neering time and helping minimize re-work on the shop floor.”

“We currently employ the biggest and best-skilled 3D simulation team in China – dozens of simulation engineers who use Robcad, Process Designer and Process Simulate.”

Dr. Stefan Sack CEO Comau (Shanghai)“This team must deliver value,” notes

Piegaia. “For example, in 2011, our biggest project was a complete body-in-white (BiW) line for Fiat China, which included around 250 Comau robots. Twenty engi-neers worked on this project, using Tecnomatix tools for nearly half a year, and delivered state-of-the-art simulations that supported the production line, which is now in operation. This project proved our ability to collaborate across continents, as we used some welding guns that were designed in Italy. Now, we are about to simulate and commission the second phase of this project, which almost dou-bles the line throughput by means of a cycle-time reduction and multiplication of the robotized stations.”

The simulation work in China is performed according to the customer’s requirements and in collaboration with car component design. The main goal of the simulation is to plan and validate the production line.

In some cases, the simulation shows that the design of a specific part should be slightly changed due to the need to use specific welding tools.

“We simulate all the BiW workcells, start-ing from spot welding, and continuing with more advanced technologies, such as stud welding and laser welding,” Piegaia explains. “Laser welding, though being much more expensive than spot welding, is more appealing in those areas of the car that are visible once the car is manufac-tured. Using Robcad simulation, we delivered a roof welding workstation to one of our customers, in which two robots do spot welding and two robots do laser welding.”

Smooth transition from Robcad to Process SimulateComau (Shanghai) recently started using the Process Designer and Process Simulate solutions, both in the Tecnomatix portfo-lio, to deliver the 3D robotic simulation work it previously created using Robcad™ software, also in the Tecnomatix portfolio. The first project executed with these tools was a framing zone on a new production line for one of the European OEMs. Process Designer and Process Simulate data were among the initial deliverables submitted to the OEM.

A car roof laser welding station simulated using Tecnomatix.

“We believe Tecnomatix is the best tool set for the 3D simulation of robotized workcells.”

“Twenty engineers worked on this project, using Tecnomatix tools for nearly half a year, and delivered state-of-the-art simulations that supported the produc-tion line, which is now in operation.”

Riccardo Piegaia Process Engineering Manager Mechanical Engineering Department Comau (Shanghai)

Piegaia acknowledges the support Comau (Shanghai) received from Siemens PLM Software to get its engineers up to speed with the new tools. He already foresees a great benefit from them. “For a line builder like Comau (Shanghai), the engineering communication framework with the cus-tomer is always a challenge – what form of communication to use, which data to share with the customer, and how fre-quently to do so. Compared to a project done using Robcad, with Process Designer and Process Simulate, I see a clear saving in engineering manpower, since there is no need for a Comau (Shanghai) engineer, who functions as a technical mechanical leader, to be involved in this communica-tion. It is straightforward to communicate directly with the customer based on the Process Designer and Process Simulate data.”

“In addition, the engineering work pro-ceeds faster and visualization is improved,” notes Congjian (Kaiser) Liu, a process engi-neer in the Mechanical Engineering Department of Comau (Shanghai). “We can actually visualize the entire production line now. Other important features are the

multi-user capabilities, which ensure that no simultaneous conflicting changes can take place. The new functionality is also of great benefit, for example the Weld Distribution Center application, or the new concept of event-based simulation, which enables a much more realistic simu-lation. It is used, for example, in a welding gun tip dressing operation, which takes place only every so many cycles.”

“Process Designer and Process Simulate also provide a good foundation for responding to requests for proposals,” says Qian Hawjia, a process engineer in the Proposal Department of Comau (Shanghai). “We have already submitted a few proposals based on these solutions, and we believe that this methodology will grow. The previous method was based on a complex Excel worksheet, but we real-ized that a quotation process, more and more, includes both engineering and finance aspects. Process Designer/Process Simulate is the platform that supports both.”

Congjian (Kaiser) Liu of Comau (Shanghai) simulates a tip dressing operation using Process Simulate.

“Another promising area would be Teamcenter Manufacturing Process Planner, integrated with Process Simulate, as it provides the means to over-come organizational and geographical barriers using global libraries and process plans.”

Mingzhi Ni Manager, Mechanical Engineering Department Comau (Shanghai)

“The new functionality is also of great benefit, for example the Weld Distribution Center application, or the new con-cept of event-based simulation, which enables a much more realistic simula-tion. It is used, for example, in a welding gun tip dressing operation, which takes place only every so many cycles.”

Congjian (Kaiser) Liu Process Engineer Mechanical Engineering Department Comau (Shanghai)

The Process Designer/Process Simulate deployment is supported by a new concept of the virtual machine (VM) developed by the Comau (Shanghai) information tech-nology (IT) department. Richard Yan, Information and Communication Technology manager at Comau (Shanghai) explains, “As the number of customers to which we deliver simulation data increased, we realized that we needed a smarter IT solution to support different data schemes. Therefore, we decided to use the VM environment and set up this innovative configuration with the support of Siemens PLM Software China. This con-figuration actually saved 60 percent of the hardware cost.” Yan notes that if this solu-tion is positively valuated, it might be adopted by Comau globally.

Tremendous growth Comau (Shanghai) has experienced tre-mendous growth in China – an average of nearly 50 percent annual growth in a span of 10 years starting in 2002. “The Chinese market represents a huge opportunity for Comau (Shanghai),” notes Dr. Stefan Sack, CEO of Comau (Shanghai). “If we take the

automotive market, for example, there are only 45 to 50 cars per thousand people in China, which is still significantly lower than the ratio in developed countries, so one can expect a significant growth of this market.

“We are already a market leader in the areas of automotive body welding and powertrain machining and assembly,” Sack continues. “We are experiencing a very fast growth due to the excellent engineering skills we have developed, our relentless effort for continuous improvement, and the big value we deliver to our customers. This would not have been possible if we were not using the Tecnomatix tools.

“We currently employ the biggest and best-skilled 3D simulation team in China – dozens of simulation engineers who use Robcad, Process Designer and Process Simulate,” Sack adds. “The Tecnomatix tools not only help us provide best-in-class production lines to our cus-tomers, but also eliminate waste within our organization by saving engineering time and helping minimize re-work on the shop floor. One of our advantages, as a line builder competing in the Chinese

A rear floor welding line simulated using Tecnomatix.

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. Excel is a registered trademark of Microsoft Corporation. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.Z8 31193 9/12 Awww.siemens.com/plm



Solutions/ServicesTecnomatix Process Designer Process Simulate Robcad www.siemens.com/tecnomatix

Customer’s primary businessComau (Shanghai), a wholly owned subsidiary of the Fiat Group affiliate, Comau S.p.A, supplies welding and pow-ertrain machining and assembly systems, as well as robots, to automakers and other manufacturers in China. www.comau.com

Customer locationShanghai China

“Process Designer and Process Simulate also provide a good foundation for responding to requests for proposals. We realize more and more that a quotation process includes both engineering and finance aspects. Process Designer/Process Simulate is the plat-form that supports both.”

Qian Hawjia Process Engineer, Proposal Department Comau (Shanghai)

market, is that we are truly a global line builder, or as we say at Comau, ‘global strategy, local execution.’ Looking forward, I can foresee that our global operations will leverage the excellent knowledge and skills we are developing.”

“Comau (Shanghai) is now looking into the next promising manufacturing engineering solutions from Siemens PLM Software. An example of this would be Process Simulate Virtual Commissioning,” explains Mingzhi Ni, Mechanical Engineering Department manager at Comau (Shanghai). “The ability to test the virtual workcells with real controllers is a very promising area as it provides a real opportunity to shorten the project duration. It may also involve some organizational changes, as control engi-neers, who are now part of another department, will have to work closely with the simulation engineer. Another promis-ing area would be Manufacturing Process

Planner in the Teamcenter portfolio, integrated with Process Simulate, as it provides the means to overcome organiza-tional and geographical barriers using global libraries and process plans.”

Process Simulate Virtual Commissioning is used to troubleshoot cell controller program.

IndustryAutomotive and transportation

Business challengesFrequent product alterations and quantity changesMany production line adjustments

Keys to successDigital material fl ow simulationWhat-if simulations to compare alternate production line scenarios

ResultsProblems identifi ed and resolved fasterGreater manufacturing fl exibilityHigher output and less wasteOptimized material fl owsInvestment decisions validated

Tecnomatix Plant Simulation models give planners more fl exibility; material fl ow simulation also increases output and reduces waste

Making driving safe and comfortable Continental Automotive GmbH is one of the leading automotive suppliers in the world. The company’s three divisions – Chassis & Safety, Powertrain and Interior – develop and manufacture products that make driving safer (air bags and sensors; brake and chassis control systems), more fuel effi cient (gasoline and diesel injection systems) and more fun (infotainment systems and multifunctional displays).

The company’s Regensburg, Germany facility is its biggest electronics plant. In an area of 16,500 square meters (approximately 177,000 square feet), nearly 2,000 employees produce about 67 million electronic devices per year. The plant operates 24/7, running 22 lines for surface-mounted devices (SMDs) along with other product-specifi c assembly and inspection lines.

The company’s different business units demand quite a lot from the manufactur-ing planners at the Regensburg plant. Frequent product alternations as well as quantity changes require repeated production line adjustments. To support

Tecnomatix

www.siemens.com/plm

Continental Automotive Group Changing production requirements are handled easily with digital factory software

the planners in this complex effort, the plant established an internal consulting agency, called the “Lean Offi ce,” that provides the business units with an expert production infrastructure and manufactur-ing expertise. “We offer our customers, the individual business units, a kind of carefree package for the manufacturing of their products,” says Dr. Markus Fischer, head of industrial engineering at Continental Regensburg.

A printed circuit board automatically mounted with components.

Identifying problems through simulationThe Lean Office increasingly relies on advanced technology, such as the Tecnomatix® software from Siemens PLM Software. This digital manufacturing solution was chosen after a rigorous benchmarking process – involving the production process for side airbag satel-lites (sensors used to detect an impact) – that turned out 120,000 parts per day, covering more than 200 variants. The task was to simulate material flow between processing stations, starting with preliminary assembly, through to SMD mounting and all the way to customized packaging. After the process was modeled in Tecnomatix Plant Simulation (in two weeks), the resulting simulation won over the plant’s management, and Tecnomatix software was quickly integrated into the Lean Office’s technology portfolio.

The office uses the Tecnomatix material flow simulation functionality to examine and optimize new production lines, as well as to optimize existing ones. The lines can be evaluated and optimized for various parameters, such as throughput, cycle times, performance limits, interferences, and so on. To make reliable predictions, simulation models must map the real line as accurately as possible. Also, modifica-tions must be tracked carefully. Given the frequent product alternations, the goal is to quickly identify potential problems in software and fix them before the actual process begins. “With a simulation, many

“ The possibilities of a simulation are really great for reducing costs.”

Stefan Lamken Lean Office Process Consultant Continental Regensburg

problems are easily fixed,” explains Stefan Lamken, a process consultant to the Lean Office and key user of Tecnomatix.

Normally at Regensburg Plant, the manu-facturing planners design lines with precise and successive processing stations. In this context, a simulation model is used to verify the planned performance of the line. “For our planners, Tecnomatix Plant Simulation is a very interesting tool,” says Fischer. “An offline simulation shows solu-tions that sometimes surprise even the most experienced colleague.” For example, a multi-product line with up to 100 vari-ants did not reach the theoretical targeted output. An unforeseen bottleneck unbal-anced the material flow. The Tecnomatix simulation showed that a processing station was operating too quickly, resulting in jams at subsequent stations. The unex-pected solution – slowing down the cycle for that particular station – would have been discovered much later had the simu-lation not been used.

Supporting sound financial decisionsIn another situation, the goal was to increase the output of a production line. Manufacturing planners developed four possible scenarios, noting the cost of each possibility. By evaluating the four alterna-tives using Tecnomatix simulations, the company was able to see that the most economical approach would meet the desired goal. “We were elated with the software,” recalls Lamken. “With it, we

Electronic component on work-piece carrier. Customized laser marking of a manufactured electronic assembly.

© 2011 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.Z1 25134 8/11 Cwww.siemens.com/tecnomatix



Solutions/ServicesTecnomatix Plant Simulation www.siemens.com/ tecnomatix

Customer’s primary businessContinental Automotive Group is one of the world’s leading automotive suppliers. www.conti-online.com

Customer locationRegensburg Germany

“ Material flows can be optimized in different ways, without having a single second of downtime.”

Stefan Lamken Lean Office Process Consultant Continental Regensburg

“ Tecnomatix simulations give us the flexibility we need in our production processes to perfectly meet customers’ demands.”

Dr. Markus Fischer Head of Industrial Engineering Continental Regensburg

could see that the cheapest concept deliv-ered as much additional output as the most expensive one.” Overall, this is one of the key advantages of the Tecnomatix solution: accurate performance data on which to base financial decisions.

Tecnomatix also saves money by eliminat-ing the need for time-consuming tests on actual production lines. For example, an SMD line occasionally bottlenecked and jammed, requiring operator intervention to resolve the problem. This jeopardized product quality and affected the line’s performance. A cooling buffer solved these problems. A Tecnomatix simulation took the solution a step further by showing how the buffer could also enable higher output. This was determined without performing any physical tests. “The possibilities of a simulation are really great for reducing costs,” says Lamken.

In addition to verifying new and revised production processes, the Lean Office uses Tecnomatix to minimize stock and to reduce waste. Questions regarding the ideal number of work-piece carriers in a line are answered in detail by the soft-ware. At the same time, simulation makes it possible to consider the effects of

various external conditions, such as poten-tial supply disturbances and personnel changes. “With Tecnomatix we are able to evaluate various scenarios in the planning stages,” says Fischer. “With this capability, we have the necessary flexibility to per-fectly meet customers’ demands.”

Currently, the Lean Office uses Tecnomatix Plant Simulation models on approximately eight projects per year, although that number is growing. “Every manufacturing planner who has experienced the benefits of simulation comes back to us and our services,” says Lamken. “Digital material flow simulation with Tecnomatix has enor-mous potential at our Regensburg plant.”

Blister belt machine for packaging of SMD components.

http://www.plm.automation.siemens.com/en_us/products/tecnomatix/


Business challengesEstablish the capability to deliver product-to-warehouse within a single dayReduce factory and warehouse inventory

Keys to successPlant Simulation for discrete-event simulationExpertise of Siemens Corporate TechnologyAccurate data and under-standing of manufacturing processesEffective change managementShop floor buy-in

ResultsDelivering products to ware-house in Germany within 24 hoursWarehouse inventory cut in halfSubstantial cash freed upLead time significantly reduced – up to 70 percent

Warehouse inventory cut in half and cash freed up with the help of the Plant Simulation solution in the Tecnomatix portfolio

Dramatic improvement in productivity Much has been written about the digital factory, but does it deliver in practice? One organization that knows the answer is Siemens Industry Sector, Drive Technology, Motion Control (Siemens Drives), based in Congleton in the United Kingdom (UK). Tom Hattersley, who heads up the Operational Supply Chain at Siemens Drives, notes, “These days, the digital factory is a key component of competitive manufacturing and was a major factor in the success of our Congleton 2011 project. Between 2008 and 2011, we achieved a dramatic improvement in productivity supported by the use of Plant Simulation.”

Tecnomatix


Siemens Drives How the digital factory at Congleton supported a business turnaround; use of Plant Simulation facilitates a significant reduction in factory lead times

Siemens Congleton’s mission“We provide our global customers with technically innovative, energy-efficient products in a sustainable environment – on demand.” That’s the mission statement of the Siemens Congleton plant and the driving axiom behind a workforce of just over 500 employees who are producing key models in the Micromaster and Sinamics range of drive inverters and distributed drive technology. Opened in 1971, the factory and offices cover 12,000 square meters.

Target: product delivery within one business dayHattersley describes the process that led up to his plant’s success: “I was production engineering manager at the time, though I came out of this role for six months to work with the Congleton 2011 project

team full time. We were already rated within Siemens as a site of best practices. Since the early ’90s, we’d used TQM (total quality management), quality circles and continuous improvement teams to help improve our performance. We’ve been lean in the office, as well as lean in manu-facturing. As a result, we’ve seen an improvement in our throughput times by a factor of ten and we have won numerous awards. However, we faced a real challenge in meeting the Congleton 2011 objective of establishing the capability of delivering product to our Nuremburg warehouse within a one-day window.

“We also wanted to reduce inventory at the back-end and to increase flexibility. If you can supply in one day or react in one day, instead of reacting in 5, 10 or 20 days, which is the standard lead time for similar production organizations, you can hold less inventory in the factory and improve delivery performance, or maintain delivery performance with less inventory in the warehouse. That frees up cash, which is very important in the current economic climate.

“I’d strongly recommend that plants wanting to improve their performance use Plant Simulation. It gives you the information – and the confi-dence – to share your plans with the relevant people, show them what is possible and get their buy-in.”

Tom Hattersley Head of Operational Supply Chain Siemens Congleton

“When we started the project in 2008, we were squeezing out what we could in terms of multiple small productivity improvements. We knew we’d need a step-change improvement if we were to make progress. We knew, too, that lean tools were not enough in isolation, and that we would need to model and test possible factory layouts. We had to get it right the first time if we were to avoid irreversible spending on inefficient layouts, unneces-sary equipment and processes that would not work. We needed a tool to achieve this, and that tool was Plant Simulation.”

