the digital enterprise ewa – elektronikwerk amberg · efficient and flexible production execution...
TRANSCRIPT
Unrestricted © Siemens AG 2016
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Site Amberg
Plants & Products
SIMATIC PLC - Programmable Logic Controller
DP - Decentral Periphery
HMI - Human Machine Interface
Aktuelle Position
SIRIUS
Contactors
Circuit board assembly/
Electronic Products
Push buttons and
signal columns Production metal parts
and assembly groups
DF FA MF EWA
DF CP MF GWA
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The products of EWA – SIMATIC
Programmable Logic
Controller SIMATIC S7
Human Machine Interface
SIMATIC HMI
Decentral IO system
SIMATIC ET 200
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EWA development Industrie 1.0 to 4.0
Industrie 1.0/2.0 • Mechanical production lines
• Mass production
• Manual drawings
SIMATIC
Industrie 3.0 • Automated production
• Lean production
• Intranet and Internet
1995
2015
1966
SIMATIC
On the way to Industrie 4.0 • Digital Product Lifecycle
• Horizontal and vertical integration
• Identification and history for all elements
Contactors
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The Internet is revolutionizing the world of business
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The main challenges and drivers in the industrial environment
• Shorter
innovation cycles
• More complex products
• Greater data volumes
Shorten time
to market
• Individualized
mass production
• Volatile markets
• High productivity
Increase
flexibility
• Energy efficiency and
resource efficiency are
critical competition
factors
Boost
efficiency
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Industrie 4.0
German future project for the vision of industrial production
Source: acatech, April 2013 “Umsetzungsempfehlung für das Zukunftsprojekt Industrie 4.0”
• Horizontal integration of the value-
add networks
• Seamless integration of the
engineering
of the entire value-add chain
• Vertical integration and networked
production systems
Cornerstones of the initiative Industrie 4.0
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Only a holistic automation approach…
…can cover all Industrie 4.0 requirements
Real World
Digital World
1 2 3
5 4
Product Design
Production Planning
Production Engineering
Production Services
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The Digital Enterprise Software Suite…
…our answer to Industrie 4.0 requirements
PLM
PLM Software
• Product Planning, Design,
Test and Simulation
• Production Planning,
Engineering and Simulation
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Product Lifecycle Management
Bring ideas faster to life
„Digital Twin”
Integration of digital
and real world of
product and
production
Seamless data flow from product idea to production
Consistent data management for all PLM tools
Leverage Big Data to gain insights into complex, global processes
Customer Challenge PLM Portfolio
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The Digital Enterprise Software Suite…
…our answer to Industrie 4.0 requirements
MES
• Planning & Scheduling
• Quality Management
• Manufacturing Execution
• Manufacturing Intelligence
• SCADA / HMI
MES Software
PLM
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Manufacturing Execution Systems (MES)
Efficient and flexible production execution
0
5
10
15
20
25
30
1970 1980 1990 2000 2010
SUV
Sports car
Coupés
Luxury class
Medium luxury class
Medium class
Compact class
Sub-Compact class
Example: Audi AG
Source: Wikipedia 2014, Audi AG
Development of number of automotive classes Customer Challenge
Flexibility in
execution to
handle high
number of
variants
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The Digital Enterprise Software Suite…
…our answer to Industrie 4.0 requirements
Integrated Automation
• Integrated Engineering
and Runtime for
Controllers, Remote I/O,
HMI, Drives, Motion
Control and Motors
• Industrial Safety and
Security
TIA
PLM
MES
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Integrated Engineering with TIA Portal…
…save up to 30% of engineering time
Unique and consistent user
interface concept
Common and centralized services
One common framework
Security Integrated
Safety Integrated
Diagnostics
PROFINET
Common Data Management
HMI Controller Distributed
I/O
Motion
Control Drives
WinCC Step7 Scout Startdrive
Totally Integrated Automation Portal
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The Totally Integrated Automation portfolio for factory automation
