Summary
Tecnomatix® Plant Simulation software enables the simulation and optimization of production systems and processes. Using Plant Simulation, you can optimize material flow, resource utilization and logistics for all levels of plant planning from global pro-duction facilities, through local plants, to specific lines.
In times of increasing cost and time pres-sures in production, along with ongoing globalization, logistics has become a key factor in the success of a company. The need to deliver JIT in-time)/ JIS (just-in-sequence), introduce Kanban, plan and build new, sustainable production facilities, and manage global production networks (to name a few) requires objective decision criteria to help management evaluate and compare alternative approaches.
Plant Simulation helps create digital models of logistic systems (e.g., production) to explore the systems’ characteristics and to optimize their performance. The digital model enables users to run experiments and what-if scenarios without disturbing an
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existing production system or – when used in the planning process – long before the real system is installed. Extensive analysis tools, statistics and charts let users evalu-ate different manufacturing scenarios and make fast, reliable decisions in the early stages of production planning.
Plant Simulation helps users:
• Detect and eliminate problems that oth-erwise would require cost- and
time-consuming corrective measures during production ramp-up
• Minimize the investment cost of produc-tion lines without jeopardizing required output
• Optimize the performance and energy usage of existing production systems by taking measures that have been verified in a simulation environment prior to implementation
Modeling manufacturing processes Plant Simulation enables you to create well-structured, hierarchical models of pro-duction facilities, lines and processes. This
Answers for industry.
Plant Simulation
Simulation and optimization of production systems and processes
Benefits
• Improve productivity of existing facilities by as much as 20 percent • Reduce investment in
planning new facilities by as much as 20 percent
• Cut inventory and throughput time by as much as 60 percent • Optimize system
dimensions, including buffer sizes
• Reduce investment risks through early proof of concept
• Maximize use of manu-facturing resources • Improve production line
is achieved through powerful object-ori-ented architecture and modeling
capabilities that enable you to create and maintain even highly complex systems, including advanced control mechanisms. Plant Simulation’s user interface follows Microsoft Windows standards, making it easy to get familiar and productive quickly. Simulation models can be created quickly by using components from application object libraries dedicated to specific busi-ness processes, such as assembly or carbody manufacturing processes. Users can choose from predefined resources, order lists, operation plans and control rules. By extending the library with your own objects you can capture best-practice engineering experiences for further simula-tion studies.
Complex and detailed simulations can be handled, understood and maintained much better than in conventional simulation tools by using Plant Simulation architectural advantages like capsulation, inheritance and hierarchy.
Simulating and analyzing system performance
Plant Simulation models are used to opti-mize throughput, relieve bottlenecks and minimize work-in-process. The simulation models take into consideration internal and external supply chains, production
resources and business processes, allowing you to analyze the impact of different Features
• Optimize systems for reduced energy usage • Simulation of complex
production systems and control strategies
• Object-oriented, hierarchical models encompassing business, logistics and production processes • Dedicated application object
libraries for fast and efficient system modeling • Graphical outputs for
analysis of throughput, resources and bottlenecks • Automatic bottleneck
detection, Sankey diagrams and Gantt charts
• 3D online visualization and animation
• Integrated neural networks and experiment handling • Automated system
optimization via genetic algorithms
• Value stream mapping and simulation
• Open system architecture supporting multiple interfaces and integration capacities (ActiveX, CAD, Oracle SQL, ODBC, XML, Socket, OPC, etc.)
production variations. Statistical analysis, graphs and charts display the utilization of buffers, machines and personnel. You can generate extensive statistics and charts to support dynamic analysis of performance parameters including line workload, break-downs, idle and repair time and proprietary key performance factors.
Model visualization
In addition to the highly efficient 2D model view of Plant Simulation, models may be visualized in a 3D virtual environment using Plant Simulation’s included libraries or your own CAD data. The result is impressive 3D virtual models that are synchronized at all times with their 2D counterparts, allowing you the flexibility to choose the appropriate method of visualization without compro-mising simulation and analysis needs.
Plant Simulation
TECNOMATIX
Contact
Siemens Industry Software Americas +1 314-264-8499 Europe +44 (0) 1276 413200 Asia-Pacific +852 2230 3308
www.siemens.com/tecnomatix
© 2013 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Man-agement Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or ser-vice marks used herein are the property of their respective holders.
