Smart Factory and Efficient Engineering 4.0 Maximilian ... · Smart Factory and Efficient...

Comprehensive solutions are our responsibility.

Efficient engineering is our mission.

Optimised engineering processes are our promise.

Smart Factory and Efficient Engineering 4.0 Maximilian Brandl, CEO EPLAN, March 20th, 2015

Efficient Engineering 4.0 | Maximilian Brandl | March 20th,2015 1

Vorführender

Präsentationsnotizen

Agenda

Introduction – Engineering 4.0 1

Three major levers 2

Implementation and summary 3


EPLAN is part of an internationally successful group

F.L.G. global group: > 11,000 employees worldwide

> 2.0 billion euros (in 2013)


Friedhelm Loh Group (F.L.G.)

Friedhelm Loh, Owners of the Friedhelm Loh Group

As a TOP employer, F.L.G offers a multitude of vacancies worldwide

EPLAN Software & Service More than 700 employees worldwide

Around 45,000 customers and 110,000 installations

Software in 17 languages and 50 countries

The enormous relevance of engineering...

Efficient Engineering 4.0 | Maximilian Brandl | March 20th,2015

Proportion of overall costs determined in engineering

4

...also for Industry 4.0

~ 5% ~ 10%

~ 70%

~ 5% 0

Source: www.dasWirtschaftslexikon.com „Konstruktion“

~ 18% ~ 7%

~ 54%

~ 28%

~ 3%

50

100

Prime costs [%]

Construction development

Production preparation

Production Materials logistics

/suppliers

Distribution/ admin.

Incurred costs (allocated)

Determined costs, partially controllable

The relevance of engineering/development/construction is extremely high. Engineering is an innovation driver and job generator

http://www.daswirtschaftslexikon.com/

PDM/Big Data

a. Networking with neighbouring engineering disciplines: -> Mechatronics

b. Networking along the value chain across the whole life cycle: -> Integrated value chain

c. Combination with the relevant product data: -> PDM/Smart Data

Three main levers...


...each with extremely high potential

5

Work preparation

Construction/engineering

Order entry

Production

Operation/service Mechanical Electrical

Software

Mechatronics

Agenda





Mechatronics a.

Integrated value chain b.

PDM/Big Data c.

Mechatronics: Interdisciplinary engineering Comprehensive view of a product


Five different disciplines need to "collaborate" in this project

Typical sequence x

1

3

4

2

5

Vorführender


Even in this field there have been considerable changes in the PDP in recent years and not everything that is discussed in the context of Industry 4.0 is new to the engineering sector. In this way, the classic switch cabinet and switchgear construction is now integrated into the comprehensive, interdisciplinary and mechatronic view of increasingly complex machines and systems. This is because the modern engineering process is ideally composed in an interdisciplinary way and views an envisaged product holistically. As here in the example of a Heller machine tool. The company Heller has merged its electronic and mechanic construction departments into one mechatronic department.

Example: Mechatronic Bill of Material

8

M - Product structure Machine

- Motor

- Switch

- Switch

-M1 motor

-S1 switch

-S2 switch

E - Product structure Machine

Mechatronic collaboration – how?

?

Completely symbolic representation Each component with EIS

(equipment identifier) Unique connection points (terminals) Functional relationships determined with EIS

Physical representation Symbols for simplifying work Position numbers and collective BoM Manufacturing and assembly focus


Electrical engineering

Mechanical engineering

?

A holistic view - consisting of M and E components must be developed, including product functions and features

Vorführender


We have just looked at the challenges that come with mechatronic work on an abstract level. I would now like to focus on how this demand can be combined with this world's specific conditions. We were already able to experience at the beginning that the trades now generally do not work perfectly together. First and foremost, this has nothing to do with IT solutions.

Goals of mechatronics

What are the potential benefits of mechatronics?

Significant expansion of the "solution space"

Consistent reuse of mechatronic components

Mechatronic configuration / variant configuration

How do I implement mechatronics?

Consolidated BoM with unique description and central administration

Parallel and synchronized engineering processes

Mechatronic requirements management

Mechatronic change and approval processes


Very extensive changes are necessary in internal processes and in the tool landscape, too

Mechatronics will be enabled by a joint PDM / PLM system


Data exchange CAD/authoring systems – PDM /PLM: the first step

Siemens NX EPLAN PTC Creo EPLAN EPLAN MCAD ...