High-impact productivity tool: Plant Simulation The Plant Simulation solution in the Tecnomatix® portfolio is a discrete-event simulation tool that helps users to create digital models of logistic systems, such as factory layouts, so that they can explore a system’s characteristics and optimize its performance. These digital models allow users to run virtual experiments and what-if scenarios without disturbing existing production systems, or do so when used in the planning process, long before the real production systems are installed. Extensive analysis tools, such as the bottleneck analyzer, statistics and charts, enables users to evaluate different manufacturing scenarios. The results provide the informa-tion needed to make fast, reliable and smarter decisions.

“Between 2008 and 2011, we achieved a dramatic improvement in productivity supported by the use of Plant Simulation.”


Experience: Siemens Corporate TechnologySiemens Corporate Technology (CT) in Munich already had experience using Plant Simulation. In March of 2008, CT carried out a factory assessment as a lead-in to the project. The three main elements of the project were value stream mapping (VSM) and design, simulation and factory re-layout. Hattersley was responsible for the value stream mapping, value stream design and the implementation, while CT led the simulation fully supported by Hattersley.

Building the model to map the value stream“Value stream mapping is a structured process that supports the lean manufactur-ing initiative, which promotes the elimination of waste and minimization of non-value added activities. It can be very intuitively described with a Plant Simulation model. We therefore created the value stream map showing how the processes looked at that time: the current steps, delays, and information flows required to deliver the target product – in this case the Micromaster 4, frame sizes A, B and C. Then we produced the value stream design, how we wanted the factory to look in the future, moving capital equip-ment around the factory, and building the mezzanine floor to accommodate the test equipment from the shop floor to create more space to move things around on the shop floor.”

It took six weeks to create the value stream map and design, and one more week to pull it all together and decide what the factory had to look like. It took another six weeks to build the model in Plant Simulation, validate it, test it and run a number of ideas. Hattersley explains, “We were creating, in essence, a mathe-matic model of the factory, which relies on data such as machine availability, MTBF (mean time between failures), MTTR (mean time to repair) and more. We would then test each hypothesis by simulation. From Tecnomatix we’d get a workplace overview showing working time and wait-ing time, off-shift time, break times and so on. We could also see utilization for each work center/bench, structure of the prod-uct in VSM, throughput histogram for each product and a buffers/Kanbans chart. I could then, for example, reduce five work-places to three and change the shift pat-terns, rerun the simulation and get the new results.”

Lead time dramatically reducedHattersley quantifies the success: “In one case, the average factory lead time, based on the simulation, was four days. We devised a new way of working, tested it, identified the bottlenecks, balanced the flows and, using Plant Simulation, showed we could get lead time down to an average of 1.5 days. That effectively means we could halve our inventory in the warehouse. For another product group, we got down from 3.5 days to 2 days. “

Plant Simulation can also flag bottlenecks resulting from demand volatility. Hattersley points out, “In the past, we used to create a spreadsheet to model some rough guesses, but with Plant Simulation we can virtually introduce proposed changes to the factory layout through a simulation model. We can then

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens, the Siemens logo, Micromaster and Sinamics are registered trademarks of Siemens AG.. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z4 30975 8/12 Awww.siemens.com/plm



Solutions/ServicesTecnomatix Plant Simulation siemens.com/tecnomatix

Customer’s primary businessSiemens Drives provides variable speed drives for the motion control of electric motors across a wide range of industries. www.siemens.com/drives

Customer locationCongleton United Kingdom

PartnerSiemens Corporate Technology

“With the help of Plant Simulation, we are now where our customers want us to be; we deliver products to our warehouse in Germany within one day, and continue to make improvements as we push forward now for our next project: Congleton 2015 – World Class provider.”


populate real operational data into the simulation model, and compare the results of the simulation with the real production results. Since the simulation typically deliv-ers very close results to the real produc-tion, the confidence in the simulation results, mainly by non-simulation experts, is increased.”

Vision, agilityThe project was initiated prior to the 2008 downturn when short-cycle business essentially just stopped, as companies across industries significantly reduced spending, though long-cycle orders were maintained for a while. Siemens Drives wanted to be ready when the economy revived, so it continued with the project, demonstrating vision and agility. “We had a firm justification for what we were doing,” says Hattersley. “We carried out the simulation, and we had the data to back it all up. By 2009, much of the factory reor-ganization had been completed and the benefits started to flow throughout that year, with more coming during 2010. Throughout 2011, we cascaded down this simulation methodology to our lower- volume products, so they benefited too.”

Effectively managing change“For a successful outcome, it is essential that you understand and prepare your process planning data – your routings, your standard times and so on,” says Hattersley. “It’s time-consuming but vital; you have to input good data into the simu-lation to get good information out. You have to be reasonably analytical, and understand your products, your processes and your machines. Of course, you have the usual issues of managing change and, as is normal for us, the shop floor was heavily involved.”

Confidence that makes a differenceAccording to Hattersley, results are the bottom line: “We reduced lead time and freed up cash by reducing inventory. With the help of Plant Simulation, we are now where our customers want us to be; we deliver products to our warehouse in Germany within one day, and continue to make improvements as we push forward now for our next project: Congleton 2015 – World Class provider.” Hattersley concludes, “I’d strongly recommend that plants wanting to improve their perfor-mance use Plant Simulation. It gives you the information – and the confidence – to share your plans with the relevant peo-ple, show them what is possible and get their buy-in.”

http://www,siemens.com/tecnomatix

http://www.siemens.com/drives

http://www.siemens.com/plm

Designing better factories, virtuallyPlant design and optimization services based on Tecnomatix are proving to be cost-effective for India’s auto industry

www.siemens.com/plm

Automotive

E I CH ER ENG IN E E R ING SOLUT ION S

Siemens PLM Software

Business initiatives

Production efficiency

Business challenges

Compete for business with in-house experience

Justify the cost of productionplanning services

Keys to success

Broad-based plant design andoptimization solution

3D virtual factory models

Support from Siemens in India

Results

Benefits to clients include:

30-35 percent increase in theutilization of space

20-25 percent saving inmaterial movement

Potential capital cost savings inthe millions of dollars

Consultants to the autoindustryEicher Engineering Solutions(EES) is a unit of VECommercial Vehicles Limited, asignificant player in India’sautomobile industry. EES wasestablished in 1997 as a centerof excellence to providedesign, development andconsulting expertise in the fieldof engineering services. This250-member organizationworks from four differentworldwide locations and isdivided into four practiceareas: design, analysis, testingand digital manufacturingsolution services. EES’s clientroster includes automotive OEMs and suppliers such as Nissan, Toyota, Daimler Chrysler,Peterbilt, Navistar, Kia Motors, GM, Harley Davidson and Johnson Controls.

EES’s Digital Manufacturing Solutions discipline is under the direction of Sachin Sanghi.Witheight years experience in industrial engineering at GM, Sanghi brings a familiarity with modernscientific plant design and optimization practices to companies that are still using 2D factoryplanning methods for the most part.“When I visit a prospective customer, my job is to convincethem that scientific methods for factory planning can improve their production processessufficiently to justify our services,” Sanghi explains.“Their other option is to rely on in-houseexperience, as they have always done. The trouble with that is that it is not scientifically basedand can not provide the accurate predictions necessary for making informed decisions.”

Broad-based software solutionSanghi chose the Tecnomatix® digital manufacturing solution from Siemens PLM Software as hisgroup’s software foundation.“I chose this software in part because I was familiar with it frommy days at GM,” Sanghi says.“But more important to me was the support of the Siemens

Automotive

organization in India. They helped me justify my business plan to EES. Had they not made thatinvestment in me, the formation of the Digital Manufacturing Solutions team would not havebeen possible.”

Another attractive feature of the Tecnomatix solution was the breadth of its functionality.WithTecnomatix, Sanghi and his eight-member team have virtual 3D factory design capabilities (inFactoryCAD), comprehensive analysis tools for factory logistics (FactoryFLOW) and simulationcapabilities that provide an intelligent foundation for business decisions (Plant Simulation). Theyalso have a unified source of factory knowledge.“This is a real benefit,” Sanghi says.“Thefactories I create virtually contain all the data about the layout, the material handling devices, theracks, the machines and so on. I take an inventory not by physically counting but by asking thesoftware for a report. This is a huge contrast to how internal groups handle their factory data,and it demonstrates a clear advantage of our approach.”

Real-world examplesThe group’s typical client is automotive and automotive component companies that are eithertrying to expand their existing capacity or to install additional capacity.While the current focus ison a specific sector, the tools and techniques are as relevant to sectors as diverse as aerospace,infrastructure, white goods, retail, etc.When Sanghi and his team plan these expansions usingTecnomatix software, the savings to the customer come in the form of better resourceutilization, higher productivity and capital cost savings, as the following examples show.

In a job for a sister company, Eicher Engineering Components, a global tier one gearmanufacturer in India, EES’s Digital Manufacturing Solutions team was called in to advise on anexpansion that needed to increase the company’s capacity by a factor of three. The company hadalready done some planning when Sanghi’s group got involved and had determined that theexpansion would need to use most of the available land. Using FactoryCAD, he was able todesign the expansion in such a way that they could increase capacity by a factor of almost fivewithout additional land.

Because he had created a 3D virtual factory in FactoryCAD, one of the options that Sanghinoticed right away was that a number of non-value-added activities could be moved to themezzanine of the existing facility.“This is thesort of thing that becomes very clear whenyou have that third dimension to work in,” heexplains.“Even the customer startedcontributing ideas once he saw the layout in3D.” Sanghi made a number of other changesas well, and for this client increased overallspace utilization by 33 percent. In addition, heused FactoryFLOW to reduce material flow inthe facility by 26 percent.“Previously they hadto move material an average of 1,000 meters(3280 feet). Using FactoryFLOW, even though I

“It is very effective to show3D simulations of assemblyprocesses, or materialhandling processes, oreven a walkthrough of anentire facility.”

Sachin SanghiPractice Area Head, DigitalManufacturing SolutionsEicher Engineering Solutions

had increased the floor space, the average move was downto 703 meters (2,300 feet),” says Sanghi. The duration ofthat entire project was three months.

In another example, a stamping supplier to the leadingIndian automotive company hired EES’s DigitalManufacturing Solutions team when it was building a newfacility to meet a mandated production increase. Internalcalculations showed that the new facility would need to beequipped with 19 stamping machines, at a cost of about$250,000 each, to achieve the target capacity.“Using PlantSimulation, we determined that they would only need 14machines,” says Sanghi.“At first they didn’t believe us buteventually we were able to convince them of the accuracyof our calculations. They decided to purchase 15 machines (an extra one to have on a contingencybasis). Our work with Plant Simulation saved that company $1 million.”

Convincing demonstrationsFor the most part, EES’s Digital Manufacturing Solutions’ customers do not supply digital data fortheir facilities or equipment. Sanghi and his colleagues create the necessary geometry usingFactoryCAD. They’ve found that this is the fastest way to work because the extensive libraries inFactoryCAD eliminate the need for modeling items from scratch. At times, Sanghi has also used theNX™ digital product development system from Siemens PLM Software to create digital productmodels, such as tires and fuel tanks for a warehouse space optimization job.

The ability to do this work quickly is sometimes important to winning business. But a moreimportant selling point is giving prospective clients the assurance that EES’s Digital ManufacturingSolutions team knows what it is doing. The Tecnomatix solution is valuable in this regard.“It is veryeffective to show 3D simulations of assembly processes, or material handling processes, or even awalkthrough of an entire facility. It meets an emotional need,” says Sanghi.

For most of India, the use of plant design and optimization software represents a new approach tofactory planning.With Tecnomatix and a growing body of case studies showing the cost-effectivenessof this approach, EES’s Digital Manufacturing Solutions team is helping Indian manufacturers makemore knowledgeable decisions as how to expand their capacity to better compete.

Automotive

Solutions/Services

Tecnomatix

NX


Eicher Engineering SolutionsDigital Manufacturing Solutions’services include: production

system optimization, warehousedesign and optimization, in-plantlogistics design, material flow

analysis and planning, 3D layoutdesign and processdocumentation.

www.eicherengineeringsolutions.com/pdo-plant-simulation.html

Client location

GurgaonIndia

“More important to me wasthe support of the Siemensorganization in India.”

Sachin SanghiPractice Area Head, DigitalManufacturing SolutionsEicher Engineering Solutions

ContactSiemens PLM SoftwareAmericas 800 498 5351Europe 44 (0) 1276 702000Asia-Pacific 852 2230 3333www.siemens.com/plm

© 2008 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG.Teamcenter, NX, Solid Edge,Tecnomatix, Parasolid, Femap, I-deas, Velocity Series and Geolus are trademarks or registered trademarks of Siemens ProductLifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks orservice marks used herein are the property of their respective holders. 8/08


Business challengesGain bigger market share through innovative productsDeliver a monorail system for food catering carts at the New Doha International AirportShorten final onsite throughput testing

Keys to successSimulate the automated material flow of complete operations Virtually commission electrified monorail systemsOptimize complex material flow systems Easily build a discrete event simulation model

Tecnomatix


EisenmannDeveloping an automated flight service cart system for New Doha International Airport

Eisenmann shortens project delivery time by conducting virtual commissioning using Plant Simulation

Virtual commissioning enabled by Plant SimulationThe process of testing a facility or plant to verify that it functions according to specifi-cations is called commissioning. Advances in technology have made it possible to conduct significant portions of this testing

using computer systems, which simulate in great detail the plant’s operation. Eisenmann Conveyor Systems (Eisenmann) is using Siemens PLM Software’s Plant Simulation solution in the Tecnomatix® portfolio to simulate such testing virtually, hence the term, “virtual commissioning.” This process can save companies substan-tial amounts of time and money by model-ing and optimizing operations long before construction or equipment installation begins.

Eisenmann electrified monorail system.

Eisenmann builds facilities for surface fin-ishing technology, material flow automa-tion, environmental technology and ceramics firing lines, as well as special facilities for energy recovery, coating, thermal processing and recycling. Eisenmann uses software tools from various product lines of Siemens PLM Software. Hundreds of Eisenmann engi-neers use NX™ software for product design and Teamcenter® software for product lifecycle management (PLM). In the area of digital manufacturing, Eisenmann uses Robcad™ software in the Tecnomatix port-folio for 3D simulation of paint production processes, as well as Plant Simulation for discrete event simulation of paint and logistic lines.

Electrified monorail system for fast, automated inbound logisticsAn electrified monorail system (EMS) is a rail-bound means of conveyance with individually driven trolleys that move

independently on the rail system. Branch points can be implemented on the line with the aid of switch points. The actual rails are typically attached to the shop ceiling. If a trolley fails, it can be slid from the transport line into the maintenance bay without major effort.

Eisenmann uses Plant Simulation exten-sively in the company’s Conveyor Systems business unit. The expected target of each simulation is defined with the customer. The objectives to be pursued differ, depending on the project phase, and may include the development of new concepts and visualization of material flow; project planning support by material flow confir-mation and determination of the number of trolleys; and execution support via impact analysis of malfunctions and by testing material flow strategies and contin-gency concepts.

The customer provides Eisenmann with the required transport matrix, which is

Electrified monorail system designed using NX.

This model created using Plant Simulation shows an inverted monorail system, including the monorail layout, a bar chart showing the order queues, a circular chart showing the level of empty trolleys and a table showing the hourly throughput values.

ResultsDesigned and built the New Doha International Airport’s electrified monorail systemDetermined optimal number of trolleys and buffers Shortened final throughput testing through virtual commissioning validation

“ We are very pleased with the discrete event simulation capabilities we have devel-oped in Eisenmann through-out the years, especially our use of Plant Simulation.”

Dr. Monika Schneider Simulation Expert Conveyor Systems Eisenmann

“ Using the joint work of the control programmer with the simulation expert who configured and used Plant Simulation, we created a virtual commissioning setup, in which we were able to identify and solve real problems of our routing strategy control program.”

“ Connecting Plant Simulation to the MFC, we were able to conduct some of this testing virtually, in the office. That’s another project first. More importantly, this means that the real commissioning effort was smaller. Because real onsite commissioning is expensive, this capability has the potential to greatly impact the competitiveness of our offering in terms of cost.”

Dr. Ullrich Ochs Senior Manager Software Electrical Engineering Eisenmann

will be processed on schedule and to rigorous standards.

With 130 trolleys and roughly 20,000 transports per day, the 1.6 kilometer long electrified monorail from Eisenmann lies at the heart of this logistical masterpiece. The monorail will effectively and effi-ciently link the various process steps involved in this delivery system, including all the measures necessary to clean and equip the carts.

Carts arriving in the incoming area will be manually pushed onto the waiting EMS trolleys and transported to the supply sta-tion, where they are emptied. The empty carts on the EMS trolleys will pass through the cleaning zone, and then proceed to the various terminals. The corresponding destinations will be specified by the mate-rial flow computer (MFC) from Eisenmann. At the terminals, the carts will be loaded with fresh goods and food. Approximately 82,000 meals will be produced and distrib-uted every day.

“In the NDIA project, we have used Plant Simulation intensively,” Schneider says. “We started with the 2D layout of the catering building, and built a simulation model that runs an animated simulation on this layout. For the quotation phase, in which we had to fix the number of trolleys and lifting stations, the track length and other parameters, we simulated a peak scenario. The material flow starts from the incoming area to the ‘main highway,’ through which all the trolleys are going. Special attention was given to the routes of empty trolleys, according to priority rules, in order to prevent blockage of trolleys by other trolleys during low profile times.

