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The Digital EnterpriseEWA – Electronics Works Amberg
April 2017Unrestricted © Siemens AG 2017
Unrestricted © Siemens AG 2017Page 2 DF FA MF
Site AmbergPlants and Products
SIMATICPLC - Programmable Logic ControllerDP - Decentral PeripheryHMI - Human Machine Interface
SIRIUS
Contactors
Circuit board assembly/Electronic Products
Push buttons andsignal columns Production metal parts
and assembly groups
DF FA MF EWA
DF CP MF GWA
Unrestricted © Siemens AG 2017 All rights reserved.
Page 3
Excellence in Manufacturing – For our Customers
Dr. Gunter BeitingerVP of Manufacturing
Our Mission
67%15%
6%12%
VA contribution by Location( ~ 85% in Germany) SEWC Chengdu (China)
SE MF Fürth (Germany)Non FA (90% Germany)
1250 1000390 200
Number of MF Employees Per Location
Our Vision
Our Locations„
Be the Role Model for Excellence in Manufacturing to provide proven Value Add for our Customers and Business Unit, based on the methods of Digital Enterprise and Lean Industrial Engineering
Shape the Digital Future. Together.
Dr. Gunter Beitinger, Vice President Manufacturing (Lebanon)
(Nanjing)
(Karlsruhe)
Amberg
Fürth
EWA SEWCSE MF
EWA Amberg (Germany)
Non FA
Chengdu
(location) = non FA locations producing FA products*) approx. 200 MF employees producing FA products
*)
Frei verwendbar © Siemens AG 2017Seite 4 DF FA MF
Produkte des EWA – SIMATIC
Programmierbarer Logik-Controller SIMATIC S7
Bedien- und Beobachtungssysteme
SIMATIC HMI
Dezentrales IO System SIMATIC ET 200
Unrestricted © Siemens AG 2017 All rights reserved.
Page 5
Industrie 4.0: The Vision of the Future of Manufacturing
Electronic Works Amberg~1.260 Employees>15 Mio. Products per year
1 Product per Second>60.000 Customers worldwideQuality level of >99,9989%
Unrestricted © Siemens AG 2017Page 6 DF FA MF
Digitalizationchanges
everything
Unrestricted © Siemens AG 2017 All rights reserved.
Page 7
The Answer to the Question:„How can I become a smart factory?“
Automation
• Automated Production• Smart Line Concepts• Industrial Engineering• Plug & Communicate Specification
Digitalization
• Digital Lifecycle Readiness• Horizontal and Vertical Integration• Identification and History for all Elements• Smart Data Management• Manual/ LCA Production
• Standardized Work Instructions• Ergonomic Workstation Design• Focus on Tact Time
Organization
Unrestricted © Siemens AG 2017 All rights reserved.
