Industrie 4.0 – Digitalization Strategy · PDF file6/17/2015 · and powerful...
Transcript of Industrie 4.0 – Digitalization Strategy · PDF file6/17/2015 · and powerful...
Unrestricted © Siemens AG 20152015-06-17Page 1 Siemens PLM Software
Industrie 4.0 – Digitalization Strategy2015 Plant Simulation Worldwide User Conference – Dr. Ulrich Rossgoderer
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Virtual world Real world
T I ATotally IntegratedAutomation
PLMProduct LifecycleManagement
Productionplanning
Productionengineering
Productionexecution
Productdesign
Digital Enterprise Platform
The Digital Enterprise Platform merges sophisticated PLM Softwareand powerful automation technologies, optimizing the entire value chain.
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Organization
Customer Services
Product LifecycleManagement
FactoryAutomation
ControlProducts
eCar PowertrainSystems
MotionControl
Integrated product portfolio paves the way for the Digital Enterprise.
Digital Factory Division
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Digital “Factories of the Future”Public/Private Partnerships
Realizing next-generation product/production processes
DIGITAL MANUFACTURING ANDDESIGN INNOVATION INSTITUTE
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Roadmap towards Industrie 4.0:Evolution, not Revolution
Introduction of electronicsand IT to further automateproduction
Integration and optimizationof the entire productdevelopment process
Industrie 4.0 –Self-optimization ofcyber-physical systems(CPS)
On the way to Industrie 4.0
1960 2010 2030
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Cyber-physical systemshave all the information as a digital model
ServicesProductionexecution
Productionplanning
Productdesign
Productionengineering
The digital model is always up-to-date and is extendedover the entire lifecycle
• Software / Informatics• Mechanics,• Electrics, Electronics• Automation, HMI• Safety, security• Maintenance
Cyber-physical system (CPS)
Physical production facility Digital model
• Location,identity…
• Status• SW version• Interfaces• …
Contains all the information on …
+
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Digitalization is Transforming the Manufacturing Industry
Smart ModelThe product model sets the objectives needed to produceitself
Digital TwinFull digital product definition that simulates reality
Optimized, Distributed ProductionAutonomous production with embedded intelligence.
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Our Digitalization Portfolio
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Siemens Integrated Product/ProductionDigital Factory HW and SW Portfolio
PLMTECNOMATIX
DigitalManufacturing
TEAMCENTERCollaborative
PDM
NXProduct
Development
SIMATICHMI
SIMATICControllers
SIMATIC IDENTIndustrial
Identification
SIMATICDistributed I/O
SINAMICSDrive Systems
SIMATIC WinCCSCADA System
SIMATIC NETIndustrial
Communication SIRIUSIndustrialControls
SINUMERIKCNC
SIMOTIONMotion Control
TIA PORTALEngineering
Framework forAutomation
Tasks
SIMATIC ITProduction
Suite
SIMATIC ITIntelligence
Suite
Field Level
Control Level
Enterprise Level
Management Level
Operator Level
ERP PLM
MES
SCADA
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Siemens PLM Software Integrated Product/Production
Design/ManufacturingCollaboration
Plant planningand feedback
IntegratedPlanning and
Simulation
Process andLayout
Collaboration
Ramp-up support
Global Production and Supplier Collaboration
JT – 3D Collaboration on ISO Standard
Teamcenter – Integrated Product/Production Platform
Product
Data
Plant
Data
Resource
Data
Process
Data
Collaboration through a common platform
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The Future of Manufacturing1. Faster development of product design through PLM software
Productdesign
Productionplanning
Productionengineering
ProductionService
12
3 4 5
Virtual Development &Planning with PLM Software
Reduced development times
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Product Design- Product Planning -
Program Management Product Data/Change Management
Requirements/System/Functional Definition Global Collaboration
ProductDesign
Productionplanning
Productionengineering Production Service
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Product Design- Product Development -
Concept Layout and Styling Multi-discipline Design
Analysis and Simulation Computer-aided Manufacturing
Text
ProductDesign
Productionplanning
Productionengineering Production Service
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Product Development DemonstrationRequirements Driven Product Development
Roof opening requirement
Roof openingobstruction requirement
Increase apertureopeningrequirement
Requirement:Open/ close time to meet marketexpectation
Criteria:Overall cycle - 7.6 sec.Retract target - 6.5 sec.Tilt target - .9 sec.
Requirement:During closure roof must reverseif obstructed
Criteria:Maximum pressure onobstruction not to exceed 40N
Requirement:Customer forum - Sun roofaperture needs to increase
Criteria:Increase runner to maximum sizemeeting roof crush properties
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Today’s Product Challenges areMore Difficult Than Ever Before…
Landing on Marsis one of the hardestjobs on Earth.
On August 5, the Mars rover Curiosity landed successfully on thesurface of Mars. There was only one chance to get it right. For thisunprecedented challenge, NASA employed Siemens PLM softwaresolutions. The development team at NASA’s Jet PropulsionLaboratory digitally designed, tested, assembled, and simulated theentire Mars rover before a single physical prototype was created.