EPLAN Vault

Status, documentation and workflow management Product synchronisation Creation and updating of BoM

Project administration Change management Version control

Siemens PTC SAP/PLM Autodesk

In the first step, the PDM systems could develop into a "hub for mechatronics"

PLC collaboration also extremely relevant ECAD – PLC software date exchange


PLC/BUS configuration PLC component data Rack design - BUS structure Wiring

Designation lists Layout of PLC connections Function texts PLC addresses

Bidirectional data exchange

11

http://www.as-interface.net/Company/PhoenixContact

Mechatronics with extremely high customer benefits ECAD example with PLC

"With the EPLAN Electric P8 macro in the .edz format (EPLAN archived data

zipped) the time needed for data integration can be reduced even further (by up to

95 %). All product data necessary for project planning, ordering and

documentation is already contained in the exchange format and can be imported

in just a few clicks for as many order numbers as desired."

Christoph Hotz, Head of Marketing & Strategy, Industry Sector I IA CE, Siemens AG

"By using bidirectional interfaces between Rockwell Automation RS Logix 5000

and EPLAN Electric P8, our customers save up to 50% in the development of

'advanced PLC control Solutions.'"

Steve Pethick, Director for Components and Safety Business EMEA, Rockwell Automation


"Revolutionary" high saving of >50% with ECAD-PLC interfaces!

Agenda





Mechatronics a.


PDM/Big Data c.

Integrated value chain – "downstream potential"

Planning & configuration

Detail engineering


Upstream

Technology engineering

Production planning

Manufacturing & assembly

Operation & service

Downstream

14

Over the product life cycle

Seamless flow of data

Vorführender


A further essential aspect of a holistic, interdisciplinary engineering process: Consistent product development from preliminary planning through to operation, service and repair

Example 1: EPLAN Fluid simulation interfaces

"Documentation supports simulation" (transfer of circuitry structures, technical component data)

15

Interface

DSHplus


EPLAN Fluid as data supplier for the external simulation tool "DSHplus"

Vorführender


In addition, virtual start-up is supported by this tool.

Example 2: Heat pockets & hotspots in a switch cabinet


Green Carbody Demonstrator project

Equipment with representation of heat loss Optimization potential in engineering

Representation of active components

16

Amount of dissi-pation loss

Self-ventilation / component ventilation

Min. installation distances as per manufacturer's

guidelines

For the technologically correct installation of a virtual prototype, extensive manufacturer info for component data is indispensable.

Vorführender


The Green Carbody demonstrator project is being carried out as part of the Green Carbody Alliance for energy-efficient switch cabinet cooling. Even exceeding the manufacturer's recommended temperature by only 10° can lead to a 50% reduction in the service life. In addition, an unexpected breakdown is likely.

Example 3: The F.L.G value chain


From engineering to manufacturing of control cabinets

Averex

Rittal production knowledge

Rittal product knowledge

1. Cutting holes

2. Assembly of components

3. Automatic wiring

Perforex

Fully automated value chain from engineering to production of control cabinets

Example 4: Integration with operators Seamless workflow over complete product live cycle up to operations

Engineering Operators


Production knowledge

Operation data Changes

Flow of information: New/other components Changes, updates Problem areas Maintenance information

EPLAN Viewer

Faster start-up without any "surprises" Additional help for maintenance personnel during downtime Optimum data quality during maintenance and modification by revision management Additional differentiation with regards to competing suppliers possible

18

Engineering data

Continuous data exchange between engineering and after-sales service, documentation from "as built" to "as used"

Example 5: Direct data exchange with PLC


Outlook – OPC communication during start-up

Online communication between EPLAN and PLC control/software via OPC UA as common language for data exchange Access to the PLC inputs and outputs via OPC UA

Visualising the status of I/O and sensors/actuators in the schematic diagram

Activating sensors in the schematic diagram with effect on PLC control

Validating the PLC control in combination with the schematic diagram

Outlook: circuit validation today not yet fully virtually enormous potential for the future Possible „quantum leap“ in collaboration between engineering and

operation with high potential benefits

Integrated value chain

Planning & configuration

Detail engineering


Upstream

Technology engineering

Production planning

Manufacturing & assembly

Operation & service

Downstream

Seamless flow of data

20

Over the product life cycle

Vorführender


A further essential aspect of a holistic, interdisciplinary engineering process: Consistent product development from preliminary planning through to operation, service and repair