“In this project, we practiced for the first time with a virtual commissioning con-cept, by connecting the MFC to the simu-lation model, and thus we were able to

actually the throughput that the facility needs to support, and where applicable, a working time model. Eisenmann develops the layout and defines the conveying characteristics, for example, the conveyor speed (in straight rail and curves) and routing strategies.

“We are very pleased with the discrete event simulation capabilities we have developed at Eisenmann throughout the years, especially our use of Plant Simulation,” says Dr. Monika Schneider, simulation expert at Eisenmann Conveyor Systems. “Typically, the results we get from the simulation include confirmation of the required throughput and the required number of trolleys, which have a strong impact on project costs; confirma-tion of the layout design; capacity utiliza-tion of conveyor system components and stations; occupancy of buffers and queues; and the impact of planned routing strate-gies. Based on the simulation results, appropriate project documentation is generated.

“Examples of Plant Simulation capabilities, which are fundamental for our usage, include our own object libraries,” says Schneider. “These libraries allow us to build a basic simulation model in half a day, with the ‘Pack-n-Go’ functionality, enabling us to deliver a dynamic simula-tion model.”

Testing a logistical masterpiece – virtuallyAs a future hub of international air traffic, the New Doha International Airport (NDIA) in Qatar set out to create a smoothly func-tioning, reliable logistics system. NDIA selected Eisenmann to install an EMS, linking all operational stations in the new state-of-the-art catering wing and assuring the airlines’ supply of flight service carts. These carts will provide the airplanes with food, drinks, duty-free articles and news-papers. Within this exceptional airport, the carts of all arriving and departing airlines

“ We have a long legacy of using Plant Simulation in the automotive business unit of Eisenmann, and we are very pleased with it. We some-times use other solutions, as requested by our customers, but Plant Simulation really stands out as a superior solution that fits our needs.”

Dr. Heiner Träuble Simulation Expert Automotive Paint Systems Eisenmann

“ The simulation model we create with Plant Simulation is often part of the deliver-able to our customers. Many of them also use Plant Simulation themselves, so they know how to run the simulation and change the needed parameters. This is a big benefit for them, because they get a virtual model of the physical line.”

Dr. Heiner Träuble Simulation Expert Automotive Paint Systems Eisenmann

virtual commissioning. Using the joint work of the control programmer with the simulation expert who configured and used Plant Simulation, we created a virtual commissioning setup, in which we were able to identify and solve real problems with our routing strategy control program. The kind of issues we identified using the virtual commissioning setup included, for example, a trolley that didn’t arrive at the designated station and the size of the buf-fers for empty trolleys (which was incorrect).

“In the final step of a project commission-ing, we usually conduct a throughput test, in which we physically run the line for several hours, typically an entire shift, with all the shop floor people. Connecting Plant Simulation to the MFC, we were able, for the first time, to conduct some of this testing virtually in the office. More impor-tantly, this means that the real commissioning effort was smaller. Because real onsite commissioning is expensive, this capability has the potential to greatly impact the competitiveness of our offering in terms of cost.”

identify and resolve most of the problems in the MFC program. You can actually visualize any improper material flow in the virtual simulation model. I worked on this side-by-side with a control programmer, who developed and debugged the control programs. As we set up this connection for the first time, we were rather impressed, because everything worked as documented.”

The complexity factor “This project was complex in the sense of the relatively many routing strategies that we had to develop,” says Dr. Ullrich Ochs, senior manager, Software – Electrical Engineering, Eisenmann Conveyor Systems. Dr. Ochs, who manages the control aspects of the NDIA project, explains, “When developing that many routing strategies, the control programmer needs to forecast virtually any possible scenario, and this is a real challenge. So we decided to use Plant Simulation for the

User terminal screen and model created using Plant Simulation during the virtual commissioning of the NDIA project.

Food cart being loaded onto the trolley

“ In the Conveyor Systems business unit, we use Plant Simulation in nearly every project. We start by using Plant Simulation in the quotation or pre-engineering phase, as well as employ it in the realization phase. We typically create one new simulation model per week.”

Ralf Weiland Senior Vice President Conveyor Systems Eisenmann The targets of the simulation in the auto-

motive business unit typically include con-firmation of throughput (jobs per day), cycle time check of conveyors and in paint shops, a sequence check of the batches (sometimes called “pearl chain”). The typi-cal challenge is that color sorting “dam-ages” the sequence, creating the need to measure the quality of the sequence.

Other targets include decoupling of conveying areas to analyze the impact of failures, checking conveying strategies, sorting for color blocks (in a paint shop), sorting to rearrange a sequence (such as to support just-in-sequence production), determining or estimating the number of skids and hangers, visualizing complex material flow, and discussing or develop-ing conveying strategies in a layout or plant.

“We have a long legacy of using Plant Simulation in the automotive business unit of Eisenmann, and we are very pleased with it,” says Träuble. “We sometimes use other solutions, as requested by our cus-tomers, but Plant Simulation really stands out as a superior solution that fits our needs. The software has unique features, such as defining a plant layout as a back-ground, highly flexible programming language, very useful ‘Pack-n-Go’ function-ality to deliver simulation models to customers, and strong library capabilities

Resolving complex challenges in automotive paint lines – virtuallyEisenmann also uses Plant Simulation in its automotive business unit to simulate various kinds of production lines, such as paint shops and overhead monorail sys-tems that deliver parts to assembly lines and automated guided vehicle (AGV) systems. Typical input parameters for the simulations include the layout of the plant, such as geometry and topology; technical parameters, such as speeds and accelera-tion; and logistical parameters, such as requested throughput, shift pattern, mean time to repair (MTTR) and availability.

“In the automotive business unit, we are using Plant Simulation to create simula-tions at different levels of detail, depend-ing on the project phase,” says Dr. Heiner Träuble, simulation expert, Automotive Paint Systems, Eisenmann. “In the concept phase, we mainly analyze the size of buf-fers before and after the paint line. The details of the conveyors won’t usually be handled at this phase. During the planning phase, the generic buffers will be changed to discrete conveyors. The scope of analy-sis will typically be the cycle time of the discrete conveyors and flow strategies. Sometimes, after several years of opera-tion, a production line will need to be re-built. Then we use the simulation model we created when delivering the line to show the impact of the changes.

“The simulation model we create with Plant Simulation is often part of the deliv-erable to our customers. Many of them also use Plant Simulation themselves, so they know how to run the simulation and change the needed parameters. This is a big benefit for them, because they get a virtual model of the physical line. Some customers require us to use their own sim-ulation standard. Moreover, selected auto-motive OEM customers provide us their own library of Plant Simulation objects, from which we create the simulation model.”

Automotive subassembly paint line delivered by Eisenmann.

“ With our virtual commission-ing capability, supported by creating realistic validations in a virtual environment using Plant Simulation, we believe we can shorten delivery time on every project.”

Ralf Weiland Senior Vice President Conveyor Systems Eisenmann

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z11 30796 9/12 Awww.siemens.com/plm

Siemens Industry Software Americas +1 800 498 5351 Europe +44 (0) 1276 702000 Asia-Pacific +852 2230 3333

Solutions/ServicesTecnomatix Plant Simulation Robcad www.siemens.com/tecnomatixNX www.siemens.com/nxTeamcenter www.siemens.com/teamcenter

Customer’s primary businessEisenmann is a leading global provider of industrial solutions and services for surface finish-ing, material flow automation, thermal process technology, and environmental engineer-ing. A family-run business based in Southern Germany, Eisenmann plans and builds made-to-measure manufactur-ing, assembly and distribution plants that are highly flexible, energy- and resource-efficient, and deployed by enterprises throughout the world for more than 60 years. www.eisenmann.com

Customer locationBöblingen Germany

(including objects with logic), which enable us to use customer libraries as well as our own.”

Using Plant Simulation for virtually every project“In the Conveyor Systems business unit, we use Plant Simulation in nearly every project,” says Ralf Weiland, senior vice president, Eisenmann Conveyor Systems. “We start by using Plant Simulation in the quotation or pre-engineering phase, as well as employ it in the realization phase. We typically create one new simulation model per week.”

Weiland explains the process: “During the quotation phase, the ability to present a suggested concept to a potential customer, supported by a simulation, is unique. This helps us demonstrate the proposed concept in a visually dynamic manner, which gives the prospect more confidence that our proposed concept

fulfills the requested throughput data. But the benefit of Plant Simulation is far beyond this. We actually reduce the risk associated with a line delivery by simulat-ing any potential operative scenarios. With our virtual commissioning capability, supported by creating realistic validations in a virtual environment using Plant Simulation, we believe we can shorten delivery time on every project.”

Eisenmann education center in Böblingen, Germany.

Tecnomatix Plant Simulation for the food and beverage industry


TECNOMATIX

Benefits• Identify and fix bottlenecks• Develop optimal cleaning

strategies• Define quantified measures

to optimize output up to 30 percent

• Invest in the right equipment• Determine feasible and

robust production plans• Secure product quality by a

stable and harmonized production flow

• Minimize discarded material

SummarySeasonal demands, high product turnover, high flexibility for new products and multi-variety packs, as well as quality and freshness are among the chal-lenges in engineering for food and beverage production plans. With highly automated sophisticated technologies and expensive equipment, it is particu-larly important to ensure that manufacturing processes meet current and future needs.

To manage these challenges, simulation is the tool to implement fully vali-dated new processes that are “right the first time.” Using simulation, you can determine the most cost effective and future-proof planning solution. Alter-nate planning scenarios can be compared to select the best balance between performance, flexibility and investment. By using simulation, it is easy to identify bottlenecks and to plan the best strategy for increasing plant output.

mated and reproducible production flow. For example, the WIP level in the tanks will decrease depending on the production of the connected filling line. The animation allows you to follow the material flow and to observe tank levels, orders, equipment status and enhanced statistics like tank levels over time or Gantt charts for all equipment with detailed order informa-tion. Simulation serves as communication platform for all parties on existing or planned manufacturing system behavior.

Use cases Using this solution, one manufacturer was able to reduce by one the number of tanks required, reducing their investment by 400,000 Euros. Other companies have tracked such improvement as: • The ability to improve service reliability

and due data quality from 85 to 100 percent without any additional investment

• A 70 percent reduction in onsite commissioning

• Reduced energy consumption by more than 5 percent, leading to reduced costs and higher profitability

Solution specific objects:• Tank• Mixer• Pipes• Grinder• Filling station • Packing• Palletizing • Storage

The iSILOG solution breaks down the bor-ders between continuous batch processing and discrete production processes com-mon in food and beverage production. It covers special functions such as cleaning, batch- and recipe-management. It makes it possible for you to model the complete flow, from incoming goods over batch pro-cessing in tanks and special equipment, filling, packing and palletizing up to stor-ing the finished goods in a warehouse. Plant Simulation provides interfaces to Excel, XML, data bases, etc. to integrate the simulation into an existing software environment. Plant Simulation can even help you cover the complete lifecycle of food and beverage production plants. From designing the manufacturing plant, through virtual commissioning of produc-tion control to the solution helps you advance online production planning and scheduling application.

This food and beverage solution can be applied in all areas of food production for products such as:• Brewing, soft drinks and milk processing• Fresh and frozen food • Instant soup• Snacks and candy• Animal food • Agricultural raw materials

A model based on the food and beverage solution can vary from a single production line to a complete plant including raw material intake and final product storage. The simulation model compasses an ani-

Tecnomatix Plant Simulation for the food and beverage industry

TEcnOMATIX

Simulation of food and beverage produc-tion processes helps you answer the fol-lowing questions:• What are the existing bottlenecks at

the plant?• What are best strategies (e.g. cleaning,

changeovers, batch sizes, production planning and control) to increase output?

• What are the existing limits of the plant regarding expected future products and demands?

• What is the best approach for harmonizing customer demands, incoming goods, batch sizes and packaging lines?

In complex systems with large interdepen-dencies such as in food production plants, it is nearly impossible to manually esti-mate how the system will perform. That is why simulation is an essential planning solution for a successful future.

iSILOG has developed an additional solu-tion for the food and beverage industry based on Tecnomatix Plant Simulation from Siemens PLM Software. The solution includes industry-specific objects such as tanks, mixers, pipes, grinder, filling sta-tions, packing, palletizing and storage. Using these standard objects makes it easy for you to model an existing or planned production process in the food and bever-age industry.

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, nX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. X3 31104 8/12 c


contactSiemens Industry SoftwareAmericas +1 800 498 5351Europe +44 (0) 1276 702000Asia-Pacific +852 2230 3333

Plant Simulation for Warehousing and LogisticsDesign, analyze and optimize warehousing and logistics operations


TECNOMATIX

Benefits• Reduced time for designing

warehousing and logistics operations

• Optimal utilization of resources, including personnel, docks, storage and other factors

• Extensive what-if analysis and evaluation of scenarios

• Optimal return on investments in equipment and WMS implementation

• Unmatched accuracy and realism of results

• Set of predefined control rules

• Visualization and animation of operations and their performance

• Powerful tool to communicate design alternatives and their performance

Features• Simulation of complex


• Object-oriented hierarchical models of warehouses, encompassing business, logistics and production processes

• Graphs and charts for analyzing throughput, resources and bottlenecks

SummaryTecnomatix® Plant Simulation for Warehousing and Logistics software enables you to rapidly create realistic simulation models of dynamic warehousing and logistics operations. Plant Simulation lets you evaluate the characteristics and performance of design alternatives long before they are implemented in real-life processes, thereby enabling you to make smarter decisions, minimizing design rework.

Challenges in warehousing and logisticsIn today’s global economy, warehousing and logistics involve more than just “shoving boxes.” Warehouses now operate in dynamic global supply chains. A highly competitive global marketplace requires rational approaches to designing dynamic warehousing and logistics operations. Speed, efficiency and quality all need to be improved simultaneously, not only at the operational level, but also during design and implementation.

Dynamic simulations of operations have become an indis pensable aid for achieving these strategic goals. To address these goals, Tecnomatix Plant Simulation provides a solution that enables you to evaluate the warehouse performance from a comprehensive, “fact-based” perspective.

Source image: DB Schenker.

applications support the analysis and re-use of existing data, such as data from an existing warehouse management systems (WMS). Plant Simulation comes with a clever toolset that enables you to run and optimize various operational scenarios and different warehouse designs. Performance metrics are displayed in a transparent manner in standard and customizable reports/ dashboards. Operations are visualized through the use of aesthetically appealing 2D and 3D animations.

Application areas

Conceptual warehouse design Conceptual design simulations should be easy to use and facilitate effective commu-nications. During this design phase, many options remain open including site and warehouse layout, delivery schedules and operating hours. Unfortunately, historical data often is not available, let alone detailed equipment specifications. However, the extensive capabilities of Plant Simulation support conceptual simulations that facilitate quick warehouse design, process flow animation and the visualization of key performance indicators.

Detailed warehouse design Accuracy and extensive what-if analyses are most important for detailed warehouse design. Conceptual warehouse designs need to be detailed further with more specific data

Speeding up design and implementationPlant Simulation offers functionality to address all areas that influence the performance of a warehouse. It provides basic capabilities, such as the ability to represent storage racks, layout and lift trucks. It also provides features for facilitating order-picking and value- added logistics.

Plant Simulation objects are capable of reflecting real-world dynamics, such as varying order volumes, downtimes of resources and varying picking times. The simulation’s unmatched realism sharply differs from solutions that rely on common spreadsheet-based calculations.

You can easily extend Plant Simulation with custom objects or control strategies. Data interfaces to most common

Plant Simulation for Warehousing and Logistics

Features continued• Comprehensive analysis

tools, including automatic bottleneck analyzer, Sankey diagrams and Gantt charts



• Automated optimization of system parameters

• Open system architecture supporting multiple interfaces and integration capabilities (ActiveX, C, CAD, MS Excel, Oracle SQL, OPC)

TECNOMATIX

Ready for today’s and tomorrow’s questionsTraditionally, companies had to make “best guesses” about their warehousing and logistics operations. Now, Plant Simulation leverages material flow simulation to enable you to make “fact-based” decisions about:• Capacity requirements for personnel,

storage and handling equipment• Site and warehouse layout, including

position, length, number and width of aisles and other considerations

• Storage, including ABC storage, zone storage, dedicated storage, random storage and cross-docking

• Order-picking, including batching, optimized routing, sorting and consolidation algorithms

• Effects of automation, including robots, AGVs, AS/RS and carrousels

• Planning and control, including consideration of schedules, order release and other factors

• Inventory management, including ordering policies, cycle counting and other considerations

• Value-added logistics

Redesigning operations At various intervals, every warehouse operation requires a redesign. For example, redesign usually becomes necessary when new customers have to be served or technological innovations are introduced. Simulation is extremely valuable in these instances. Accurate data is readily available for existing operations. Plant Simulation is the perfect tool to address even the most challenging redesign efforts. You can quickly and accurately build simulation models, as well as communicate alternative designs and results in clear reports and 3D animations.

© 2011 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. X9 16794 9/11 B


ContactSiemens Industry SoftwareAmericas +1 800 498 5351Europe +44 (0) 1276 702000Asia-Pacific +852 2230 3333

about equipment and flow of goods. Plant Simulation provides a range of fully configurable equipment types and control policies to support accurate simulations. The solution’s automated experimentation capability enables you to analyze and optimize a wide range of scenarios, including completely different layouts.

Optimizing existing operations Benchmarking a warehouse’s operation against a simulation model is an objective way to optimize warehouse performance. Simulation models also can be used for operational planning. Re-use of data and flexibility are the keys to efficient benchmarking. You can easily feed various kinds of data into Plant Simulation, including past orders, inbound and outbound flows, equipment breakdowns and other kinds of information, without regard to their source. Simulations provide accurate benchmarks with clear visualization of the operation and key performance indicators.