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Digital ModelLeverage Hybrid Machining for Replacement Parts
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Digital Model (https://www.youtube.com/watch?v=s9IdZ2pI5dA)Leverage Hybrid Machining for Replacement Parts
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The Future of Manufacturing2. Simulation of production planning reduces time to market
Productdesign
Productionplanning
Productionengineering
ProductionService
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3 4 5
Complete Simulation &Optimized Production
Up to 50% reducedtime to market
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Smart Models in Production PlanningExample: Energy Efficiency
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Problem Statement
Not only the CO2 emission during use of a product isrelevant but also the CO2 emission spent duringmanufacturing
Therefore manufacturing companies are giving moreand more attention to energy efficiency of theirfactories
Besides using more smart and more energy efficientequipment, the manufacturing processes themselvescan be optimized for energy efficiency as well
Digital Models should help analyzing various energysaving scenarios without disrupting runningproduction
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Green Carbody Technology Research Project
INDUSTRYROBOTS
INDUSTRYROBOTS
LOGISTICSMATERIAL FLOW
LOGISTICSMATERIAL FLOW
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SustainabilityPROFIenergy Profile
Plant Simulation supportsthe creation of simulationmodels testing the effectsof PROFIenergy relatedenergy control strategiesfor manufacturingequipment.
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Case Study
Saving 1.66 Mio kWh per year through“start-stop” control strategy for machines
Measurement did match simulationprediction
Additional 1.4 Mio kWh saving throughturning of high-pressure pumps for coolinglubricants in case of idling machines
Positive side-effect: noise reduction
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Energy Simulation in Tecnomatix Process Simulate
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Tecnomatix Process SimulateRobot – Human Interaction
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Digital Twin in Production Planning
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Problem Statement
Most planning projects are dealing with “brown-fieldplanning”
Can I use my current production line for a new ormodified product?
Can I fit another piece of equipment into my currentproduction line?
I would love to do this in a digital model withoutdisturbing running production, but:• Do I have a complete enough digital model?• Can I be sure that my digital model matches reality?
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• Verify plant installation 3D-CADgeometry and point cloud
• Plant items designed in CAD will beverified against actual scans
• Integrate factory design with PLM• Re-use of point cloud data with
Bentley .POD format• Change Management between
process and layout engineering
• Visualize the assembly process inthe real plant context
• Adjust simulation layout accordingto “as built” plant
Usage of Point Clouds in Digital Manufacturing
Planning in factory context* Visualization of point clouddata and planning data
Simulation and verification
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Hannover fair Siemens boothLaser scanning workflow
Survey andScan
Registration& Pre-
processing
Referencescan inProcessPlanning
model
Simulationand
Validation
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Hannover fair 2014 – Laser scanning of Siemens Future ForumLaser Scanning process and pre-processing
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Hannover fair 2014 – Laser scanning of Siemens bothTecnomatix Process Simulate - Reference scan in Process Planning model
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3D Scan Use-Case Material FlowSiemens Stuttgart
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Digital TwinDynamic Human Motion – Record and Analyze
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The Future of Manufacturing3. Cost savings through highest efficiency in production engineering
Productdesign
Productionplanning
Productionengineering
ProductionService
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Smooth Communicationof all components
Integration of all Automation Functions
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Operation
Typical Engineering and Commissioning
Mechanical Engineering
Physical
Commissioning
Testand
Debug
Job 1
Automation Engineering
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Operation
New Engineering and Commissioning
Virtual
Comm.
Testand
Debug
Physical
Comm.
Job 1MechanicalEngineering
AutomationEngineering
Job 1
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Team
cent
er
From Planning to Virtual Commissioning On All Levels
Planning, Validation, Commissioning
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Process SimulateVirtual Commissioning
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The Future of Manufacturing4. Efficient Production based on one high performance network technology
Productdesign
Productionplanning
Productionengineering
ProductionService
12
3 4 5
Fully integratedProduct & System Portfolio
Data integration fromshop-floor to top-floor
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ProductionDigital Twin – Plant Behavior
Customer Value:• Analyze impact and demand for manufacturing
changes• Determine production system parameters based on
actual order look-ahead
Our approach:• Maintain a precise behavior model of your factory• Leverage data from MES and Order systems to
feed the model• Allow for on-demand simulations, where the model
represents the current real production to the bestpossible level
ProductDesign
Productionplanning
Productionengineering Production Service
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Production
Manufacturing
Quality SolutionsIntegrating Design, Manufacturing and Production
Design
Continuous improvement through a PLM Platform
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Overlaying Production Measurement with Virtual Planning
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Big Data for DPV in ProductionParsing 1.6 million data files a month
Data Load Verification and Transformation:Automatically extract translate & load plant floormeasurement data to Teamcenter:• Real time data flow from 360+ data drops around
the world.• ~.8 GB of measurement database inserts a day.
Advanced Analysis:SSAS Cube – multidimensional statisticalaggregations:• Automating multiple complex quality metric
calculations for monthly, weekly and daily basis.• ~.6 GB of stored statistical calculations a day
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Digitalization is Transforming the Manufacturing Industry
Smart ModelThe product model sets the objectives needed to produceitself
Digital TwinFull digital product definition that simulates reality
Optimized, Distributed ProductionAutonomous production with embedded intelligence.
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Visit us online today and get in on the conversation:
Tecnomatix Manufacturing Discussion Forum
www.siemens.com/plm/community/tecnomatix
World Wide Web
www.siemens.com/tecnomatix
www.siemens.com/plm
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