Enterprise Level
Management Level
Operator Level
Control Level
Field Level SIMATIC NET Industrial
Communication
SIMATIC Controllers
SIMATIC IDENT Industrial
Identification
SIMATIC Distributed I/O
SINAMICS Drive Systems
SIRIUS Industrial Controls
SINUMERIK CNC
SIMATIC HMI
SIMOTION Motion Control
TIA PORTAL Engineering
Framework for
Automation Tasks To
tall
y In
teg
rate
d
Au
tom
ati
on
SIMATIC IT
Intelligence Suite
SIMATIC IT
Production Suite
SIMATIC IT
R&D Suite
PLM ERP
MES
SCADA
SIMATIC WinCC SCADA System
TECNOMATIX
Digital
Manufacturing
TEAMCENTER
Collaborative
PDM
NX
Product
Development
Plant Cloud
Services
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Already today, customers can invest in future-proof solutions…
…for Industrie 4.0 with Siemens’ Digital Enterprise
• Digital Enterprise…
…the Siemens portfolio for the implementation of Industrie 4.0
• Digital Enterprise portfolio elements…
…built on class-leading portfolios of PLM, MES, Automation
... are already available today
• Digital Enterprise comprises …
…the Digital Enterprise Software Suite
…and Totally Integrated Automation
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Siemens: Realization of our own Digital Factory
Electronics Works Amberg
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Siemens: Realization of our own Digital Factory
Electronics Works Amberg: Reducing time-to-market
• Shorter innovation cycles
• More complex products
• Bigger but smarter data volumes
Reducing
time-to-market
~ 5000 work plan changes per year
(> 20% due to component
discontinuation)
> 120 variations are built per day
based on 75% automation
~ 50 mill. process & product items
entered in SIMATIC IT per day
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Siemens: Realization of our own Digital Factory
Electronics Works Amberg: Enhancing flexibility
Enhancing
flexibility
• Mass customization
• Volatile markets
• Highest productivity
~ 350 changeovers per day to handle
1000 different products
> 99.5% delivery reliability to assure
24h delivery time
± 20% personal capacity flexibility to
meet customer demand on time
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Siemens: Realization of our own Digital Factory
Electronics Works Amberg: Increasing efficiency
Increasing
efficiency
• Optimal capacity utilization
• Highest quality standards
• Efficient resource utilization
> 75% line utilization (+ 20% flexibility)
to serve 60,000 customers
~ 11 dpm-A equals 99.9989% built in
quality
~ nine-fold of shop floor utilization till
start of production (1990) equals 1pc./
sec.
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Electronics Works Amberg
Consistency from design to production
Simatic IT
Customer
NC-Programmgenerator Routing ERP
Teamcenter
Templates SMT SPI AOI ICT / FP
X-Ray THT Labels IFT Inspection
Supplier
Production order
Capacity
Inventory Mgmt. Process interlocking
Traceability
Serial number report
Test protocol
BOM
Ressource
Routing
Relevant product
data information
Intelligent
preprocessing
Material forecast
Automatic order
Delivery
Immigration …
Altsysteme
PLM Software (NX)
Recipe
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Gapless monitoring of the entire value-added chain
Intuitive Drilldown
Analyzing and management
information
Watchdog and push mails
Two mouse clicks from plant view…
Big Data to Smart Data
…to unicum
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Our employees are integrated into the Digital Factory
Fully digital supported work
Test instruction/
Data Collection
Packaging
Label Printing
History
Monitoring
Pack parts
Product provision
Scanning
Product provision
Scanning
Label Printing
Entry in history
Conditions
satisfied
Selection:
CV, Test instruction
Check &
collect
History
check
Monitoring
packing list
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Only what is measured can be improve
dpm-A (log)
1
10
100
1000
90/91 92/93 94/95 96/97 98/99 00/01 02/03 04/05 06/07 08/09 10/11 12/13 14/15
Amount of Process Data per Day • 1995: > 5,000
• 2000: > 50,000
• 2015: > 50,000,000
Equipment > 1,000 Online Checkpoints
> 1,000 Scanners
> 1,000 Machines online
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How can digitalization of
manufacturing improve
your business?
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Digitalization of Manufacturing
Manufacturability
analysis Process
planning
Prozess
Validation Layout
Throughput
optimization Execution