TECNOMATIX


Tecnomatix Plant Simulation for the high tech and electronics industryVirtually build, test and optimize plants to find and fix production issues before they happen


TECNOMATIX

Benefits• Enhanceproductivityby20

to40percent• Reduceinvestmentupto20

percent• Reduceworkinprogressup

to75percent• Cutthroughputtimeupto

60percent

Features• Simulationofcomplex

productionsystemsandcontrolstrategies

• Object-oriented,hierarchicalmodelsencompassingbusiness,logisticandproductionprocesses

• Dedicatedapplicationobjectlibrariesforfastandefficientmodelingoftypicalscenarios

• Graphsandchartsforanalysisofthroughput,resourcesandbottlenecks

• Comprehensiveanalysistools,includingautomaticbottleneckdetection,SankeydiagramsandGanttcharts

• 3Donlinevisualizationandanimation

• Integratedexperimenthandling

• Automatedoptimizationofsystemparameters

SummaryThehightechandelectronicsindustryisrapidlygrowing,agileandglobal.Manufacturersfacemassivepricepressure,extremelyshortproductlifecyclesandhighnumbersofvariants.Thisrequiresongoingchangesintheproductioninfrastructure.Tecnomatix®PlantSimulationsoftwarefromSiemensPLMSoftwarehelpsproductionmanagersandplannersmodel,simulate,visualize,analyzeandoptimizecomplexproductionscenarios.ItiscriticaltothereturnonyourR&Dinvestmentthatyoubeabletore-useintellectualpropertyfornewproducts.

PlantSimulationenablesyoutosimulateandoptimizematerialflow,resourceutilizationandlogisticsforalllevelsofoperationsplanningfromglobalproductionfacilitiesthroughlocalplantstospecificlinesandprocesses.Withincreasingcostandtimepressuresinproduction,alongwithongoingglobalization,logisticsmanagementhasbecomeakeyfactorforsuccess.

PlantSimulationenablesyoutodetectandeliminateproblemsearlyintheplanningprocessthatotherwisewouldhaverequiredcostlyandtime-consumingcorrectionmeasuresduringactualproductionramp-up.Thesoftwarehelpsyouminimizeyourinvestmentinproductionlineswithoutjeopar-dizingtherequiredoutput.Italsohelpsyouoptimizetheperformanceofproductionsystemsbyimplementingmeasuresthathavebeenverifiedinasimulationenvironmentpriortoimplementation.

ManufacturingoptimizationwithTecnomatixPlantSimulationenablesyoutooptimizeassemblyplantstoachievesuccessfulproductlaunches,reduce

Plant Simulation in action: higher efficiency, faster throughput, reduced work in progressAmanufacturerofprintedcircuitboardcontrolunitswasproducingpartsin35variants.BeforeusingPlantSimulation,thecompanywasproducing1,380,000partsevery1.8days.AfterusingPlantSimulation,theyproduced1,400,000partsevery1.3days,a40percentimprovementinefficiency.Theplantenjoyed29percentfasterthroughputtime–whatusedtotake40hourscannowbedonein31hours.

What’smore,theplanthasreducedworkinprogressandcapitalburden.Theaveragenumberofunitsinproductionbeforesimulationwas120,000.Aftersimulation,itwas85,000,areductionof42percent.

productionrampupandshortentime-to-market.SiemensPLMSoftwaresolutionsmakeitpossibletore-useexistingproductiondataandprocessinformationmoreeffectively.

PCassemblycanbesimulatedusingPlantSimulation,includingallresourcessuchaspersonnel,machines,materialsandtransportsystems.Thegoalistocheckthefeasibilityofproductionplansgeneratedbyaproductionplanningsystem.Productionplanexecutionforeachshiftisoptimizedinarealisticmannerthatconsidersthecurrentcircumstancesintheplant.Measurescanbecheckedbeforetheyarecarriedoutinpractice.PlantSimulationhelpstodevelopandverifynewshiftmodels,workorganizationsandotherchangesinproduction.

Tecnomatix Plant Simulation for the high tech and electronics industry

Features continued• Opensystemarchitecture

supportingmultipleinterfacesandintegrationcapacities(ActiveX,CAD,OracleSQL,ODBC,XML,Socket,OPC,etc.)

TECNOMATIX

©2012SiemensProductLifecycleManagementSoftwareInc.Allrightsreserved.SiemensandtheSiemenslogoareregisteredtrademarksofSiemensAG.D-Cubed,Femap,Geolus,GOPLM,I-deas,Insight,JT,NX,Parasolid,SolidEdge,Teamcenter,TecnomatixandVelocitySeriesaretrademarksorregisteredtrademarksofSiemensProductLifecycleManagementSoftwareInc.oritssubsidiariesintheUnitedStatesandinothercountries.Allotherlogos,trademarks,registeredtrademarksorservicemarksusedhereinarethepropertyoftheirrespectiveholders.X2307146/12B

www.siemens.com/plm

ContactSiemensIndustrySoftwareAmericas +18004985351Europe +44(0)1276702000Asia-Pacific +85222303333


Business challenges Increase competitiveness of services offeringImprove margin on delivered projects

Keys to SuccessDeploy Process Simulate Virtual Commissioning for improved production equipment utilizationBring more line installation know-how back into the organizationRemove barriers between mechanical, electrical and control engineers

ResultsRobotics workcells 98 percent ready before ever going to the shop floorReduced number of issues found on the shop floor

Use of Process Simulate Virtual Commissioning enables early detection of production issues

Innovative automation solutions expanding in South AmericaKUKA Systems Group is one of the world’s leading providers of engineering services and manufacturers of flexible automatic production systems. Its customers come from a diverse array of industries, includ-ing automotive, aerospace and solar. The solutions of KUKA Systems do Brasil (KUKA Brazil) encompass comprehensive applica-tions for the industrial processing of metallic or non-metallic materials. With approximately 3,500 employees in more

Tecnomatix


KUKA Systems do BrasilLeading automotive line builder delivers state-of-the-art robotics production lines

than 15 countries, each of the KUKA Systems Group’s companies is focused on providing the most advanced and high-value production solutions.

KUKA Brazil was founded in 1998. Having made an important investment in engi-neering capacity, the company’s solutions are now present at virtually every automo-bile manufacturer’s site throughout Brazil. Recently KUKA Brazil introduced its automation technologies to small and medium-sized companies in the aerospace and general industry markets. As a result, the company doubled its size in just three years. With 170 employees, KUKA Brazil is now one of South America’s top produc-tion-line integrators.

An automotive body-in-white production line delivered by KUKA Brazil.


Moving from Robcad to Process SimulateKUKA Brazil has been harnessing the value of solutions in the Tecnomatix® portfolio for years, including Plant Simulation and Robcad™ software, and recently Process Designer and Process Simulate for automo-tive robotics, body-in-white (BIW) produc-tion lines. As the advantages of Process Simulate became more evident, the company began transitioning from Robcad to Process Simulate.

A Kuka Brazil engineer using Plant Simulation to analyze production capacity.

“Due to the superiority of the robotics simulation tools in the Tecnomatix portfo-lio, we decided to use them exclusively,” says Marcio Sampaio Tubini, digital manu-facturing project leader, KUKA Brazil. “For years we have been using Robcad, and we are very satisfied with its capabilities.

“Due to the superiority of the robotics simulation tools in the Tecnomatix portfolio, we decided to use them exclusively.”

Marcio Sampaio Tubini Digital Manufacturing Project Leader KUKA Brazil

“The use of Process Simulate Virtual Commissioning brings together engineers with different kinds of expertise. The fact that electrical, mechanical and control engineers sit together in the same room, working on the same scenario, is a big advantage.


“In 2012, we delivered a project to one of the automotive OEMs (original equipment manufacturers) using Robcad. For evalua-tion purposes, we performed some of the work with Process Simulate, and then demonstrated its value. The customer was very pleased with the results, so we decided to deliver the next project in its entirety using Process Simulate.

Tubini notes that his team is especially impressed that migrating data from Robcad to Process Simulate is a non-issue.

Virtual commissioning for higher competitivenesKUKA Brazil had been looking for ways to increase its competiveness. As part of this initiative, it evaluated Process Simulate Virtual Commissioning in the Tecnomatix portfolio, which enables connecting a 3D robotics simulation with a physical cell controller. Use of Process Simulate Virtual Commissioning provides the ability to control a virtual simulation using the operator’s human machine interface (HMI), exactly as it is done on the shop floor.

“There is substantial benefit in doing the robotics cell optimization, as much as pos-sible, at the engineer’s desk, rather than doing it on the shop floor,” notes Gilmar Miranda, engineering manager, KUKA Brazil. Using Process Simulate Virtual

Results (continued)Continuously improving operational efficiency; lower costsOutsourcing of start-up work substantially reducedImproved profitability

KUKA framing in body shop.

Commissioning proved to be beneficial in several ways. Miranda explains, “With Process Simulate Virtual Commissioning, we can get the robotics workcells 98 per-cent ready before ever going to the shop floor.

“Typically, after the initial production-line installation, we outsource the line start-up to suppliers. We estimate that approxi-mately 70 percent of the start-up work is robotics and control-programs tuning; we believe that by using Process Simulate Virtual Commissioning we can reduce that by 20 to 30 percent. This results in two significant benefits. First, a financial sav-ings, as the amount of work outsourced is smaller; in fact, we have created a table that maps those tasks that are moved from the line installation team to the virtual commissioning team. Second, KUKA Brazil is now much more knowledgeable regard-ing such scenarios. Greater start-up know-how means improved operations and fewer issues on the shop floor from project to project.”

Another important benefit is a more effi-cient start-up in terms of equipment oper-ation. Tubini explains, “The use of Process Simulate Virtual Commissioning brings together engineers with different kinds of expertise. The fact that electrical, mechan-ical and control engineers sit together in the same room, working on the same scenario, is a big advantage. Instead of troubleshooting the cell control program by reviewing lines of code, the control engineer can now easily visualize any scenario.

“In the past, many of our technical discus-sions took place only on the shop floor; now they are conducted in a virtual-line environment. Using our previous approach, sometimes we encountered physical collisions, resulting in damage to equipment (such as robots and grippers) and the prototype part itself. When using Process Simulate Virtual Commissioning, the risk of such incidents is significantly reduced. For example, in a recent project using Process Simulate Virtual Commissioning, we identified a problem in the sequential plan: a clamp was not opening on time, thus causing the part to crash into the equipment.

“We estimate that approxi-mately 70 percent of the start-up work is robotics- and control-programs tun-ing; we believe that by using Process Simulate Virtual Commissioning we can reduce that by 20 to 30 percent.”

Gilmar Miranda Engineering Manager KUKA Brazil

“Process Simulate Virtual Commissioning also enables a higher level of cycle-time productivity, as the robotics cell interlocks are optimized. This means producing more units with the same equip-ment or, as the experts in the automotive companies say, ‘higher jobs per hour (JPH),’ which is a huge bene-fit for our customers.”


A BIW production line simulated using Process Simulate Virtual Commissioning.

Glass material handling.

Solutions/ServicesTecnomatix • Robcad • Process Designer • Process Simulate • Process Simulate Virtual Commissioning • Plant Simulation www.siemens.com/tecnomatix

Customer’s primary businessKUKA Systems Group (KUKA) concentrates on advanced solutions for the automation of industrial production pro-cesses. Since the company’s founding more than 100 years ago, KUKA solutions have been known for quality and innovation. KUKA, with its Robotics and Systems divi-sions, is one of the world’s leading companies in the field of mechanical and systems engineering. www.kuka-systems.com/brazil

Customer locationSão Bernardo do Campo Brazil

“With Process Simulate Virtual Commissioning, we can get the robotics workcells 98 percent ready before ever going to the shop floor.”

Gilmar Miranda Engineering Manager KUKA Brazil

“Process Simulate Virtual Commissioning also enables a higher level of cycle-time productivity, as the robotics cell interlocks are optimized. This means producing more units with the same equipment or, as the experts in the automotive companies say, ‘higher jobs per hour (JPH),’ which is a huge benefit for our customers. For instance, robotics hemming processes require maximum interlocks optimization, because the robots are working simultane-ously very close to each other.

“We were also impressed that we can engage Process Simulate Virtual Commissioning perfectly with non- Siemens controllers – for example, Allen Bradley controllers – using an OPC (OLE for Process Control) server. This highlights Siemens PLM Software’s strength as a solutions provider with open tools.”

Kuka Brazil engineers use Process Simulate in the company’s virtual commissioning lab.

Automatic measurement.

An automotive body-in-white production line tested by KUKA Brazil prior to shipment.

© 2013 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z22 32446 2/13 Awww.siemens.com/plm





http://www.kuka-systems.com/brazil

IndustryLife sciences

Business challengesWide range of component combinationsChanging customer demand

Keys to successDigital models simulate flow and critical interfacesWhat-if simulations enable clear analysis and evidence-based decision-making

ResultsOptimized flow of components and assemblies Problems identified and resolved fasterGreater manufacturing flexibilityMore efficient production line with less waste

Siemens Magnet Technology uses Plant Simulation to optimize complex production lines

The search for accurate production forecastingDid you know that 30 percent of the MRI scanners installed in hospitals worldwide contain a superconducting magnet manu-factured by Siemens Magnet Technology? The company accounts for about 45 per-cent of the total market, and 100 percent of the magnets produced at its facility near Oxford are exported overseas for final assembly into imaging systems. The business has been awarded several Queen’s Awards; most recently it was the recipient of the Manufacturing Excellence Awards (MX) 2010, sponsored by the Institution of Mechanical Engineers for Product Innovation. Siemens Magnetic Technology won the Cranfield School of Management Best Factory Awards: Most Improved Plant and Innovation (Process and Design). In November 2011, Siemens Magnet Technology also picked up one of Siemens’ Environmental Awards for its pioneering work in minimizing the consumption of helium.

Each magnet is manufactured for custom-ers who incorporate it into an end-user product. Given the nature of healthcare procurement, both the sales process and the logistical chain leading up to installa-tion can be long and detailed. As the

Tecnomatix


Siemens Magnet TechnologyImproving capacity planning with digital factory software

company plans its workload based on cus-tomer forecasts, any increase in demand from one customer may affect other customers.

The challenge is always to find a balance. “This has been an ongoing issue for us,” says Michael Burke, project manager logistics at Siemens Magnet Technology. “As demand has risen, complexity has increased and our products have become more sophisticated as well. In addition, final testing can only be done when a magnet is fully assembled and ready to go: the point of its highest value. Whilst we have an extremely low failure rate, any glitches at the testing stage can have an impact throughout production.”

Siemens Magnet Technology produces nine models, each one comprising a distinct assembly of components and undergoing a specific series of processes within four main stages of manufacturing. These are coil manufacture; magnet termination; assembly and weld; and test. The manufacturing journey involves numerical and cyclical complexity as components and assemblies are grouped together in varying combinations as they pass through each stage on the factory floor.

Shining a light on manufacturing complexitiesAt each stage of manufacturing, managers maintain independent sets of capacity data. This means that there is a critical supply and inventory interface at the point of handover to the next process manager. “We do a lot of capacity modeling, but cur-rently cannot integrate this,” notes Burke. “Knowledge remains relatively isolated within each process. When predicting whether we can cope with a particular surge in demand, managers must make a judgement based on their own analysis and experience. This has worked well so far but can be time-consuming, and there is no real backup system. It is impossible to verify our decisions, because there is no overview of the complete manufacturing journey.”

Kevan Straughan, PLM software analyst at Siemens Magnet Technology, adds, “The

volume going through the factory has increased significantly over a number of years, yet we are still using separate spreadsheets. We know that we need an overview of products, skills and possibili-ties, so that we can adapt production more quickly and easily. If we had an accurate model of our production line, we’d be able to see how everyone is affected by even the slightest change. To resolve this, we went to the board with a proposal and a clear business case to implement simulation software.”

The Plant Simulation solution in the Tecnomatix® portfolio was an obvious candidate. Burke explains: “We’d previ-ously installed such an application and although we’d never really got it to work properly, we were familiar with this type of software. Plant Simulation really impressed us: it is logical, easy to under-stand and we could immediately see what it could do for us.”

Industrial engineer Peter Taylor is now taking the lead on the modeling project, which began in October 2010. “We have excellent support from Siemens PLM Software, so we thought we would develop a sound knowledge of Plant Simulation by beginning with the most challenging department, coil manufacture – where each magnet begins life as an array of superconducting wire. Even our consultant confessed to sleepless nights over its complexity.”

“Plant Simulation really impressed us: it is logical, easy to understand and we could immediately see what it could do for us.”

Michael Burke Project Manager Logistics Siemens Magnet Technology

Consistent and indisputable analysis“We are creating the 2D building blocks of our many processes by defining hierarchy, showing relationships between individual resources, logging skill sets and indicating the cycle times and usage of tools and machines,” says Taylor. “There is a massive amount of statistical information to enter. As we build the model, we are identifying what level of detail we require. We are bal-ancing what individual process managers want to see in terms of their own section’s output and what the business needs to see from the overall manufacturing perspec-tive. We also aim to be consistent, so that the company can utilize the same method-ology in other areas. Coil manufacturing is the most complicated, but once we get it right, other models should follow similar formats.”