Tecnomatix Plant Simulation
Value Stream Mapping
www.siemens.com/tecnomatix
TECNOMATIX
Benefits • Increase productivity of existing production facilities by as much as 20 percent • Reduce investment in planning for new production by as much as 20 percent • Reduce inventories and cycle time by as much as 60 percent • Optimize the system dimensions, including buffer sizes • Reduce investment risk through early feasibility analysis • Increase resource utilization • Better line planning and allocation Typical questions for the simulation: • How can we minimize the investment costs? • Is the required output achieved? • What happens when quantity changes? • How can stocks be reduced? Implementation The Plant Simulation Value Stream Mapping Library (TN75096) is an optional extension to the Plant Simulation Standard or Professional license. Summary The Plant Simulation Value Stream Mapping library supports the user, taking into account the dynamic relation-ships of complex manufacturing sequences to increase the share of value-added pro-duction, variability, quality, speed and efficiency for increased produc-tion, while reducing inventory and capi-tal commitment, and securing on-time delivery. Tecnomatix Plant Simulation Plant Simulation helps you create models of logistic systems (e.g., pro-duction) to explore the systems’ charac-teristics and to optimize their per-formance. The digital model enables users to run experiments andTecnomatix Plant Simulation Value Stream Mapping
Visualization, analysis and improvement of dynamic value chains what-if scenarios without disturbing an existing production system or – when used in the planning process – long before the real system is installed. Plant Simulation contains powerful object-oriented archi-tecture and modeling capabilities that enable you to create and maintain even highly complex systems, including advanced control mechanisms. Plant Simulation’s user interface follows Microsoft Windows standards, making it easy for you to quickly become productive. Simulation models can be created quickly by using components from application object libraries dedicated to specific busi-ness processes. You can extend the library with your own objects through a powerful programming environment for the further-ing of simulation capabilities. Tools for automatic optimization, analysis of simula-tion results and 3D visualization of simulation models are also available. Extensive analysis tools, statistics and charts let users evaluate different manu-facturing scenarios and make fast, reliable decisions in the early stages of production planning. Plant Simulation helps users: • Detect and eliminate problems that otherwise would require cost- and time-consuming correction measures during production ramp-up • Minimize the investment cost of production lines without jeopardizing required output • Optimize the performance of existing production systems by taking measures that have been verified in a simulation environment prior to implementation
Tecnomatix Plant Simulation
added in manufacturing and for identify-ing, reducing and eliminating non-value added processes and operations. Value Stream Mapping is a modern method of process optimization based on the methods of lean management, as described by the well-known Toyota Production System and as applied by the Siemens Production System. The goal is to easily and quickly map and better understand the value chain for the purpose of optimizing it.
Objectives and benefits
The traditional goals of the Value Stream Mapping process are: • Increase production variability • Increase production quality • Increase production rate • Increase production efficiency The aim is to optimize production resources, the layout of the controls and the lot sizes to guarantee a steady flow of production without buffer stock build-up while simultaneously maintaining quality of order receipt and delivery.
Source: Value Stream Mapping – The Road to Lean Manufacturing
Erlach, Klaus; Springer-Verlag, 2010 Plant Simulation allows for the creation of complex production systems and processes in easy to understand computer models. Using Plant Simulation, material flow, resource utilization and supply chains at all levels of corporate planning may be optimized.
What is Value Stream Mapping? Value stream mapping is an established method for studying the economic value • Easy to use through Microsoft Windows conformity • Block libraries for the fast and efficient modeling of typical scenarios • Graphs and diagrams • Analysis of throughput, resource utilization and bottlenecks
Why perform value stream mapping in Plant Simulation? • Reduction of cost for data collection by reducing the number of objects describing the processes through pre-defined logic blocks • Reduction in analysis effort through automated analysis modules Through computer simulation, examine the dynamic effects of the value stream, which remain hidden in the static, paper-based mapping of the value chain Approach Traditional: Depiction of production by manual, graphical sketch of the value stream using symbols on a sheet of paper showing the conditions, such as material flow, information flow, inventories, value-added and non-value adding activities. Based on customer demand, inventory and cycle times, analysis of the current state of production is performed as a team. Revision and improvement of the value stream is then derived from this current value stream mapping of the production process. Standardized method based on generally accepted symbols Tecnomatix Plant Simulation is part of the Plant Design and Optimization solution offering from Siemens PLM Software. These are coordinated software components that enable you to plan the complete production of a plant by way of a computer model to visualize and simulate the processes in production lines, warehouses and work-shops, so as to quickly, easily and safely achieve the required findings and results. The extensive portfolio allows for an optimized manufactur-ing process design lifecycle, including planning, factory lay-out design, and manufacturing processes and factory simula-tion, enabling the seamless connection with higher-level planning systems. The traditional, static value stream analysis is extended to include the critical time ele-ment for stock availability. Thus, you can depict dynamic fluctuations of the daily production due to lot sizes, setup procedures, product variations, or other disturbances. The dynamic material flow simulation in Tecnomatix Plant Simulation permits the reduction of the number of products in production and thus the capital investment required for robust production, ensuring that natural fluctuations in production do not impair the ability to deliver.
© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. X3 00000 7/12 B www.siemens.com/plm Contact Siemens Industry Software Americas +1 800 498 5351 Europe +44 (0) 1276 702000 Asia-Pacific +852 2230 3333
TECNOMATIX
Value Stream Mapping Library in Plant Simulation Predefined symbols based on the general standard: • Quick and easy to learn • Predefined dialogs with configurable user objects • Control logics • Analysis objects Application The Plant Simulation Value Stream Mapping Library allows users to quickly and easily map and improve their supply chains with real dynamic behavior. The Plant Simulation Value Stream Mapping Library was developed in collabo-ration with industry practitioners for use by industry practitioners, providing the necessary objects. Predefined core objects: • Process • Supplier • Customer • Stock • Supermarket • Internal and external transport • Predefined controls for mapping of: - Kanban processes - Heijunka Box - Compensation box Predefined objects for analysis and evaluation of: • Throughput time • Loading/unloading or waiting time • Value-added time • Analysis of the process utilization • Availability of resources (time sensitive)
Moscow Domodedovo Airport is Russia’s largest airport. Handling 46 percent of air passengers in Moscow, the airport is used by 74 airlines and serves 228 destinations across the globe, with 91 destinations exclusive to the Moscow region. The airport works with 46 foreign and 28 domestic airlines. This includes 11 countries from the Commonwealth of Independent States (CIS). In 2009 Moscow Domodedovo Airport handled 18.7 million passengers.
The cooperation between Domodedovo and Siemens PLM Software began in 1999, when Moscow Domodedovo Airport implemented a major redevelopment program – among the largest European civil aviation investment projects of the decade – with a proposed series of airport infrastructure upgrades that required the development and evaluation of various designs.
Moscow Domodedovo Airport selected Siemens PLM Software as an instrumental technology provider for its reconstruction program.
To effectively plan for the airport renovation, qualitative and quantitative efficiency indicators needed to be set. In addition, the equipment, floor space and transport requirements needed to be determined. Moscow Domodedovo Airport’s experts used advanced computer-aided design (CAD) tools and some of the best practices of airports
globally to address these requirements. Among Moscow Domodedovo Airport’s strategic tools for design and analysis is the Plant Simulation solution, part of Tecnomatix® software from Siemens PLM Software. The first assignment for Tecnomatix was a cargo handling simulation project. The objective was to model the handling of incoming air cargo in order to identify bottlenecks and to improve overall efficiency. Within three weeks the model had been developed. Key information included the aircraft landing schedule, the
Business challenges
Plan for airport upgrade and passenger traffic increaseKeys to success
Use Tecnomatix Plant Simulation for modeling air cargo handling, passenger flows in the international terminal, as well as various terminal performance scenariosStart with single application; with success, implement simulation across projects
Results
Bottlenecks identified at the design stage and timely corrections made
Investment risks reduced for reconstruction of the international terminal Airport attained a leadership position in the Russian civil aviation market
Renovating Russia’s largest airport – virtually
Tecnomatix provides the tools to simulate optimum passenger and cargo handling workflows, helping airport become a leader in the Russian civil aviation market
MOSCOW DOMODEDOVO AIRPORT
Aerospace
TECNOMATIX
www.siemens.com/tecnomatixnumber and specifications of cargo handling transports, the storage capacity and timeline. The model provided an evaluation of both the cargo handling system “as is” and with several proposed upgrades, which led to the optimal solution for the air cargo terminal.
Next, using Tecnomatix, a series of joint projects were simultaneously implemented, including a simulation and evaluation of the international terminal’s reconstruction plan. Since the airport anticipated a sharp increase of international flights, it was important to make sure that the design solutions were correct. It was also essential that the investment risks related to the terminal’s reconstruction be minimized and controlled.