Page 8
The Totally Integrated Automation portfolio for factory automation
Enterprise Level
Management Level
Operator Level
Control Level
Field Level SIMATIC NETIndustrial
Communication
SIMATICControllers
SIMATIC IDENTIndustrial
Identification
SIMATIC Distributed I/O
SINAMICSDrive Systems
SIRIUSIndustrialControls
SINUMERIKCNC
SIMATICHMI
SIMOTIONMotion Control
TIA PORTALEngineering
Framework for Automation TasksTo
tally
Inte
grat
ed
Auto
mat
ion
SIMATIC ITIntelligence Suite
SIMATIC IT Production Suite
SIMATIC IT R&D Suite
PLMERP
MES
SCADA
SIMATIC WinCCSCADA System
TECNOMATIXDigital
Manufacturing
TEAMCENTERCollaborative
PDM
NXProduct
Development
Plant CloudServices
The Totally Integrated Automation portfolio for factory automation
Unrestricted © Siemens AG 2017Page 9 DF FA MF
Essential requirements –throughout the manufacturing industry
Security
Speed Flexibility Quality Efficiency
Unrestricted © Siemens AG 2017Page 10 DF FA MF
Integrating and digitalizing the entire value chainis key to staying competitive in the future
Cloud-based, open IoT operating system: MindSphere
Third party applications
Suppliers and logistics
Collaboration platform: Teamcenter
ServicesProductionexecution
Productionengineering
Productionplanning
Productdesign
Unrestricted © Siemens AG 2017Page 11 DF FA MF
Creating a Digital Twin of the entire value chainIntegrating and digitalizing the entire value chainis key to staying competitive in the future
Productdesign
Productionplanning
Productionengineering
Productionexecution
Services
Collaboration platform: Teamcenter
Suppliers and logistics
Third party applications
Cloud-based, open IoT operating system: MindSphere
Productdesign
Productionplanning
Productionengineering
Productionexecution
Services
Unrestricted © Siemens AG 2017Page 12 DF FA MF
And only the holistic automation approach……can cover all Industrie 4.0 requirements
REAL WORLDDIGITAL WOLD
Unrestricted © Siemens AG 2017Page 13 DF FA MF
Product Lifecycle ManagementBring 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 toolsLeverage Big Data to gain insights into complex, global processes
Customer Challenge PLM Portfolio
Unrestricted © Siemens AG 2017Page 14 DF FA MF
Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Reducing time-to-market
• Shorter innovation cycles• More complex products
• Bigger but smarter data volumes
Reducingtime-to-market
~ 5,000 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 per day
Unrestricted © Siemens AG 2017Page 15 DF FA MF
Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Enhancing flexibility
Enhancingflexibility
• Mass customization• Volatile markets
• Highest productivity
~ 350 changeovers per day to handle more than 1,000 different products
> 99.5% delivery reliability to assure 24h delivery time
± 20% personal capacity flexibility to meet customer demand on time
Unrestricted © Siemens AG 2017Page 16 DF FA MF
Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Ensure stable quality
Ensure stablequality
• Decreased production failure• Increased product quality
Production process defect dropped to11dpm (99.9989% built in quality)
Field return rate decreased by 79% in last decade
Unrestricted © Siemens AG 2017Page 17 DF FA MF
Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Increasing efficiency
Increasingefficiency
• Optimal capacity utilization • Efficient resource utilization
> 75% line utilization to serve 60,000 customers
~ tenfold of shop floor utilization till start of production (1990) equals 1pc./ sec.
Unrestricted © Siemens AG 2017Page 18 DF FA MF
Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Security in production
Security inproduction
• System Protection• Network Protection
• Plant Protection
Secure production environment:- separated networks for production- secure cell principle in use
Protection level 3 in selected areas
Integrity: The software we developed is exactly what is in your product!
Regularly Security Awareness training
Unrestricted © Siemens AG 2017 All rights reserved.
Page 19
Perfection and Productivity through Automation @ EWA
More than 75% Automation• Production• Material- and• Information flow
More than 1,000 SIMATIC applications
Unrestricted © Siemens AG 2017Page 20 DF FA MF
Electronics Works Amberg Consistency from design to production
Simatic IT
Customer
NC-ProgrammgeneratorRouting 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 productdata information
Intelligent preprocessing
Material forecastAutomatic order
Delivery
Immigration …
Legacy Systems
PLM Software (NX)
Recipe
Unrestricted © Siemens AG 2017 All rights reserved.
Page 21
A maximum of transparence for logistics and quality
Identification of all objects and process• All products, parts,…• All machines, adapters• All programs, data, …
Record of all process values• Soldering temperature• Pass or fail• Torque …
Autonomous process analysis• Real-time• All employees• All processes
Record big data and push smart data
EWA-Unified Label
Unrestricted © Siemens AG 2017 All rights reserved.