The coil manufacture model was ready for its first proper review by the middle of 2011. “The most important aspect is to ensure that we are modeling as close to reality as possible and that process and manufacturing managers agree on the content. When they give their approval, we’ll know that all the information in the model is correct; and once we have a valid model, it will underpin constructive debate about internal processes.”

Forecasting potential bottlenecks through simulationSiemens Magnet Technology aims to run simulations for the manufacturing team that will clearly show an object moving along the production line; high-light blockages where there is a finite amount of tooling capacity and demon-strate the potential consequences of any decisions made at that point. Taylor explains, “We aim to develop a protocol, so that we do not run simulations at ran-dom; there is an inbuilt mechanism that acts rather like a control experiment. It is very important to go through a logical sequence of events. We are taking the time to document all these processes and create a comprehensive handbook.”

Burke notes that the model includes stand-alone methodology. “Our Siemens PLM consultant has explained how to interface coding of the different processes, so that we can control how far we see a change ripple down the line. The benefit is that when one inbuilt function does not quite do what we want it to do, it is very easy to change the code without unduly affecting other aspects of the model.”

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. SAP is a trademark or registered trademark of SAP Aktiengesellschaft. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z6 26056 2/12 Awww.siemens.com/tecnomatix



Solutions/ServicesPlant Simulation (Tecnomatix portfolio) www.siemens.com/tecnomatix

Customer’s primary businessSiemens Magnet Technology is the world’s leading designer and manufacturer of superconducting magnetic resonance imaging magnets for medical applications. www.siemens.co.uk/magnet-technology

Customer locationOxford United Kingdom

“Plant Simulation takes away manual updating and gives us a clear overview and analysis, something we’ve never had before.”

Kevan Straughan PLM Software Analyst Siemens Magnet Technology

Preparing for the future“We’ve achieved a lot,” says Taylor. “Plant Simulation allows us to view what we’ve done to model demand and throughput.” With a significant success completed, a new project is already underway. “We are using the main model as the starting point in order to visualize different scenarios two or three levels down,” notes Taylor. “That will inform our decision-making in certain areas, for example, the potential for reprocessing helium lost during manufacture.”

Straughan adds, “Plant Simulation takes away manual updating and gives us a clear overview and analysis, something we’ve never had before. We are also looking to implement Teamcenter in the future, and all the work we are doing now to document and model our processes will be of huge benefit further down the line. The objective is to integrate manufactur-ing systems and link them into SAP, which we use for enterprise resource planning. This will give us complete control and flexibility within a fully optimized production line.”

IndustryAutomotive OEM

Business challenges Manage global markets and competitionShorten the vehicle develop-ment lead time to reduce time-to-marketMinimize manufacturing launch issues to accelerate production ramp-upMeet increasing demand for highly customized vehicles

Keys to SuccessGet the new Chakan plant up and running quicklyImprove quality and consis-tency in manufacturing, supporting “first time right” approach Analyze the impact of product mixes on production through-put and optimize facilities layouts Virtually analyze complex assembly scenarios of the new product linesShare best practice process data between multiple sites and with suppliers

Mahindra Vehicle Manufacturers Limited (Mahindra Vehicles) uses Tecnomatix to establish a state-of-the-art automotive manufacturing plant

A world leader in vehicle manufacturing rises in South AsiaMahindra Group (Mahindra) is among the biggest and most powerful publicly listed companies in the world. It operates in the key industries that drive economic growth, enjoying a leadership position in tractors, utility vehicles, information technology (IT) and vacation ownership. Mahindra focuses on enabling people to “Rise,” a call to action to unite the many companies within the Mahindra Group to a common purpose. More specifically, Mahindra employees are encouraged to rise, to suc-ceed and to create a better future for

Teamcenter • Tecnomatix

www.siemens.com/plm

Mahindra Vehicles Mahindra rises with digitally planned new vehicle manufacturing facility

themselves, their families and their com-munities. In the spirit of “Rise,” a new Mahindra manufac turing facility recently rose in the Chakan corridor near Pune, India.

Mahindra Group’s Automotive Sector man-ufactures and markets light commercial and utility vehicles, including auto rick-shaws (three-wheelers). The sector has been the leader in India’s utility vehicles market since its inception, and currently accounts for about half of India’s utility vehicle market. The company exports its products to Europe, Africa, South America, South Asia and the Middle East.

Mahindra decided to expand its lineup to include a new range of medium and heavy commercial vehicles, including SUVs, trucks and buses. This expansion required a new plant, so Mahindra decided to

The new Maxximo light commercial vehicle, manufactured at the Mahindra Chakan plant.

Final Assembly of the Mahindra Navistar truck in the Mahindra Chakan plant.

www.siemens.com/plm

establish a new manufacturing facility in Chakan. Mahindra’s challenge was how to assess, design and build the facility, plus get it running and producing vehicles according to the aggressive schedule that management had defined.

As of 2012, 1,500,000 cars are produced annually in the Chakan corridor by Mahindra, Volkswagen, General Motors, Mercedes Benz and other automotive man-ufacturers. Mahindra is one of the largest manufacturers in this area, producing light commercial vehicles (LCV), pick-up trucks, SUVs and the Mahindra Navistar heavy duty trucks.

Revisiting engineering processes to establish “state-of-the-art” plantMahindra is a long-time customer of Siemens PLM Software. Designers, data administrators and some of its product assembly suppliers use Teamcenter® soft-ware for product lifecycle management (PLM). The company also uses NX™ soft-ware for some of the powertrain product design, and a few years ago Mahindra started using Tecnomatix® software for digital manufacturing.

“In 2007, we selected and introduced the Tecnomatix solution, because it offers a full range of digital manufacturing tools that serve our needs, integrates smoothly with our existing product data manage-ment systems and clearly stands out in

ResultsReduced lead time and the overall duration of a vehicle projectDecreased capital investment in machines and conveyorsSubstantially shortened lead time for concept design of production facilitiesReduced bottlenecks in productionIncreased re-use of manufac-turing toolsMaximized production resource utilization

“In 2007, we selected and introduced the Tecnomatix solution, because it offers a full range of digital manu-facturing tools that serve our needs, integrates smoothly with our existing product data management systems and clearly stands out in meeting the criteria we had defined.“

Nagesh Nidamaluri Senior General Manager Assembly Systems, MES and Digital Manufacturing Mahindra Vehicle Manufacturers Limited

meeting the criteria we had defined,“ says Nagesh Nidamaluri, senior general man-ager, Assembly Systems, MES and Digital Manufacturing, Chakan plant, Mahindra Vehicles.

Mahindra uses the Manufacturing Process Planner solution in the Teamcenter portfolio for the planning of various pro-duction processes; as well as Plant Simulation, FactoryCAD™ software and FactoryFLOW™ software, all in the Tecnomatix portfolio, for plant design and optimization; Process Designer and Process Simulate and Jack™ software, also all in the Tecnomatix portfolio, for assembly planning and validation.

The establishment of a new plant was a good opportunity to revisit Mahindra’s cur-rent engineering processes. “We have realized that in order to shorten a vehicle manufacturing project, we need to deploy concurrent engineering methods,” Nidamaluri says. “This means that manu-facturing engineering needs to work concurrently with product design. Digital manufacturing tools provided by Siemens PLM Software facilitate this approach. This is a dramatic change to our current engi-neering processes.

“We have a gate system, and one of the gates is the virtual validation gate. In the past, mostly the product design group was actually doing validations for this gate; but

A Mahindra manufacturing engineer uses Manufacturing Process Planner.

“Providing the essentials needed to create detailed and intelligent factory mod-els, FactoryCAD allowed our planners to use ‘smart objects’ to represent their factory resources.”

“We use the workflow mecha-nism of Teamcenter which ensures that every change goes through a pre-defined sequence of events and an authorized approval. These capabilities are unique, and provide us the ability to put a lot of structure into the MBOM creation process.”

Anupam Patil Senior Manager IT and PLM Mahindra Vehicle Manufacturers Limited

now, with the help of Tecnomatix digital manufacturing tools, the manufacturing engineering group is very active in prepa-rations for this gate.”

Mahindra decided to execute the digital manufacturing journey at the Chakan plant in a series of steps, deploying point solu-tions to address specific needs, followed by the manufacturing bill of materials (MBOM) and finally the bill of process (BOP). Mahindra plans to clone proven methodologies developed in the Chakan plant at other plants.

Laying out the new Chakan plant in 3DWhile constructing the new plant in Chakan, Mahindra decided to significantly upgrade the way it creates and manages plant layout data. There were a number of issues to deal with, including the fact that there was no uniform plant layout method across the enterprise. Each site was man-aging plant layout separately. Plant layout drawings were not maintained in a central repository, which made it very time-con-suming to locate them when they were needed. There was no revision manage-ment system and only one engineer at a time could work on any given layout. Drawings provided by suppliers were main-tained in different layers in the same file, resulting in duplication of data and unnec-essarily large files, which degrade visualization performance.

To resolve these issues, FactoryCAD was used to create 3D plant layouts for all of the Chakan plant production lines, includ-ing body and trim, chassis and final (TCF). “Providing the essentials needed to create detailed and intelligent factory models, FactoryCAD allowed our planners to use

‘smart objects’ to represent their factory resources,” says Anupam Patil, senior man-ager, IT and PLM, Chakan plant, Mahindra Vehicles.

“This was especially advantageous because the objects provided the ability to snap a layout model together, instead of wasting time drawing the individual equipment. Using FactoryCAD, we were able to resolve many issues before erecting and commissioning of the factory, such as interferences of process and utility equip-ment with the civil structure, for example, as well as a monorail system that caused interference with the supporting beams at a specific area and a robot that caused interference with the building column in another area.”

A planned production line, virtually simulated Before building the production line, Mahindra completed a number of simula-tion projects that helped to make important decisions in configuring the production line. One of the projects addressed the inter-connections of the body-in-white (BIW) welding shop, paint line and the TCF assembly line, where all the parts are assembled to form a com-pleted vehicle.

The goal of the simulation project was to find out the optimal buffer storage capac-ity in between these production lines. The challenge arose because there were three BIW planned production lines (for the Maxximo, Genio and XUV vehicles) going into a single paint line, which then goes into three separate TCF assembly lines. Tecnomatix Plant Simulation was used to conduct a what-if simulation to determine the best scenarios for the plant’s inter-shop conveyor system. Several scenarios of mixed-model production volumes were simulated and the optimal size of central painted body buffer storage and individual BIW shop storage was determined. This simulation project substantially reduces the lead time in designing the storage.

Truck cargo mounting analysis created with Jack human simulation.

Interference of a robot and a column found using FactoryCAD.

Engine docking station simulation created with Jack human simulation.

“So, we decided to use dedi-cated tools for this task, and developed a robust MBOM creation and update methodology using Manufacturing Process Planner.”

Anupam Patil Senior Manager IT and PLM Mahindra Vehicle Manufacturers Limited

“Manufacturing engineers used Process Simulate to validate hanger design that could support sufficient door opening. The limit to which the doors can be opened was calculated based on the virtual 3D simulation, instead of waiting for actual parts to arrive at plant. This resulted in cost and saving of time and iterations of the hanger design.”

Amit Jahagirdar Digital Manufacturing Manager Mahindra Vehicle Manufacturers Limited

Another project was to determine the optimal routing method of painted vehicle bodies from the single paint line to the three TCF assembly lines. “The simulation helped to identify bottlenecks, and verify the robustness of the selected option,” says Amit Jahagirdar, digital man-ufacturing manager, Chakan plant, Mahindra Vehicles. “One simulated option was a clockwise flow of bodies with no cross-over. The simulation showed that in the event that one of the three TCF lines is shut-down, the respective bodies in the main line would create blockage in moving bodies to the other TCF lines. The second option was a counter-clockwise flow, with a cross-over for the empty skids to flow back to the paint shop. This is a more robust option because each TCF feeder line is practically independent of others. So, there is little or no impact on the overall performance of the line shutdowns.”

Using Plant Simulation, Mahindra gained critical insight regarding its factory layout and installation processes across vehicle lines. Accurate and fast validation of pro-cesses enabled the company to achieve its

goal of getting the implementation right the first time. Detailed throughput exami-nation notably reduced bottlenecks, and what-if analysis capabilities substantially decreased unnecessary capital investment in machines and conveyors.

MBOM creation means no part is forgotten in the productionThe engineering bill of materials (EBOM) is created and managed using Teamcenter. Then manufacturing engineers create the MBOM using Manufacturing Process Planner by consuming parts from the EBOM. The MBOM is then sent from Manufacturing Process Planner to SAP® software, the enterprise resource planning (ERP) system Mahindra uses.

“In the previous method, planners used Microsoft Excel to define and maintain the MBOM,” Patil says. “While the tool is intui-tive, it was clear to us that this is not sustainable for handling large BOMs and sharing engineering data. So, we decided to use dedicated tools for this task, and developed a robust MBOM creation and update methodology using Manufacturing Process Planner. Using this methodology, planners adjust the EBOM and add relevant production information such as a ‘make or buy’ definition for each item and the point of consumption along the production line, which is later used by the shop floor logis-tics management system.”

“The MBOM will include the car parts in their form through the entire production process. For example, in the paint line, the chassis will be represented by a bare chas-sis, cathodic electrocoat deposition body and painted body. These forms, which we call ‘semi-finished parts,’ appear as a single assembly in the EBOM, but as different assemblies in the MBOM. Another example of MBOM-specific information is the addi-tion of scrap weight to the stamped parts, as this information is used downstream in the recycling process.

Plant Simulation model – routing with no cross-over.

Plant Simulation model – routing with a cross-over for empty skids.

“Handling the MBOM changes throughout the development lifecycle is crucial for us. Therefore, the engineering notifications are transferred along with the EBOM from Teamcenter. The notifications are put into a common pull, and from there they are assigned to the relevant MBOM planner. In addition, once an initial MBOM is created, all subsequent changes in the MBOM are done in a controlled configuration, using the incremental change mechanism, which enables us to analyze very clearly the impact of any EBOM change on the MBOM. Within the incremental change, we use the workflow mechanism of Teamcenter which helps ensure that every change goes through a pre-defined sequence of events and an authorized approval. These capabil-ities are unique, and provide us the ability to put a lot of structure into the MBOM creation process.”

Due to the importance of maintaining an accurate MBOM, starting from the engi-neering team and down to the shop floor, Mahindra uses Teamcenter to execute a

daily update to synchronize any incremen-tal changes to the EBOM. In a similar manner, Teamcenter integration for SAP synchronizes the MBOM daily with SAP based on make or buy attributes. For example, any assembly node with chil-dren, which was identified in the MBOM as a purchased assembly, will be automati-cally exported and will appear in SAP as a single node.

Dynamic 3D simulation supports analysis of complex assembly scenarios for the new MaxximoThe painted body of the Maxximo mini-truck is transported inside the new assembly shop for operations. The car body is moved along using a hanger sys-tem in the underbody areas and on transfer lines. The system was initially designed to carry the car body with the doors closed. After analyzing the concep-tual flow of assembly, other possible assembly operations were analyzed. It was found that in order to reduce production time, some assembly operations could be executed when the car body is on the hanger, as long as the doors could be opened to a certain extent, which will enable operators to work inside the cabin area.

“Manufacturing engineers used Process Simulate to validate hanger design that could support sufficient door opening. The limit to which the doors can be opened

Process Simulate is used to simulate the doors opening while the truck is on a hanger.

MBOM in Manufacturing Process Planner with “make or buy” definitions.

“We have defined a workflow using Teamcenter to classify our existing and new tools by part number, so that eventually we will have a structured library of tools across the Mahindra auto-motive sector.”

Amit Jahagirdar Digital Manufacturing Manager Mahindra Vehicle Manufacturers Limited

“The benefits of the Tecnomatix digital manufac-turing tools for Mahindra are already invaluable. This tool-set deployment strengthens the ‘first time right’ mindset we have in Mahindra, as it enables us to conduct differ-ent ‘what-if’ analyses of production scenarios.”

Nagesh Nidamaluri Senior General Manager Assembly Systems, MES and Digital Manufacturing Mahindra Vehicle Manufacturers Limited

was calculated based on the virtual 3D simulation, instead of waiting for actual parts to arrive at plant. This resulted in cost and time savings and reduced the number of iterations of the hanger design,” says Jahagirdar.

The assembly process for the Maxximo was planned so that the engine assembly from the engine production unit is transferred to the final assembly shop from a logistic area. It moves on a predefined track and gets synchronized with the conveyor carry-ing the Maxximo car bodies on hangers. Because this is a complex scenario, which involves many parameters, manufacturing engineers also performed a dynamic 3D simulation of this scenario. “The main objective of this simulation was to validate the planned process and its duration esti-mation. The ergonomics of operators was also evaluated based on Mahindra stan-dards,” Jahagirdar says.

Tools management lowers cost by enabling re-useMahindra plans to use the resource classifi-cation capability of Teamcenter to manage its many production tools. According to Jahagirdar, “The objective of this initiative is to lower costs, reduce lead time and improve quality by helping the manufac-turing engineer/planner select the proper resource, increasing the re-use of manu-facturing tools, reducing tool inventory, maximizing resource utilization and deliv-ering digital models for verification and simulation.”

“We have defined simple categories for any tool we have in our production plants, including a tool suitable to a specific part, such as fixtures or specific gauges. There are also more generic tools, such as robots and torque wrenches. Based on this, we are defining a workflow using Teamcenter to classify our existing and new tools by part number, so that eventually we will have a structured library of tools across the Mahindra automotive sector.”