Using Plant Simulation, Moscow Domodedovo Airport produced a detailed model of passenger flows within the terminal. Airport experts were able to experiment with a variety of scenarios to evaluate and determine the optimal approach. For example, extensive parameters were entered to arrive at various solutions that depended on a range of anticipated passenger situations. Parameters included flight
schedules and data, incoming passenger traffic, service regulations, passenger routes across the terminal, equipment for check-in, customs, security, luggage claim areas, the locations of stores, food outlets, and duty free zones.
Peak loads were a special concern,
especially relative to the equipment needed to handle the high-traffic times. Plant Simulation accounted for different passenger flow patterns, considering both incoming and outbound flight schedules. Bottlenecks were readily revealed and corrective action taken.
“With such outstanding virtual planning, Tecnomatix Plant Simulation has significantly reduced the risks and uncertainty associated with our airport
reconstruction planning,” says Helen Galanova, spokesperson for Moscow Domodedovo Airport. “Thanks to Tecnomatix, we have made considerable improvements to everyday airport workflows, including check-in planning, buses, gates, and boarding management.”
Galanova notes, “Using advanced technologies such as Tecnomatix, Moscow Domodedovo Airport has become a leader in the Russian civil aviation market.”
Solutions/Services
Tecnomatix www.siemens.com/tecnomatixClient’s primary
business
Moscow Domodedovo Airport is the largest Russian airport and holds the leading position among Moscow area airports in terms of passenger traffic. Located 22 kilometers southeast of Moscow, it is the first passenger airport terminal in Russia to be certified under ISO 9001:2000. www.domodedovo.ru/en/Client location
Moscow Russia“ Thanks to Tecnomatix,
we have made consid
erable improvements
to everyday airport
workflows, including
checkin planning,
buses, gates,
and boarding
management.”
Helen Galanova Spokesperson Moscow Domodedovo AirportAerospace
TECNOMATIx
© 2010 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, Nx, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.
x9 22973 11/10 B www.siemens.com/tecnomatix Contact Siemens PLM Software Americas 800 498 5351 Europe 44 (0) 1276 702000 Asia-Pacific 852 2230 3333
Industry
Semiconductor equipment Industrial machinery
Business challenges
Deliver new and innovative machines
Shorten machine delivery cycle
Adjust production capacity to market conditions, while maintaining cost control
Keys to success
Simulate new production lines before they are commissioned Analyze production
scenarios and recommend best alternatives
Optimize the sequencing of production processes
Results
Created a pilot in which real-world results were compared against simulation models created using Tecnomatix, proving that actual production performance/metrics can be accurately imitated
A leading provider of lithography
systems for the semiconductor
industry uses Plant Simulation to
optimize production scenarios
Innovative consumer and industrial electronics products require state-of-the-art microchipsASML is one of the world’s leading provid-ers of lithography systems for the semi-conductor industry, manufacturing complex machines that are critical to the production of integrated circuits and microchips. These advanced systems help ASML’s customers, the chipmakers, to reduce the size and increase the function-ality of microchips within consumer elec-tronics equipment. As a result, ASML helps to create more powerful electronics systems for consumers and industry professionals.
The “digital revolution” has been realized by the semiconductor industry and indi-rectly by lithography: the process responsi-ble for imaging smaller features on silicon wafers and continuing “Moore’s Law,” which predicts that technology will double the number of transistors on a microchip at regular intervals. Thanks to lithography, ever-shrinking microchips have brought better, more affordable and energy-effi-cient electronics and services to everyone, improving mobility, connectivity, safety and digital entertainment.
Tecnomatix
•NX
•Teamcenter
www.siemens.com/plm
ASML
Digital manufacturing tools support a world leader in a growing market
Amid the global financial crisis of 2009, chipmakers sharply reduced capital expen-ditures. Halfway through the year, the semiconductor industry was among the first to recover, and orders picked up, lead-ing to two subsequent years of record sales for ASML. Sales in 2010 were nearly three times those of 2009, followed by another sales increase in 2011. During this strong rebound, ASML had to ensure that it would continue to deliver its machines on time and in accord with the highest quality standards.
Evolving high-productivity TWINSCAN NXT platform, manufactured by ASML.
As demand in the semiconductor industry is cyclical, ASML must continuously adjust its production capacity to meet the requirements of the market. This is a sophisticated process that involves fore-casting demand, setting detailed output plans and aligning with a large and complex supply chain. This process also involves the use of the Plant Simulation solution in the Tecnomatix® portfolio.