Page 22
Gapless monitoring of the entire value chain
Intuitive drilldownAnalyzing and management informationWatchdog and push mails
Big data to smart data
Two mouse clicks fromplant view to unicum
Unrestricted © Siemens AG 2017Page 23 DF FA MF
Our employees are integrated into the Digital Factory
Fully digital supported work
Test instruction/Data Collection
Packaging
Label Printing
History
MonitoringPack parts
Product provision
Scanning
Product provision
Scanning
Label Printing
Entry in history
Conditionssatisfied
Selection: CV, Test instruction
Check & collect
Historycheck
Monitoringpacking list
Unrestricted © Siemens AG 2017 All rights reserved.
Page 24
0
100
200
300
400
500
600
90/91 91/92 92/93 93/94 94/95 95/96 96/97 97/98 98/99 99/00 00/01 01/02 02/03 03/04 04/05 05/06 06/07 07/08 08/09 09/10 10/11 11/12 12/13 13/14
Our Success with “Design to Quality”
dpm-A
08/09 09/10 10/11 11/12 12/13 13/14
19 171416
12,5 11,5
Success through quality
Perfection for our customers
Unrestricted © Siemens AG 2017 All rights reserved.
Page 25
Success through logistics performance
Highest Quality and Efficiency
89.0%
94.0%
97.0%98.0% 98.0%
99.4% 98.9% 99.4%98.0% 98.6% 98.0% 98.9%
99.9% 99.8% 99.6% 99.6%
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
60%
65%
70%
75%
80%
85%
90%
95%
100%
105%
99/00 00/01 01/02 02/03 03/04 04/05 05/06 06/07 07/08 08/09 09/10 10/11 11/12 12/13 13/14 14/15
Delivery items [mio.]
Logistic performance [1. BLT]
Unrestricted © Siemens AG 2017 All rights reserved.
Page 26
The Answer to the Question: „Why should I become a smart factory?“
Interpretation -Ability
Pattern RecognitionMeasure -Ability
Information Gathering
Prognostication -Ability
Stabilization
Decision -Ability
Adaptation
REALITYREALITY PLANINGSIMULATIONSIMULATION
… to increase “-abilities”!
Reactive Proactive
Unrestricted © Siemens AG 2017 All rights reserved.
Page 27
Industrial Data Management ExampleEnergy Management with SIMATIC
Field Level Control Level Operator Level Management Level
Measure-Ability… of Energy data
Interpretation-Ability…of Energy consumption
Prognostication-Ability…of Energy hot spots
Decision-Ability… Energy management
ET200-Energy meter, SIRIUSSIMOCODE, SENTRON PAC, …
Energy Box
S7-1200, S7-1500, S7-300 Basic Panels, Comfort Panel, … SIMATIC WinCC V7, PCS7,
SIMATIC powerratePROFIenergy
TIA PortalWinCC V12, STEP7 V12
SIMATIC B.Data (On-Site)Energy Analytics (als Managed
Service)
S7-300, S7-400, Industrial PC
Observe Analyze Predict Prevent
Unrestricted © Siemens AG 2017 All rights reserved.
Page 28
Industrial Data Management ExampleLogistic Management with SIMATIC
Field/ Control Level Operator Level Operator Level Management Level
Automation-Ability… of Logistic Systems
Interpretation-Ability…of Logistic Systems
Prognostication-Ability… of Logistic behavior
Decision-Ability… Logistic Planning
S7-1200, S7-1500, S7-300, ET200S SP; Basic Panels, Comfort
Panel, …
Plant Simulation PreactorWinCC
Observe Analyze Predict Prevent
Unrestricted © Siemens AG 2017Page 29 DF FA MF
Siemens: Realization of our own Digital FactoryElectronics Works Amberg
Thank You!April 2017Unrestricted © Siemens AG 2017
Unrestricted © Siemens AG 2017Page 31 DF FA MF
Information and Rules
Brochures in the foyer
Personal protective equipment for shopfloor visits, if required:
Button up the coats1 stripe per person
Don’t interfere with running machinesand systems!