The next step is the development of the BOP using Manufacturing Process Planner. Assembly operations and their duration are defined, and then linked to the parts that should be handled and to the specific tools required to carry out the work. This meth-odology enables Mahindra manufacturing engineers to re-use best practices and cap-tured knowledge in planning or modifying a production line.

“The digital manufacturing tools play a key role in the first steps of a car project,” says Nidamaluri. “These tools are already used in the requirements definition phase of a new or modified production line. This enables us to provide more mature engi-neering information upfront to our system suppliers, and will therefore reduce lead time and the overall duration of a car proj-ect. I also expect that our production facilities and tools suppliers will interact with the system, and introduce their inputs.”

Mahindra Vehicles receives top awardMahindra Vehicles received the top honor in Siemens PLM Software’s Asia Pacific Innovation Awards 2012, which places a spotlight on how PLM technology enables companies to make smarter decisions that lead to the creation of better products. The top award is presented to the company that uses PLM technology in a way that enables it to be a hallmark of success in the manufacturing industry, maximizing the value derived from its products throughout the entire lifecycle to stream-line its productivity and performance.

Implementing Tecnomatix portfolio enabled Mahindra Vehicles to come closer than ever before to real-time digital manu-facturing. Other benefits included a 25 percent reduction in the green field plant set-up time, a 28 percent improvement in effective working time by validating and reducing non-value added activities and an overall increase in flexibility, which

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, FactoryCAD, FactoryFLOW, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. Jack is a trademark or registered trademark of The Trustees of The University of Pennsylvania. AutoCAD a registered trademark of Autodesk, Inc. SAP is a trademark or registered trademark of SAP Aktiengesellschaft. Excel is a registered trademark of Microsoft Corporation. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z19 30584 8/12 Bwww.siemens.com/plm



Solutions/ServicesTeamcenter Manufacturing Process Planner www.siemens.com/teamcenterTecnomatix Process Designer Process Simulate Plant Simulation FactoryCAD FactoryFLOW Jack www.siemens.com/tecnomatix

Customer’s primary businessMahindra Vehicle Manufacturers Limited manu-factures and markets utility and light commercial vehicles, including auto rickshaws (three-wheelers). It is the lead-er in utility vehicles in India and currently accounts for about half of the country’s utility vehicle market. The Mahindra Group’s Automotive Sector is part of the globally recognized Mahindra Group, which is among the top 10 industrial companies in India. www.mahindra.com

Customer locationChakan, Pune, Maharashtra District India

PartnerTesis PLMware GmbH www.tesis.de/plmware

produced more product model mixes and reduced time-to-market.

“First time right” will lead to a brighter future“The benefits of the Tecnomatix digital manufacturing tools for Mahindra are already invaluable,” Nidamaluri says. “This toolset deployment strengthens the ‘first time right’ mindset we have in Mahindra, as it enables us to conduct different ‘what-if’ analyses of production scenarios. Still, we are looking forward to make more

progress in the digital manufacturing jour-ney. For example, we have more than 100 robots in our Chakan plant. Currently, even the slightest change in a robot program requires us to contact the line builder and ask for modifications. I believe we can develop skills by using the Tecnomatix robotics off-line programming tools to conduct some of this work ourselves. This will bring multiple benefits, including higher flexibility due to greater engineer-ing capability, shortening the modifications lead time and reducing cost.”

Robotic simulation created with Tecnomatix to reduce cycle time of welding operations.

www.siemens.com/plm

www.siemens.com/teamcenter


www.mahindra.com

www.tesis.de/plmware

IndustryFood and beverage

Business challengesDetermine the right dimen-sions of components for the breweryInvest in the right equipmentDevelop feasible and robust production plans

Keys to successSecure product quality with a stable and harmonized production flowCompare alternative maintenance strategiesIdentify and fix bottlenecks

ResultsDeveloped optimal strategies to fulfill customer demandUnderstood the consequences of different sequencing strategiesRealized limits of the planned brewery for future products and demandsSecured product quality

Plant Simulation provides Paulaner with key planning tool for new brewery

Finding the right balanceThere are a number of factors that have to be taken into an account when engineer-ing a brewery, including seasonal demand, product turnover, the flexibility to produce new products and multi-variety packs, and quality and freshness. It takes highly automated and sophisticated technologies and expensive equipment to effectively manage these factors, so it is particularly important to ensure that processes can meet current and future requirements.

To meet this goal, simulation is the tool of choice to implement fully validated processes that are “right the first time.” By using simulation, the brewer can deter-mine the most cost-effective and future-proof planning solutions. Alternate planning scenarios can be compared to select the best balance between perfor-mance, flexibility and cost. By using simu-lation, it is easy to identify bottlenecks and plan the best strategy for profitably meeting customer demand.

Optimizing systems and processesThe first official mention of Paulaner Brewery on 24 February 1634 is the brew-ery’s foundation date, and since then Paulaner Brewery has been a permanent part of the culture, tradition and history of Munich. The popularity of the Paulaner beer has always went well beyond the bor-

Tecnomatix


Paulaner Use of Tecnomatix enables premier brewer to efficiently expand business


Evaluating performanceThe input data of the simulation model is defined in a spreadsheet program. Structured into different registers, there are inputs for customer demand and prop-erties of the process steps (brewery, fer-mentation, filter, BBT, filling, warehouse). Using additional registers, it is possible to define the tank capacities (number, size), availability of filling lines and shift calen-dars for several process steps.

Paulaner can use this application without the detailed knowledge of how to create a simulation model; it is only required to define the input data in the spreadsheets. After import into Plant Simulation, the components of the model are generated and configured automatically according to the input data. This makes the solution easy to use and creates the opportunity to effectively investigate many different sce-narios in a short time period. The solution provides many different key performance indicators to evaluate the performance of the brewery.

Using this solution, Paulaner is able to evaluate the influence of stochastic pro-cess behavior (consumer demand, break-downs, etc.) and to confirm that they are making the right investment in tanks and equipment.

ders of Munich. This is especially true of Paulaner Hefeweißbier, which today is one of the most popular beers in the world. More than two million hectolitres leave the brewery every year for more than 70 countries.

Unfortunately, there is no room to expand at the current Paulaner production site, and even if there were, the nearby trans-portation connections are inadequate to accommodate an increased volume of product. To enable the company to grow, Paulaner started planning a new brewery on the outskirts of Munich.

To facilitate the building of a state-of-the-art brewery, iSILOG, a leading simulation service provider, provided a solution for the beverage industry using the Plant Simulation solution in the Tecnomatix® portfolio from Siemens PLM Software. The solution includes brewery-specific objects, such as the brew house, fermentation tanks, filters, bright beer tanks (BBT), fill-ing lines and storage. Using these objects makes it easy to investigate the production process and to evaluate different planning strategies and scenarios.

Solutions/ServicesTecnomatix www.siemens.com/tecnomatix

Customer’s primary businessThe Paulaner Brewery was founded in 1634 in Munich, Germany. Today, Paulaner produces about 2.4 million barrels or almost 74 million gallons of beer annually. It is one of six breweries that pro-vide beer for Oktoberfest, the German beer festival dating back to 1810. www.paulaner.com

Customer locationMunich Germany

PartneriSILOG GmbH Rheinstraße 219 D-76532 Baden-Baden www.isilog.de

© 2013 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z11 34281 7/13 Awww.siemens.com/plm


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Meeting key challengesPaulaner’s objectives for the project were to continue to improve key performance indicators, including heat requirements, power consumption, water consumption and extract loss; implement environmen-tally-friendly energy concepts; and ensure that processes, workflows and capacities are balanced and optimized.

Using Plant Simulation, Paulaner was able to get a grasp on a number of key issues. These included determining existing bot-tlenecks; developing best strategies, such as cleaning, changeovers, batch sizes, pro-duction planning and control, to fulfill cus-tomer demand; understanding the limits of the new planned brewery regarding

expected future products and demands; establishing the best approach for harmo-nizing customer demand, incoming goods, batch sizes and packaging lines; and understanding the performance of differ-ent sequencing strategies as a function of product mix and quantity.

In complex systems with large interdepen-dencies such as in beer production plants, it is nearly impossible to manually estimate how the system will perform. The use of Plant Simulation technology makes the effective management of such interdepen-dencies a reality. Having proven its value, Paulaner considers Plant Simulation to be an essential planning tool for its current and future success.

Using Plant Simulation, Paulaner was able to get a grasp on a number of key issues.


http://www.paulaner.com


http://www.isilog.de

IndustryEnergy and utilities

Business challengesAn optimized manufacturing process for a new conduit plantExpanded conduit product portfolio

Keys to successDigital material flow simula-tion using Plant SimulationAnalyses of what-if scenarios Many interacting variables evaluated in a single simula-tion model

ResultsLower capital and operational costs for the tempering furnace Bottlenecks eliminated and optimal material flows definedBaseline established for fur-ther process optimizations Excess capacity avoided

Complex material flow simulations identified areas of inefficiency during the planning process, reduced both capital and operating costs

Dynamic player in a dynamic marketThe Siemens AG Energy Sector (Siemens Energy) is the world’s leading supplier of products, solutions and services for power generation, transmission and distribution, as well as for the production, conversion and transport of oil and gas. Delivering innovations in fossil and renewable tech-nologies, Siemens Energy is steadily expanding its leading position in the dynamic energy market.

Siemens Energy’s High Voltage Products business unit, part of the Power Transmission division, manufactures conduits for circuit breakers that are con-sidered the centerpiece of all switching stations. These conduits are made of fiber-reinforced polymers created by hardening a mixture of epoxy and fiber optics, or aramid, which is typically used for bullet-proof vests.

Innovation to deliver an ambitious pilot projectTo improve its position in the global energy market, Siemens Energy Power Transmission decided to increase its

Tecnomatix


Siemens Energy Power Transmission A new production plant is fully optimized before construction

manufacturing capacity by building an entirely new conduit manufacturing plant. The purpose of this plant was ambitious: to manufacture conduits that are significantly longer and have greater diameters than the previous versions. To accommodate the new dimensions, a new, automated thread winding process would be needed to replace the old manually organized vacuum method. The new

400-kV outdoor high-voltage switching station.

facility and machinery would allow the company to manufacture conduit more cost-efficiently and also improve quality.

In the course of building the new plant, manufacturing planners at the Siemens Energy offices in Berlin took advantage of the Plant Simulation solution in the Tecnomatix® portfolio from Siemens PLM Software. This software makes it possible to simulate and optimize material flows and resource utilization. It also enables offline analyses of production system com-ponents as well as evaluations of different what-if scenarios.

The new conduit production method was a pilot project, which meant that manufac-turing planners had to design a complex, highly interlinked production process and ensure that annual target quantities would be met, without any comparable experi-ence to guide them. “Surely, we would have been able to plan the plant layout with conventional methods,” explains

“Plant Simulation helped us avoid significant capital in-vestments and operational costs.”

Yasin Vardar Manufacturing Planner Siemens Energy

Yasin Vardar, a manufacturing planner with Siemens Energy and the main Plant Simulation software user on this project. “Without Plant Simulation, we would have never been capable of determining produc-tion quantities.” The software solution was critical to the success of the new facility.

Siemens PLM Software partner, SimPlan AG, helped create the simulation models. Having already optimized many material flows using the Plant Simulation solution in the Tecnomatix portfolio, SimPlan brought a wealth of experience to the project. Arne Frenkel, project manager at SimPlan, implemented the simulation model on-site while at the same time training Vardar in the use of the software. “We assist our cus-tomers from initial purchase considerations to routine application of simulation during operations,” says Frenkel. “The use of Plant Simulation helps make certain that the manufacturing planners will achieve their ambitious goals.”

Test of a high-voltage circuit breaker.

“Plant Simulation was a key to the success of the entire project. It’s hard to imagine how we planned previously.”

Yasin Vardar Manufacturing Planner Siemens Energy

Simulation and optimization of complex material flowTo create the simulation model, all auto-mated portions of the proposed plant were modeled digitally. This included the mandrels (the tools on which conduits are made), the winding machine (whose spools wind plastic threads onto the man-drels), the pre-hardening furnace, and the conduit removal machine, as well as the tempering furnace in which the conduits are hardened.

To define material flow, the planners had to consider several parameters: number of tools, availability of machines, speed of transportation systems, cycle times, man-power requirements, control of the furnaces, and so on. In addition, three types of conduits requiring different mate-rials with different hardening times were going to be manufactured. “With Plant Simulation, we were able to incorporate a variety of interacting variables in a single model,” says Vardar.

Delivering clear business valuePlant Simulation made a clear and signifi-cant difference in terms of added business value. One simulation showed that one of the three initial chambers of the temper-ing furnace could be eliminated through the use of an intelligent buffer concept for pre- and post-transportation tracks. The furnace had not been purchased when the simulation was run, so it was possible to

modify the order accordingly. “In this situ-ation, Plant Simulation helped us avoid significant capital investments and opera-tional costs,” explains Vardar.

The new thread winding method optimizes production of conduits made of fiber-reinforced polymers.

Another optimization involved the control of the start of the tempering furnace. Simulations of the planned start times led to a strategy that showed that it is more efficient to turn the furnace on when it is fully filled with conduits rather than at the end of each shift. This small change would lower energy costs. In addition, simulation helped planners identify the optimum number of mandrels. And by evaluating in detail the cooling phase of the tools, simu-lations were able to make significantly more precise predictions than previous cal-culation methods. As a result, unnecessary overcapacity was avoided.

Aramid-isolated selector rod for power transmission.

© 2011 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.Z7 25933 10/11 Awww.siemens.com/tecnomatix



Solutions/ServicesPlant Simulation (Tecnomatix portfolio) www.siemens.com/ tecnomatix

Customer’s primary businessThe Siemens AG Energy Sector (Power Transmission division) provides efficient power transmission, reliable switchgear, high-performance transformers and advanced power transmission systems. www.energy.siemens.com

Customer locationBerlin Germany

PartnerSimPlan AG www.simplan.de

The digital model also revealed that the original cycles of the pre-hardening furnace led to congestion at the winding machine. A cycle change eliminated that blockage and ensured a continuous mandrel supply. The planners also saw that the speed of the transportation system was too slow throughout the entire material flow. “Using Plant Simulation was a key to the success of the entire project. It’s hard to imagine how we planned previ-ously,” says Vardar.

Even now that the new plant is opera-tional, manufacturing planners at Siemens Energy still benefit by using Plant Simulation. As a “living virtual model,” the software helps determine the right man-power requirements for different quantity scenarios, and also helps in organizing shift work. The company is now consider-ing the use of Tecnomatix for digitally modeling and optimizing manufacturing processes at other, older plants.

Fiber optic conduit.

IndustryConsumer products

Business challengesFaster design of more efficient factories

Keys to success3D factory layouts everyone can understandFast, easy-to-prepare logistics simulationsIn-house reliability algorithms integrated with plant simulationStandards-based, lightweight CAD (JT) files

ResultsMillions of dollars in global cost savings33 percent increase in utiliza-tion of factory space and material handling resources 20-25 percent savings in costs of moving materialsGreater confidence in new facility designsOptimized material handling, logistics and indirect labor across the organization Increased planning accuracy and efficiency

Tecnomatix supports efficient design and delivers cost savings by boosting productivity at new and existing plants

Faster design of more efficient factoriesThe Procter & Gamble Company (P&G) has one of the strongest portfolios of trusted brands, including the following trademarked products: Pampers, Tide, Ariel, Always, Whisper, Pantene, Mach3, Bounty, Dawn, Gain, Pringles, Charmin, Downy, Lenor, Iams, Crest, Oral-B, Actonel, Duracell, Olay, Head & Shoulders, Wella, Gillette, Braun and Fusion. The P&G community includes approximately 138,000 employees working in more than 80 countries worldwide.

P&G is taking advantage of the Tecnomatix® plant design and optimization solution from Siemens PLM Software in its efforts to minimize production losses, and improve the efficiency of manufacturing operations. Engineers use the Tecnomatix FactoryCAD, FactoryFLOW and Plant Simulation applications to improve manufacturing processes at both new and existing facilities.

Tecnomatix


Procter & Gamble Designing and optimizing efficiency in consumer packaged goods manufacturing

“We have used these tools to improve different aspects of our manufacturing operations throughout P&G,” says Brad Whitmore, technology section head in P&G Global Computer Aided Engineering.

“The Tecnomatix applications work well together and let you visualize proposed factory layouts and determine quantitatively how they will perform.”

Efficient from scratchPrior to building new facilities, Whitmore and his colleagues use Tecnomatix FactoryCAD to create optimized layouts. “FactoryCAD allows us to design and visualize different concepts for a proposed facility,” says Whitmore. “The difference with FactoryCAD is concepts are now presented in 3D – a huge improvement over conveying ideas on drawings.”

“Seeing a layout in 3D brings it to life, especially for people who have trouble interpreting 2D drawings,” Whitmore says. “We now get input from people who might not have given their input in the past.” He estimates that as many as 20 design review meetings can be held to fine-tune a plant layout. This doesn’t slow the project schedule because it is easy to update the FactoryCAD layout with people’s input before we’ve started project execution. Whitmore estimates review cycles happen much faster compared to earlier projects where FactoryCAD wasn’t used.

The FactoryCAD layouts are converted into lightweight JT™ files that people can review at their desks. The use of JT files brings a number of advantages, including a smaller size compared to the original

“Tecnomatix lets us apply the concepts used in equipment design to optimize factories and facilities.”