Bridging the gap between product design and manufacturing
ASML uses several Siemens PLM Software solutions, including Teamcenter® software for digital lifecycle management and NX™ software for product design. Recently, the Industrial Engineering department of ASML began using Plant Simulation, a discrete-event simulation tool.
“The Industrial Engineering team functions in between D&E (Development and Engineering) and M&L (Manufacturing and Logistics),” explains Andreas
Schoenwaldt, Industrial Specification
Management (ISM) team manager at ASML. “The production simulations that we develop using Plant Simulation support building a bridge between these groups. We have to make many decisions regard-ing the establishment of new production facilities, or improving existing ones. Plant Simulation helps us make these decisions after simulating what-if production scenar-ios. Our machines have to perform to high standards; they need to print very small features on silicon wafers, printing 30-40 layers exactly on top of each other, and do it extremely fast. Precision is measured in nanometers. A relentless drive to innovate is part of the ASML culture, and has allowed us to meet this challenge. In this context, we had the need for a discrete-event software simulation tool to simulate and optimize our production.”
Results (continued)
Optimized a production line configuration that supports the needed throughput and reduces the investment in production resources for a new EUV machine
Boosted production capacity for a new design by using two positioning module qualifica-tion tools
Created library of simulation objects, e.g. an optimization algorithm object that identifies the most efficient sequencing of manufac- turing steps
Implemented Plant Simulation as part of the company’s pro-duction process approach that enables continuous delivery of the most innovative and cost-effective solution to customers
Production of the new EUV machine in a clean room.
“Maintaining world leader-ship is a tough task. You must be innovative and cost-effective. Plant Simulation will be part of our engineering decision-making process. A lot of production scenarios will be simulated virtually using Plant Simulation, before we will actually commission the production line.”
Andreas Schoenwaldt Industrial Specification Management Team Manager ASML
Creating a Plant Simulation model for the production phase, with a target of shortening machine lead time
Machine testing is the production phase that requires the longest duration, even significantly longer than the final assembly phase. ASML is constantly striving to shorten lead times, increase production capacity and lower costs in order to increase its appeal as a go-to supplier. In studying these challenges, data analysis showed that one source of delays is the late delivery of processed wafers. Joris Bonsel, an industrial engineer on the Industrial Specification Management (ISM) team at ASML, notes, “These wafers are produced in our process lab, mainly for the purpose of machine testing. We used data from a five-month period of actual wafer orders requested by the test department, combined with the corresponding actual delivery times. We then created a Plant Simulation model that delivered the same results that were collected, reflecting a surprisingly high level of accuracy. “Once we knew that we had a simulation model that reflected reality, we started to do the industrial engineering analysis. It was clear that adding more manpower in the lab would improve delivery perfor-mance, but we were able to simulate the actual production, and proved that there is a clear financial benefit to adding one employee to the process lab, rather than invest, for example, in a new track. Just to prove that this result is not trivial, we sim-ulated and showed that adding a second employee was not cost beneficial. This analysis was previously done based on gut feeling, rather than a simulation, and therefore it was difficult to argue with the simulation recommendation.” Bonsel notes, “This was actually the project we used to pilot Plant Simulation, and we
were impressed when we realized that with Plant Simulation, we can build a model that will accurately imitate the per-formance of a physical production line.”
A new generation of lithography systems
ASML has developed a new generation of lithography systems that uses extreme ultraviolet (EUV) light and will allow chip-makers to continue to shrink feature sizes on chips. The first systems intended
The NXE:3300B.
for volume manufacturing, dubbed NXE:3300B, will ship in 2012, and the engineering teams had to plan production facilities to support the rollout. Maurice Schrooten, an industrial engineer on the ISM team at ASML, explains: “One of the main questions was: ‘Which production resources were needed for manufacturing the MBMM (main body mid module), one of the major modules of this machine?’ Naturally, we were looking for the most cost-effective investment, and therefore we have used Plant Simulation to analyze the implications of three different alterna-tives on clean room space consumption, throughput variation, and labor and hard-ware investment. The three alternatives were: 1) cloning the current production line, 2) outsourcing, called HLQB (high-level qualified buy), some of the produc-tion and, 3) using a new producproduc-tion line methodology, which splits the assembly work between three different work areas. The simulation showed that the cloning alternative required a higher investment in equipment, so we abandoned it. Out of the other two alternatives, which were largely equal, we selected the one with the lowest risk for ASML. The Plant Simulation result is an optimized produc-tion line configuraproduc-tion that supports the needed throughput and reduces the investment in production resources.”