Example 1: Configuration of components

Web configuration by EPLAN data via Endress+Hauser homepage

Endress + Hauser Configurator integrated into EPLAN data portal

Generation of EPLAN data with the EEC (commercial data, macros, data sheets)


Web-based product configuration

Configuration of complex component combinations can be web-based and automated

Product configurator

EPLAN Data Portal

Process (e.g. special purpose machines) based upon „building blocks“

Engineering

Classical process for custom-made prducts:

Production 20% ETO

Production Marketing Engineering

100% ETO

80% CTO

Building blocks

Development

Construction Marketing

ETO … Engineering To Order CTO … Configure To Order

22

Example 2: Mechatronic configuration of a plant


CTO instead of ETO saves time, reduces costs and increases quality

Agenda





Mechatronics a.


PDM/Big Data c.

Seamless information flow in product lifecycle Success factor – Digitalisation and virtualisation

Fluid & electro-engineering

Mechanical engineering

Preliminary planning

ERP/PPS

PDM

Component data data

Virtual layout

PLC programming Thermal design

Production Test - operation -service


Appropriate component data necessary for all steps during product development lifecyle

Vorführender


Even the digitalization and virtualization of the product development process required in the context of Industry 4.0 has today been realized to a large extent. [ Click] In this way, powerful tools are available as early as in the preliminary planning stage for the structuring of machines and plants. Their data can then be used again in detail engineering. With this, other trades are incorporated, [Click] with the help of expert systems and the consistent data discussed ... [Click] ... hardware engineering and virtual planning for technological implementation is carried out in 3D – Key word virtual prototyping [Click] Overlapping methods, workflows and interfaces integrate the authoring systems in ERP concepts and PLM strategies [Click] Up to the provision of manufacturing data e.g. for switch cabinet construction or cable assembly – consistent and without system or media disruptions [Click] Summarized in the as built product documentation as a guideline for QA and testing, commissioning, operation service or repair. [Click] Next slide

Success factor: Completeness of component data

Logic information

Connection and wiring lists

Drawings, component and assembly lists

Assembly construction (3D macros)

Electrical macro for schematic diagramm

Data for ordering and disposition

Data for terminal mounting robots

Control of wiring robots

Master data with commercial information

3D data for analysis and optimization

Project & product documentation "as built"

Control of (NC) assembling machines


ECAD MCAD PLC

25

In some cases a total of > 100 data fields are required per item/component

Vorführender


This raises the questions: If engineering has advanced so much today and �all covers and supports all areas of product development, �is that not enough to meet the demands, that �Industry 4.0 will place on engineering in future? NO! Lets take a look at Industry 4.0 from the point of view of switchgear and control engineering. [Click]

EPLAN Data Portal ensures consistency

Online availability

> 480,000 items/components

72 manufacturers

17 languages

> 70,000 users

Simple "drag & drop"

Very fast engineering without discontinuities

26 Efficient Engineering 4.0 | Maximilian Brandl | March 20th,2015 26

Strong demand – among customers as well as among component manufacturers

Vorführender


Max. 50% of today's product development processes are digital Max. 50% of the necessary data are provided digitally The majority of processes in product development and production are shaped by incompatible systems and incompatible data.�

Agenda





Summary "Engineering 4.0":

1. Complete virtual product development with complete virtual representation of the machine – without additional learnings in live operation

2. High level of flexibility via building blocks and standardization even for „segment of one“ – for the same price as the standard product

3. Cross-manufacturer and cross-system consistency – without media disruptions

4. Use of engineering data throughout complete product life cycle (service, modification, etc. ) – instead of only in the engineering disciplines

5. Ever increasing intelligence via network and self-learning systems – instead of only the original manufacturer's know-how


We are already on our way in the new direction, but goals are far ahead

Let us join forces for this way into the future!


Yesterday

Today

Tomorrow: "Industry

4.0"

Which topics should I address today? – discontinuously if

necessary ...?

…instead of running in the wrong direction?

"Reverse polation" instead of "extrapolation" from the customer's perspective


Thank you!

Smart Factory and Efficient Engineering 4.0 Maximilian ... · Smart Factory and Efficient...

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