Brad Whitmore Technology Section Head Global Computer Aided Engineering Procter & Gamble

CAD model. JT files can be 10 to 20 percent smaller than the CAD files and engineers no longer need CAD software to view the files. JT files also help in the layout of manufacturing equipment in FactoryCAD. Objects such as walls, windows, doors and building supports can be modeled in FactoryCAD, but 3D models of manufacturing equipment designed in other CAD systems can be imported as JT files into the FactoryCAD layout.

The result of using FactoryCAD to help develop a new facility or revise an existing one is greater confidence in the design. “We have a better idea what the final plan will look like because we have already seen it and flown through it in the computer,” Whitmore notes. “Our teams have a lot more confidence in what will be built, what it will look like, and how it will operate before we’ve broken ground. That’s a real success story.

The use of FactoryCAD supports P&G’s organizational performance goals for new facilities in a number of ways. One aspect involves making the construction of the facility more efficient by doing things right the first time and avoiding scrap and rework. Building the plant virtually and working out problems in the computer is proving to be helpful in achieving this goal.

Improving logisticsP&G uses other Tecnomatix solutions, such as FactoryFLOW and Plant Simulation as well. “We use Tecnomatix FactoryFLOW to directly compare plant and equipment layouts, to understand how our people, fork trucks, and materials flow to and from manufacturing lines,” he explains. “Without software such as this, the teams can talk through different layouts, but FactoryFLOW lets us match them up quantitatively.”

Whitmore explains that P&G uses FactoryFLOW as a screening tool to identify and select layouts that have the greatest potential before performing a detailed analysis with Plant Simulation. “FactoryFLOW provides a good first pass because it doesn’t require a lot of effort or data to evaluate proposed layouts,” he adds.

P&G uses Tecnomatix Plant Simulation to optimize material flow, resource utilization and logistics. Users create computer models of production systems, then run experiments and what-if scenarios to optimize them – quickly and without disturbing ongoing operations. “Plant Simulation is very fast in how it does the calculations,” says Whitmore. “There are a lot of benefits in how easy it is to implement and how models can be built and re-used.”

P&G has coupled Plant Simulation with its own expertise in computer experimentation, a comprehensive approach that identifies the factors most likely to cause losses through simulation of manufacturing operations. The openness of the Tecnomatix software supports this kind of computer experimentation, which “adds another layer to the simulation, so we have a

better understanding of productivity,” Whitmore notes. For further information about P&G’s capabilities in computer experimentation, contact Mary Ralles ([email protected]) in P&G External Relations.

Whitmore estimates the use of Tecnomatix software has resulted in millions of dollars in cost savings across the global organization. He also reports one project saw a 33-percent increase in the utilization of factory space and 20 to 25-percent savings in the cost of moving materials. Overall for P&G, Tecnomatix means faster design of more efficient factories with optimized logistics and productivity in their manufacturing organization. With Tecnomatix, P&G has powerful tools for focusing the company’s engineering and manufacturing talents effectively.

© 2011 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.Z9 17502 10/11 Awww.siemens.com/plm



Solutions/ServicesTecnomatix www.siemens.com/ tecnomatix

Customer’s primary businessProcter & Gamble Company is one of the world’s largest consumer products compa-nies, with approximately 300 brands in more than 160 countries around the world. www.pg.com

Customer locationCincinnati, Ohio United States

“Tecnomatix applications work together well to let you visualize different factory layouts and deter-mine quantitatively how they will perform.”

“We got a lot more confi-dence in what the real plant will look like [using Tecnomatix], because we had already seen it and flown around it virtually.”

Brad Whitmore Technology Section Head Global Computer Aided Engineering Procter & Gamble

Industry or productAutomotive and transportation

Business challengesDeliver trains to customers on time and per quality require-mentsPlan the production process for a highly complex product against significant time pressureSupport the production of products for different custom-ers, with high levels of variationReduce shop floor production errors and scrap

Keys to successRemove barriers between Product Design and Manufac-turing Engineering groups through Manufacturing Pro-cess PlannerDefine the M-BOM out of the E-BOMPlan a production process, in-cluding operations sequence, needed tools and handled partsIntegrate Manufacturing Process Planner with existing engineering IT systems

Train manufacturer uses Manufacturing Process Planner and Process Simulate to ensure its products are manufactured at the highest quality standards against continuously shorter delivery times

All tracks lead to the Krefeld- Uerdingen plantEvery regional and high-speed train built by Siemens in Germany passes through the doors of its Siemens Rail Systems plant in Krefeld (Uerdingen district). Krefeld is strategically placed between the two major cities of Düsseldorf and Dortmund. Siemens has taken advantage of this loca-tion by making its Krefeld facility one of the most important centers of competence for the railway industry. Every year, more than 450 car bodies are delivered by the plant, where approximately 2,000 people work on the development and production of rolling stock, electrical systems and components.

At the Siemens Rail Systems plant, the aluminum components for the body shells are fitted together, welded and painted. Individual parts are then put together, and the car bodies take on the form and shape that passengers will later see and use. Only when every seat and door has been correctly installed is the train rolled out the doors and ready for service. Regional trains like the Desiro and high-speed trains like the Velaro, both used in the United Kingdom (UK), are built in

Teamcenter • Tecnomatix

www.siemens.com/plm

Siemens Rail Systems Digital manufacturing tools strengthen rapid organic growth

Krefeld, with some of them put through their paces at the company’s own test center. The high-speed Velaro train is already operating successfully in Spain, China and Russia. The latest generation of the train is also due to run in its home country – Germany.

The Siemens Rail Systems plant in Krefeld.

The Siemens high-speed Velaro train.

Planning the production of complex products requires dedicated toolsUlrich Semsek, who manages the Krefeld Plant, describes the organization’s business challenges, “We are now facing a huge pressure to deliver trains, due to our ever- increasing order book. The commercial trend we are experiencing is that the time from order to delivery becomes shorter, and the complexity of projects becomes higher. A typical train is a very complex product and includes 400,000 parts. The level of commonality among trains manu-factured for different countries is some-times as low as only 10 percent – so they are very different from each other. The bottom line is that we need a tool to man-age this complexity. Therefore, we per-ceive the digital manufacturing project deployment – which uses the Manufact-uring Process Planner solution in the Teamcenter portfolio as its foundation technology – to be a key element in our ability to deliver trains to customers on time and according to quality requirements.”

Bridging the gap between the product design and manufacturing engineering processes“One of the big benefits of Manufacturing Process Planner is that it helps to remove the typical barriers we have between the product designers and manufacturing engineers,” says Semsek. “Manufacturing

engineers are now exposed to product data during product development, and can immediately start to plan the needed production process. This clearly shortens product development time.” Siemens Rail Systems’ digital manufacturing capability includes a tight, bi-directional interface between its enterprise resource planning (ERP) system, SAP® software, and its manufacturing engineering backbone, Teamcenter® software. The engineering bill of materials (E-BOM) is imported into Teamcenter from SAP, and includes the structure (hierarchical information), relevant attributes (such as materials), transformational matrices and the associ-ated geometric data (JT™ data format, which is used also within the ERP environment). The seamless integration of Teamcenter and SAP supports updating an existing BOM with a new version.

The process works as follows. The manu-facturing engineers define the manufac-turing bill of materials (M-BOM) out of the E-BOM. Dedicated functionality allows the engineers to easily change the hierarchy, as the M-BOM is structured the way the product will be manufactured, as opposed to the E-BOM, which is structured accord-ing to product design considerations. In addition, the manufacturing engineers add a number of manufacturing features to the M-BOM, such as lubricants, which are not

ResultsProject delivery time is reducedProduct changes are system-atically handled by manufac-turing engineering through a controlled change processVisualized and self- explanatory shop floor work instructionsDynamic 3D simulations of complex assembly scenarios

Train assembly is a complex process.

Planning a train assembly process with Manufacturing Process Planner.

“ We perceive the digital manufacturing project deployment – which uses the Manufacturing Process Planner solution in the Teamcenter portfolio as its foundation technology – to be a key element in our ability to deliver trains to customers on time and according to quality requirements.”

“Oneofthebigbenefits of Manufacturing Process Planner is that it helps to remove the typical barri-ers we had between the product designers and manufacturing engineers.Manufacturing engineers are now exposed to product data during product devel-opment, and can immedi-ately start to plan the needed production process. This clearly shortens product development time.”

Ulrich Semsek Krefeld Plant Manager Siemens Rail Systems

part of the E-BOM. Teamcenter is also used to obtain other information from SAP, including tooling data that is designed with Pro/Engineer® software and managed using the Windchill PDMLink® software environment.

At an appropriate time, the M-BOM is exported back to SAP to feed the shop floor systems. Martin Olbrich, who is responsible for assembly manufacturing engineering at the Krefeld Plant, notes, “We were impressed with the openness of Siemens PLM Software’s manufacturing engineering solution. It enabled us to create seamless integrations between Manufacturing Process Planner and other commercial and legacy systems that we have in our engineering IT (information technology) landscape.”

Digital manufacturing supports transportation network improvementThe transportation network in and around the city of Sochi in Russia, near the Black Sea, will go through a major improvement. To support this, Siemens has received an order from Russian Railways (RZD) to sup-ply a total of 54 regional trains. The first 38 trains, similar to the Desiro, will be manufactured entirely at the Siemens Rail Systems plant in Krefeld. These trains are

capable of top speeds of up to 160 kilome-ters per hour and are expected to enter service in the autumn of 2013.

The Sochi project demonstrated to the Krefeld crew the tremendous advantages of using Manufacturing Process Planner. In this project, manufacturing engineers defined both the assembly and the weld-ing process using Manufacturing Process Planner by preparing the manufacturing operations, linking the train parts to the operations, and defining the tools that were required for each shop floor operation. The duration of each manufacturing operation was accurately calculated through an interface between Manufacturing Process Planner and a dedi-cated time analysis system, which is used by Manufacturing Engineering. The work-flow is based on a high level of automa-tion that saves notable time for the manufacturing engineers, as well as extensive consistency checks that ensure that no single part is left untreated. Eventually, the complete work packages are exported to SAP and consequently other systems are updated as well. Olbrich points out, “One of the clear benefits we have realized though the deployment of this train project is the ease and speed with which changes can be handled. A train is a complex product, with a high

Analysis of the cabin rear part using Manufacturing Process Planner.

level of customization per customer. Our group, Manufacturing Engineering, typically encounters extensive product changes throughout a project. With Manufacturing Process Planner, we have a clear methodology that readily identifies the changes, analyzes their impact, and carries them out in the process plan.”

Strategic deployment demonstrates value across disciplines“We don’t calculate the benefits of the digi-tal manufacturing project in the sense of saving manpower, as we treat this project as a much more strategic initiative,” says Semsek. “In Siemens Rail Systems, our cul-ture is to invest in innovative solutions, and push for real values.” Semsek notes that this typically means taking some chances, pushing for practical benefits and, in many cases, exceeding expecta-tions. He explains, “We now see more and more value in the digital manufacturing project – more structured methodologies and work procedures from engineering on the top floor down to production on the shop floor. What is interesting is that we now experience some benefits that we did not foresee in the first place; for example, in the Krefeld Plant, the perfect fit of the digital manufacturing tools to our lean assembly initiative.”

Bernd Niesel, who manages welding across the manufacturing engineering environ-ment at the Krefeld Plant, describes another benefit of implementing Manufacturing Process Planner: “When we first started the deployment, we planned to employ the software mainly in the assembly area, but as the benefits became more evident, it was clear to us that we would deploy the tools in the welding area as well. There are 1,500 to 2,000 parts in the chassis, and the major-ity of the welding operations are manual. Therefore, using Manufacturing Process Planner, we experience a big benefit in analyzing and defining the right welding sequence upfront, taking into account the physical constraints of the materials; for example, weld on one side, then balance with a weld on another side.”

A Sochi car in the production line.

Aluminum ribs that form the car chassis on the production line.

Using Manufacturing Process Planner to define the welding sequence is straightforward and effective.

“ We were impressed with the openness of Siemens PLM Software’s manufacturing engineering solution. It enabled us to create seam-less integrations between Manufacturing Process Planner and other commer-cial and legacy systems that we have in our engineering IT landscape.”

Martin Olbrich Manufacturing Engineering Assembly Manager Krefeld Plant Siemens Rail Systems

Manufacturing Process Planner helps avoidshopfloormistakesHighly visual, self-explanatory work instructions represent a key resource for avoiding assembly mistakes, which often result in costly rework and scrap. The Krefeld Plant’s Manufacturing Engineering department was experiencing a number of obvious problems on the shop floor that were related to work instructions. Specifically, the work instructions were often difficult to understand and insuffi-ciently visual. In addition, it wasn’t always clear that the instructions were up-to-date. Ultimately, the shop floor workers’ use of the instructions was inconsistent and less than optimal.

To address the problems associated with the work instructions, Siemens Rail Systems Krefeld engaged the 3D portable data format (PDF) Work Instruction appli-cation of Manufacturing Process Planner. Olbrich explains, “While looking for a solu-tion that would support the reduction of shop floor scrap and rework, we became excited about the ability to create highly visual work instructions for our shop floor personnel. So we created a PDF template and used it to start generating work instructions in a format that could be eas-ily loaded on any workstation throughout the shop floor. Each work instruction, delivered in PDF format, includes a list of sequenced production or assembly steps, the necessary tools to address each step, specific production values (for example, fastening torque), relevant security warn-ings such as needed protective equipment, and generic information like requisite worker qualifications and associated imag-ery. With such clarity of work instruction content, especially through the use of visualized processes, we have decided to optimize communication by purchasing 23-inch monitors and positioning them throughout the shop floor.

“Another big advantage of using Manufacturing Process Planner is the ability to easily update documents. For example, if there is an engineering change to one of the parts, the use of Teamcenter makes it easy to make that change and it’s automatically reflected in any related imagery in the work instructions. As part of our previous process, we used to invest a lot of effort in order to generate 2D assembly drawings for the shop floor personnel. This is no longer needed, due to our highly effective, new work instruc-tions solution.”

An example of a crash box assembly 3D PDF work instruction.

Dynamic 3D simulation of complex assembly scenariosSiemens Rail Systems uses the Process Simulate solution in the Tecnomatix® portfolio to analyze any planned assembly operation that requires virtual validation. This analysis occurs in an entirely 3D environment. Process Simulate is inte-grated with Manufacturing Process Planner. Simulations typically include the product being assembled and the tools that are used for the assembly, fixtures and logistic jigs.

Olbrich explains, “When putting all this data into the context of an assembly, we can validate upfront whether a planned process is feasible for execution on the shop floor. For example, consider the assembly of the coupling and the crash box modules at the front-end of a train. This is a tricky assembly scenario, because whatever module you assemble first makes assembling the second module difficult. In the past, the assembly sequence for such modules was determined by the product designers. Now, manufacturing engineers use Process Simulate to analyze the opti-mal assembly sequence of the train mod-ules. Using Process Simulate, we combined product data with tools and fixtures, and we found that the coupling had to be assembled after the crash box to avoid additional assembly steps and unnecessary shop floor complexity.

Coupling assembly after crash box – a Process Simulate analysis.

Coupling assembly – a Process Simulate analysis.

“Another important aspect of using Process Simulate is that Manufacturing Engineering now has a tool to carry out assembly analysis whereas, with our prior approach, this task had to be performed by Product Design. As we are dealing with a complex assembly process, the simulation (including animations and images acquired during this analysis) represents a valuable resource in training our shop floor personnel.”

The future – capacity planning and disassemblySiemens Rail Systems has realized signifi-cant benefits from the deployment of Siemens PLM Software’s digital manufac-turing tools. The organization is now eval-uating additional digital manufacturing applications that are well-suited to deliver significant process advantages, including Plant Simulation in the Tecnomatix portfo-lio. “We already did an evaluation of the Plant Simulation tool,” says Olbrich. “We built a discrete-event simulation model for one of the pre-assembly lines in order to support resource capacity planning. The manufacturing process and resources are defined using Teamcenter and populated to Plant Simulation. This is a big benefit. The planned scheduling is imported from Excel. The initial outcome shows the potential for notable productivity advan-tages, so the deployment of Plant Simulation appears imminent.”

Crash box assembly (with the needed tools) – a Process Simulate analysis.

“ Another important aspect of using Process Simulate is that Manufacturing Engineering now has a tool to carry out assembly analy-sis, whereas with our prior approach, this task had to be performed by Product Design. As we are dealing with a complex assembly process, the simulation (including animations and images acquired during this analysis) represents a valu-able resource in training our shopfloorpersonnel.”

Martin Olbrich Manufacturing Engineering Assembly Manager Krefeld Plant Siemens Rail Systems

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. Excel is a registered trademark of Microsoft Corporation. SAP is a trademark or registered trademark of SAP Aktiengesellschaft. Pro/Engineer and Windchill PDMLink are trademarks or registered trademarks of Parametric Technology Corporation or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z18 27246 7/12 Cwww.siemens.com/plm



Solutions/ServicesTeamcenter www.siemens.com/teamcenterTecnomatix www.siemens.com/tecnomatix

Customer’s primary businessSiemens Rail Systems com-bines comprehensive urban, interurban and logistics mobility expertise to deliver integrated mobility solutions – precisely tailored intermodal technologies for rail, road, and air traffic – that enable its customers to transport people and goods more efficiently. www.mobility.siemens.com

Customer locationKrefeld Germany

“We now experience some benefitsthatwedidnotforeseeinfirstplace;forexample, in the Krefeld Plant,theperfectfitofthedigital manufacturing tools to our lean assembly initiative.”