Plant Simulation result chart: comparison of investment in three production line alternatives.
Higher throughput through simulation
One of the key modules of the TWINSCAN NXT:1950i machine is the positioning module (PM). As ASML was considering how to boost production capacity for a new design, the team wanted to know how many qualification tools, that is, posi-tioning module qualification tools (PMQTs) would be needed, and how could the tool utilization be maximized. The team also planned to compare deployment of two parallel workstations with the same tasks versus two serial workstations, each with half of the tasks. Ron Clauwers, an indus-trial engineer on the ISM team at ASML, notes: “To deliver the highest throughput, four scenarios were compared with each other, and the Plant Simulation results showed that we should use two identical PMQTs in a flexible (not fixed) manner, in other words, each PMQT can accommo-date any needed production step, com-bined with priority rules, and use parallel workstations (rather than serial worksta-tions), in front of the PMQTs.”
Plant Simulation result box plot: the time (in weeks) needed to produce a specific volume of PMs is shown. The highest throughput is obtained with two tools, flexible utilization and parallel workstations.
“We were impressed when we realized that with Plant Simulation, we can build a model that will accurately imitate the performance of a physical production line.”
Joris Bonsel Industrial Engineer Industrial Specification Management
ASML
“The Plant Simulation result is an optimized production line configura-tion that supports the needed throughput and reduces the investment in production resources.” Maurice Schrooten Industrial Engineer Industrial Specification Management ASML
© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. TWINSCAN NXT, TWINSCAN NXT:1950i, and NXE:3300B are trademarks of ASML Netherlands BV. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.
Z13 29753 4/12 A www.siemens.com/plm Solutions/Services Tecnomatix www.siemens.com/tecnomatix NX www.siemens.com/nx Teamcenter www.siemens.com/teamcenter
Customer’s primary business
ASML, one of the world’s leading manufacturers of chipmaking equipment and a key supplier to the chip industry, designs, develops, integrates and services advanced systems to produce semiconductors. The company has manufacturing, customer support centers and training facilities in more than 15 countries. www.asml.com Customer location Veldhoven Netherlands Partner cards PLM Solutions B.V.
Siemens Industry Software
Americas +1 800 498 5351 Europe +44 (0) 1276 702000 Asia-Pacific +852 2230 3333
Plant Simulation becomes part of the decision-making tool kit
“One of the strengths of Plant Simulation is the ability to create a library of objects with certain logic, and re-use these objects in different models,” says Schrooten. “We worked closely with the Siemens PLM Software deployment partner, cards PLM Solutions B.V., and they have provided us with an initial, useful library of objects. For example, we created the genetic algorithm (GA) optimization object in our object library. When we simulate a manu-facturing process, we define a lot of constraints between the manufacturing steps, such as the precedence constraint, which defines which step should be done prior to another step; time constraint, which defines waiting time that is some-times needed after executing some of the manufacturing steps; and constraints that are related to physical aspects, for instance, two steps that can’t be done simultaneously, as they are done on the same physical area of the machine.
“The GA optimization object uses the genetic algorithm capability of Plant Simulation to recommend a sequence of process steps, taking into account all the constraints, and to assign the steps to the required production personnel.
Another useful capability of Plant
Simulation we are using is the experiment manager. With this, we run simulations of several scenarios, and can very easily com-pare the results of different alternatives.” Schoenwaldt concludes, “Maintaining world leadership is a tough task. You must be innovative and cost-effective.” He notes, “Plant Simulation will be part of our engineering decision-making process. A lot of production scenarios will be simulated virtually using Plant Simulation, before we will actually commission the production line.”
Industry
Processing technology
Business challenges
Increase completeness of the solution offered to customers Deliver a cost-effective solution for unloading ships Increase effectiveness of food production equipment operation
Keys to Success
Provide field engineers and sales with a cutting-edge software to demonstrate solution superiority Analyze different ship unloading solutions
Select the optimal production sequence
Results
Cut cost of unloading ships by embedding proprietary algorithm in a simulation model
Reduced operational cost of mixing plants by using optimal production sequence
Plant Simulation enables the
delivery of complete solutions
Innovative automation solutions delivered with Swiss accuracyDid you know that 65 percent of the chocolate and 40 percent of the pasta manufactured globally is done so with the machines of the Swiss company Bühler Group? Bühler is a specialist and global technology partner for plant, equipment and services for processing foods and manufacturing advanced materials. The organization holds leading market positions worldwide in the fields of technology, such as processes for transforming grain into flour and animal feeds, producing pasta and chocolate, and manufacturing die-cast components.
