the digital enterprise ewa – elektronikwerk amberg · efficient and flexible production execution...

The Digital Enterprise

EWA – Elektronikwerk Amberg

Unrestricted © Siemens AG 2017


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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

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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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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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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

../../800 Präsentationen/EWA Besucher/Industrie_4.0_ZVEI_I4_v02_HQ.mp4


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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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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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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

Thank You!


최유순 부장 ( YouSoon Choi )

010 4697 3449

[email protected]

the digital enterprise ewa – elektronikwerk amberg · efficient and flexible production execution...

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