Ulrich Semsek Krefeld Plant Manager Siemens Rail Systems

Another promising area is engineering disassembly analysis, which is needed for maintenance and service tasks. “Maintenance and service are part of the overall solution we provide to our custom-ers,” says Olbrich. “It is clear that with the Process Simulate tool, which is integrated within the Teamcenter environment, we can simulate disassembly activities in order to define the best disassembly meth-odology and effectively train maintenance personnel.”

Semsek concludes, “Our train manufactur-ing business is doing extremely well. We recently received an order from Deutsche Bahn (German Rail) for the ICx train – the biggest single order in the history of our company. To support such growth,

we must be technology leaders, and an advanced digital manufacturing deploy-ment is another reflection of our leader-ship. Additional plants in our division are already looking to learn from our plant, and adopt the digital manufacturing tools and methodology we have developed using the tools of Siemens PLM Software. Luckily for our other plants, they will get the system production-ready to support their unique needs.”

Intercity trains production hall.

Plant Simulation for shipyardsSimulation, visualization and optimization of shipbuilding processes


TECNOMATIX

Benefits• Optimized space and

crane utilization• Advanced assembly

sequence scheduling• Increased planning safety

and accuracy• Higher service reliability• Improved logistics and

material management with clarity of complex processes

• Safer investment decisions• Ability to better decide upon

make versus buy issues• Ability to more accurately

predict delivery times• Ability to reduce the risk of

product failure or delay

User case• Decreased throughput

time from 60 to 52 days (-14 percent)

• Decreased direct labor on the panel line from 8,280 to 6,600 hours (-20 percent)



• Object-oriented, hierarchical models of shipyards, encompassing business, logistic and production processes

SummaryTecnomatix® software’s Plant Simulation enables the simulation and optimization of complex shipyard production systems and processes. Using Plant Simulation, you can optimize material flow, resource and space utilization as well as the logistics for all levels of the shipyard from scheduling individual welding activities up to the complete ship assembly.

The challenges of today’s shipyard industry are complicated by having to deliver increasingly complex products in a highly competitive marketplace. Shipyards now face the need to build more ships in a shorter time and to offer services at compet itive prices and with short delivery times. Plant Simulation is an event-driven simulation tool that helps shipyards handle these needs more easily, providing computer-supported answers to major questions such as when and where to develop what products and with resources limited by availability and restricted materials.

Plant Simulation is a simulation-based and modular toolset with proven benefits for optimizing production and logistics in the shipbuilding industry, allowing the graphical representation of parts and resources and interfacing

cannot be accounted for when traditional planning tools are used. In addition, the visualization does not offer 3D animation capabilities.

ResultPlant Simulation facilitates the simulation of the highly complex shipyard environment. It offers a good basis for deciding the outsourcing and production strategies, while facilitating cross-project resource planning, increasing planning safety and improving the utilization of major resources such as employees, cranes and square footage.

Where Plant Simulation applies• Predicting schedule problems• Predicting workplace-efficiency • Finding concept changes for expanding

shipyards• Sequence-control of assembly lines• Optimizing warehouse and transport

capacities • Steel planning• Optimizing availability of needed

manpower

References• Aker Yards, Germany• Center Of Maritime Technologies,

Germany• Flensburger Schiffbau-Gesellschaft,

Germany• Meyer Werft Papenburg, Germany• ThyssenKrupp Marine Systems: Blohm + Voss, Germany Nordseewerke Emden, Germany Kockums, Sweden• Volkswerft Stralsund, Germany

to database systems. This toolset enables you to model the employment of available shift calendars with customer-specific user-interfaces and interactive model manipulation. Plant Simulation is used to optimize the building of cruise liners, car and passenger ferries, container vessels and gas tankers, aircraft carriers, submarines and naval ships. Plant Simulation supports strategic corporate projects by enabling project managers to identify the best shipyard at which to build new ships. Plant Simulation also can be used to manage internal production and outsourcing strategies, as well as the operational work sequences and schedules that are used to distribute the daily workload.

All processes follow easy-to-understand interactive and iterative functions. Users start the scheduling, look at results and, if needed, make changes (for example excluding a special sub-block). Users restart the scheduling to verify that the changes were correct. Plant Simulation is able to predict utilization in each project area, depending on the number and kind of blocks being assembled every day, week and month.

Why traditional planning tools do not workStatic planning tools, such as spreadsheets or flow-charting software, are unable to generate results that account for variability and changing conditions over time. Relevant interdependencies between system components and technological constraints are not usually taken into consideration. Complex rules that control the flow of information and material often

Tecnomatix Plant Simulation for shipyards

Features continued• Graphs and charts for

analyzing throughput, resources and bottlenecks

• Comprehensive analysis tools, including automatic bottleneck checking

• Sankey diagrams and Gantt charts




• Open system architecture supporting multiple interfaces and integration capacities (ActiveX, C, CAD, MS Excel, Oracle SQL, ODBC, XML, Socket, OPC, etc.)

TECNOMATIX

© 2011 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. X10 8852 9/11 B



Digital planning boosts shipyards’ efficiencyTecnomatix production planning software helps shipbuilder optimize production across multiple facilities, reducingdevelopment costs and ensuring on-schedule deliveries

www.siemens.com/plm

Shipbuilding

F I NC ANT I E R I

Siemens PLM Software

Business initiatives

Commonization and re-use

Production efficiency

Business challenges

Ensure high quality

Limit costs

Meet delivery times

Keys to success

Scientific approach toproduction planning

Ability to simulate productionalternatives

Common library forproduction data

Standardized productiondocumentation

Results

Closer cooperation betweenshipyards

Optimized production capacityat each shipyard

Reduced development costs

Better ability to meetdelivery dates

Ambitious targetsFincantieri is one of the biggestshipbuilding companies in theworld, with particular expertisein the production of cargo andcruise ships. In 200 years of itshistory, the company haslaunched more than 7,000 shipsand is the leader in supplyinghulls, surfaces and submarines ata global level. Divided into sixbusiness areas (cruise ships,cargo ships, military ships, megayachts, ship repairs andremodels, ship systems andcomponents), the companyemploys 9,200 people, with atleast twice as many working forits supplier companies.Production takes place at nine facilities across Italy.

Fincantieri invests five percent of its turnover into research and development to ensure itsleadership position into the future. Along with goals for increasing in both size and marketshare, the company is working to reduce costs through the adoption of digital manufacturing.

Planning revolutionFincantieri has implemented the Tecnomatix™ digital manufacturing solution from Siemens PLMSoftware to enhance production planning, to integrate production systems so that the entireorganization functions as one shipyard, and to transform strategic goals into operationalactivities. All of this is aimed at providing the highest quality services, at lower costs andmeeting delivery times.

The adoption of Tecnomatix created a revolution in the production planning process, startingwith production engineering and extending through shop floor operations. The starting pointwas a new way of breaking down a hull to best exploit the capabilities of the various plants

without exceeding their limits. This begins as atop-down process that divides the ship intoareas, sections, blocks, sub blocks, panels and soon. Then the process reverses, that is itbecomes bottom-up, to plan the production ofevery single object, including constraints(material availability, type, weight, sizes anddelivery date) and optimize the work of theindividual shops.

The use of the Tecnomatix suite allowedFincantieri to achieve a dramatic reduction inplanning time for the hull construction andprovided the ability to investigate more process and planning alternatives as well as analyze eachproject on the basis of the shipyards’ production capacity – simulating the same process on thevarious yards.

Innovative approachThe Tecnomatix implementation, which was performed by Fincantieri along with representatives fromSiemens PLM Software, introduced an innovation into the company’s way of working. “The mostinteresting result is a more scientific approach to production planning through all of our plants,” addsAlessandro Nevierov, methods and technology development manager at Fincantieri. “Also,Tecnomatix led to the adoption of a common method as well as the creation of a reference librarythat makes it possible to share production analysis data with the various plants. It has also enabled usto standardize our planning documentation.”

The use of Tecnomatix has reduced development costs as well as the risks associated with missingdelivery dates. The most significant results of the new approach have been time and cost savingsresulting from the increased quality of the planning.

Simulation optimizes productionIn the production of a hull, the use of the Tecnomatix Plant Simulation enables production engineersto analyze multiple production strategies in relation to the machinery and labor constraints of thedistinct workshops or Homogeneous Technological Areas (HTAs). This type of analysis makes itpossible to optimize each shipyard’s throughput and more easily balance the allocation of materialsand capacity across multiple sites.

The introduction of Tecnomatix has allowed Fincantieri to centralize the initial planning processwhile improving decision making. It also fosters the re-use of data, thus shortening the developmenttime for detailed production plans.

“The use of Tecnomatix has also opened the way to closer collaboration between the variousshipyards by allowing the exchange of the data,” says Nevierov. “Transfer times for constructiondocumentation from one plant to another have been reduced to the minimum, to days instead ofmonths.” Moreover, the automatic production of product planning reports and summary documentshas eliminated a significant amount of time-consuming compilatory work.

Shipbuilding

Solutions/Services

Tecnomatix


Fincantieri is the world’s leadingsupplier of cruise ships andlarge ferries, and among the

leading companies in the field ofhull supplies.

www.fincantieri.com

Client location

Trieste and GenovaItaly

“The use of Tecnomatix hasopened the way to closercollaboration between thevarious shipyards.”

Alessandro NevierovMethods and TechnologyDevelopment ManagerFincantieri


© 2008 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG.Teamcenter, NX, Solid Edge,Tecnomatix, Parasolid, Femap, I-deas, Velocity Series and Geolus are trademarks or registered trademarks of Siemens ProductLifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks orservice marks used herein are the property of their respective holders. 9/08

M E Y E R W E R F T

Plant Design and Optimization solution helps protect centuries-oldmarket leadership

Tecnomatix

Meyer Werft – Jos. L. MeyerGmbH was founded in 1795and can look back on a verysuccessful track record,especially in the building ofspecial-purpose ships. Theworldwide demand forluxury liners with a capacityof 2,000 passengers andabove is growing, as isconfirmed by the full orderbooks of Meyer Werft. Tocater to the need of building more ships in less time, shipyards have to make their productionprocesses more efficient. Improving efficiency can also help Meyer Werft counter heavycompetition from the Far East.

Throughout its long company history, Meyer Werft set goals to use innovative tools, take newdirections and turn visions into reality. The growing demand gave rise to the vision of a “digitalshipyard” and in Siemens Tecnomatix, Meyer Werft found the ideal partner for turning thisparticular vision into reality. The Tecnomatix Plant Simulation application within the PlantDesign and Optimization solution has now been in use since 1998. Tecnomatix is used for theplanning, simulation and optimization of production systems and processes. Using Tecnomatix,Meyer Werft can optimize its existing production systems and develop planning alternativesmore easily. Future manufacturing processes in the shipyard can thus be developed morequickly and optimized from the start. At the same time, the software cuts shipbuildingdevelopment times and costs significantly by simulating and improving the work process,accounting for various factors and resources (for example workers, equipment and transportinfrastructure). Because the shipyard has only limited space available for large, heavy shipcomponents means storage of the semi-finished products is a major production challenge.However, this problem has likewise been overcome thanks to simulations using Tecnomatix.

Issues:

Process excellence

Approach:

Apply Tecnomatix® PlantSimulation software to optimizeproduction and speed newproduction planning

Results:

Improved overall productionprocess, including planning

Improved storage and readinessof semi-finished products

Reduced development time

Lower shipbuilding costs

Construction sequencedemonstration for customersduring the offer phase

Tecnomatix Plant Design and Optimization proves to be a most effective solution for thedemands placed on a modern shipyard.

www.siemens.com/plmSiemens PLM Software

Tecnomatix

Solutions/Services

Tecnomatix Plant Simulation


Shipbuildingwww.euroyards.com/

ey_companies_jos.html or www.meyerwerft.de

Client location

PapenburgGermany

Following extensive product benchmarks, Plant Simulation proved to be the tool most suitable tocope with the demands placed on a modern shipyard, due to its modular architecture and seeminglyendless scope of functionality.

According to Dr. Frank Roland, Manager of Research & Development, Meyer Werft is “…now ableto plan and simulate different production processes via Tecnomatix, such as the use of personnel byworker skill level and by project priority.” Furthermore, the software “optimizes the use of transportequipment, such as cranes.”

Dr. Roland adds that Tecnomatix is “eminently suitable for visualizing and optimizing productionactivities, and that users are particularly enthusiastic about its 3D graphics capabilities. This is veryhelpful in making production-related decisions,” explains Dr. Roland, adding that “unnecessary risksare avoided and the entire productivity increased as all processes can be simulated and tested before implementation.”

Meyer Werft is one of the first shipyards to use Plant Simulation on a large scale. Chantierd´Atlantique, Fincantiari and Flensburger Schiffsbaugesellschaft also recently decided to use Tecnomatixin this manner. This confirms that a constantly growing demand for digital manufacturing also existsin this market, joining the heavy industries, consumer electronics and automotive industries.

On the whole, nothing but benefitsMeyer Werft derives considerable benefits from the use of Plant Simulation as explained by Dr. Roland: “Our planning engineers can already digitally demonstrate in the offer phase theconstruction sequence of the new ship to the commissioning shipping line. We can also determinequickly whether or not a specific ship can indeed be built, and if so, how.”

As the shipbuilders in Papenburg were already well versed in the use of simulation, it comes as nosurprise that a development partnership formed between Meyer Werft and Siemens. This resulted inthe creation of an enhanced tool for space allocation that has already been integrated in PlantSimulation, as well as numerous other developments, including a library of shipyard-specific objects.The overall Tecnomatix offering from Siemens has proven an effective solution for the optimizationof planning and production at shipyards.


© 2008 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG.Teamcenter, NX, Solid Edge, Tecnomatix, Parasolid, Femap, I-deas, JT, Velocity Series, Geolus and the Signs of Innovation trade dress are trademarks orregistered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos,trademarks, registered trademarks or service marks used herein are the property of their respective holders. 3/08

Tecnomatix Plant Simulation Student downloadPlant Simulation discrete-event simulation modeling – helping prepare students to meet the manufacturing challenges of the future


TecnomaTix

Benefits• Free annual license to

production software used in industry

• Early job market preparation by learning industry-leading production simulation technology

• Networking opportunities through access to a global forum of users



• Object-oriented, hierarchical models encompassing business, logistic and production processes

• Dedicated application object libraries for fast and efficient modeling of typical scenarios

• Graphs and charts for analysis of throughput, resources and bottlenecks

• Comprehensive analysis tools, including automatic bottleneck detection, Sankey diagrams and Gantt charts


• Integrated experiment handling


SummaryTecnomatix® Plant Simulation software from Siemens PLM Software enables the simulation and optimization of production systems and processes. Using Plant Simulation, you can optimize material flow, resource utilization and logistics for all levels of operations planning from global production facilities through local plants to specific lines and processes. In times of increasing cost and time pressures in production, along with ongoing globalization, logistics has become a key factor in the success of a company. The need to deliver JIT/JIS (just-in-time/just-in-sequence), introduce Kanban, plan and build new production lines and manage global production networks requires objective decision criteria to help management evaluate and compare alternative approaches.

Plant Simulation helps create digital models of logistic systems (e.g., production) to explore the systems’ characteristics and to optimize their performance. The digital model enables you to run experiments and “what-if” scenarios without disturbing an existing production system or – when used in the planning process – long before the real system is installed. Extensive analysis tools, statistics and charts let you evaluate different manufacturing scenarios and make fast, reliable decisions in the early stages of production planning.

By registering for the Plant Simulation Student download you will become part of a global user community. Siemens hosts dedicated channels on YouTube, Slideshare, Facebook, Twitter and other public social sites that include tips, current events and useful training materials.

Who it is forThe Plant Simulation Student download is available to any active student of any age who is attending any academic institution such as accredited universities, technical colleges, trade and high schools. You can create models up to 80 objects in size and utilize the Plant Simulation class libraries. The software is available only for the Windows platform. The duration of this offering is valid for one year, but can easily be extended with re-registration. Usage of Plant Simulation Student download is intended for academic course work, and files created in the Student download cannot be opened in commercial versions of Plant Simulation.

Features continued • Open system architecture

supporting multiple interfaces and integration capacities (CAD, ODBC, XML, etc.)

• Interactive training materials and social media access to relevant content

© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. X7 30544 6/12 C



What is includedThe Plant Simulation Student download contains the same core functionality used by leading engineers and leverages the software’s powerful object-oriented architecture and modeling capabilities that enable you to create and maintain even highly complex systems, including advanced control mechanisms. Plant Simulation’s user interface follows Microsoft Windows standards, making it easy for you to quickly become productive. Simulation models can be created quickly by using components from application object libraries dedicated to specific business processes. You can extend the library with your own objects through a powerful programming environment for the furthering of simulation capabilities. Tools for automatic optimization, analysis of simulation results and 3D visualization of simulation models are also available.

Training and supportThere are a number of ways for you to learn how to use Plant Simulation. Included within the product are example models, demonstration videos, and an interactive tutorial that covers essential modeling and simulation, along with a step-by-step online help guide. These training tools are a perfect way for you to learn how to use the discrete-event simulation modeling techniques in Plant Simulation, to increase your productivity and gain the skills required by some of the world’s leading engineering and product design companies.

Tecnomatix Plant Simulation Student download

TECNOMATIX

Demonstration of the different behavior of an assembly line once with a Push-control and then again with a Pull-control (Kanban) – Andreas Eiband, October 2011 Student Plant Simulation Contest Winner.


tecnomatix plant simulation

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