Tecnomatix
siemens.com/tecnomatix
Bühler
Leading process technology partner uses advanced tools
to increase value for its customers
Bühler’s core technologies are in the areas of mechanical and thermal process engineering. With its expertise and over 150 years of experience, Bühler enables its customers to succeed by consistently rolling out unique and innovative solutions. Over the years, Bühler has acquired a reputation as a reliable partner, thanks to its global presence and commitment to customer value.
Bühler operates in over 140 countries, and has a global payroll of over 10,000 employees.
To increase its operational efficiency, Bühler uses product lifecycle management (PLM) solutions from Siemens PLM Software: NX™ software, and the Plant Simulation solution in the Tecnomatix® portfolio.
Ship unloading solution validated with Plant Simulation
As part of its grain handling products, Bühler delivers ship unloading solutions to its customers. The unloading process for a ship requires many hours, and every hour the ship is in the port is very expensive. As a result, there is a high motivation to unload the ship as safely and quickly as possible. During the unloading process, the ship’s center of gravity shifts and the ship tilts. Any tilt above the allowed tilting angle during unloading might break up the ship. Therefore, the sequence of unloading the different compartments of a ship is very important. Moreover, there is a need to balance the unloading of neighboring compartments.
“We are very pleased with our usage of Plant Simulation, as it allows us to easily test different scenarios with little effort, and embed it in the simula-tion of our own algorithms”. “When quantifying the
expected improvements into an economical benefit, we found an impressive cost reduction enabled by the usage of Plant Simulation for the production sequence determination.”
Dr. Mukul Agarwal
Expert for Intelligent Process Operation
Corporate Technology Bühler
When a company is interested in acquiring a new ship unloading solution or modify-ing an existmodify-ing system, it must consider the number and type of unloaders that will be needed. Naturally, there is a compro-mise between the number of unloaders, the type and the unloading time. This compromise can be optimized by analyz-ing different scenarios.
Bühler field engineers and sales represen-tatives had challenged the Bühler Corporate Technology department with finding a solution that would help pros-pects resolve this complex decision. Such a solution should enable a customer to easily define an unloading scenario for a specific ship, simulate different scenarios and compare them.
“We analyzed several potential solutions and realized that an event simulation tool would be the most suitable for this task,” says Dr. Mukul Agarwal, expert for Intelligent Process Operation, Corporate Technology at Bühler. “Since we were already using Plant Simulation, we decided to use it for the ship unloading scenarios analysis. So we created a simulation model and embedded in it an unloading algorithm that we developed. We are very pleased with our usage of Plant Simulation, as it allows us to easily test different scenarios with little effort, and embed it in the simulation of our own algorithms.”
Mixing production equipment operation optimized with Plant Simulation
Bühler delivers a complete mixing solution, including process definition, plant engi-neering, process automation, manufactur-ing, installation and start-up, as well as customer service. An example of a mixing application would be the blending done by flour mills, which mix different types of flour and sometimes add additional ingredients.
In its drive to increase its competiveness and the completeness of the solution it delivers to its mixing production equip-ment customers, Bühler decided to check the feasibility of also offering a software tool which would enable it to test differ-ent production scenarios. Therefore, it cre-ated a model using Plant Simulation that is easy to use and identifies the recom-mended production sequence.
A Bühler mixing production line.
“When implementing the suggested sequence identi-fied using Plant Simulation, we found there was a signifi-cant reduction in the overall production time and the number of delayed order deliveries was minimized.”
Dr. Mukul Agarwal
Expert for Intelligent Process Operation
Corporate Technology Bühler
© 2013 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.
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Client’s primary business
Bühler is the specialist and technology partner for plant, equipment and services for processing foods and for manufacturing advanced materials. www.buhlergroup.com Client location Uzwil Switzerland
“Offering a Plant Simulation model and methodology as a means to optimize the operation of the equipment our customers are buying from us is an important step in increasing our competiveness and the completeness of our solution.”
Klaus-Jochen Lisner head of Intelligent Process Control
Corporate Technology Bühler
Siemens Industry Software
Americas +1 800 498 5351 Europe +44 (0) 1276 702000 Asia-Pacific +852 2230 3333
Buhler conducted several pilots to validate the benefit of this simulation model. “We analyzed the performance of an exist-ing line, and compared the production sequence that was used with an optimized production sequence suggested by the analysis done with Plant Simulation,” notes Dr. Agarwal. “When implementing the sug-gested sequence identified using Plant Simulation, we found there was a signifi-cant reduction in the overall production time and the number of delayed order deliveries was minimized. When quantify-ing the expected improvements into an economical benefit, we found an impres-sive cost reduction benefit as well.”
“Offering a Plant Simulation model and methodology as a means to optimize the operation of the equipment our customers are buying from us is an important step in increasing our competiveness and the completeness of our solution,” says Klaus-Jochen Lisner, head of Intelligent Process Control, Corporate Technology at Bühler. “It directly supports our slogan, ‘Engineering Customer Success.’”
Industry
Industrial machinery and equipment
Business challenges
Acquire both domestic and foreign automotive manufac-turing customers
Support accelerated growth Expand to new areas such as aerospace
Keys to success
Use Tecnomatix process plan-ning and simulation tools to validate production lines Leverage global knowledge and engineering
methodologies
Use Process Designer and Process Simulate to generate quotations
Results
Tremendous growth – an average of 50 percent annu-ally in a span of ten years One of the biggest and most talented 3D simulation teams in China
Comau (Shanghai) simulates
more production scenarios in
less time using Tecnomatix
Expanding innovative automation solutions to ChinaComau (Shanghai) Engineering Co., Ltd. [Comau (Shanghai)] is a wholly owned subsidiary of the Italian-based company Comau S.p.A, a Fiat Group affiliate. Comau (Shanghai) was established in 1997 as Comau (Shanghai) Automotive Equipment Co. Ltd. but after 15 years in operation, the company is no longer confined to the automotive industry. Having expanded its advanced automation technology into other areas of industrial manufacturing, the company officially changed its name to Comau (Shanghai) Engineering Co., Ltd. in 2010.
Comau (Shanghai) employs more than 900 people at several facilities in China. In the Chinese auto market, Comau (Shanghai) is a major supplier of body welding and powertrain assembly and machining equip ment. The company started manufacturing robots in 2011 and has developed a well-balanced portfolio of customers, including joint ventures of global brands. The company’s five business units are Body Welding, Powertrain Systems, Robotics, Aerospace, and Adaptive Solutions.
Strategic decision to use the best
In building production lines for automotive original equipment manufacturers (OEMs),
Tecnomatix
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Comau (Shanghai)
Digital manufacturing tools support rapid growth
Comau (Shanghai) is often required by customers to deliver line and workcell simulations. For simplicity, the company typically uses the same planning and simu-lation system used by its customers.
Comau (Shanghai) technicians setting up a production line in its Shanghai facility.
“Most of our customers require us to use tools in the Tecnomatix portfolio, such as Robcad, Process Designer and Process Simulate,” explains Riccardo Piegaia, pro-cess engineering manager in the Comau (Shanghai) Mechanical Engineering Department. “But even for those few customers who use other tools, we have taken the strategic decision to use only the Tecnomatix tool set. Why? Because we believe Tecnomatix is the best tool set for the 3D simulation of robotized workcells.
Results (continued)
Delivered complete turnkey automotive body welding lines to leading automotive OEMs
Improved proposal writing More efficient resource utilization
“Using the Tecnomatix tools, we are able to simulate more production scenarios in less time.”
Piegaia, who relocated from Italy, brought to China his experience using the
Tecnomatix® portfolio from Siemens PLM Software. When he started with Comau (Shanghai), he was the only person using 3D simulation, but as the company was awarded more and more projects, he trained other engineers and significantly increased the size of the team.
“The Tecnomatix tools not only help us provide best-in-class production lines to our customers, but also elimi-nate waste within our organization by saving engi-neering time and helping minimize re-work on the shop floor.”
“We currently employ the biggest and best-skilled 3D simulation team in China – dozens of simulation engineers who use Robcad, Process Designer and Process Simulate.”
Dr. Stefan Sack CEO
Comau (Shanghai) “This team must deliver value,” notes
Piegaia. “For example, in 2011, our biggest project was a complete body-in-white (BiW) line for Fiat China, which included around 250 Comau robots. Twenty engi-neers worked on this project, using Tecnomatix tools for nearly half a year, and delivered state-of-the-art simulations that supported the production line, which is now in operation. This project proved our ability to collaborate across continents, as we used some welding guns that were designed in Italy. Now, we are about to simulate and commission the second phase of this project, which almost dou-bles the line throughput by means of a cycle-time reduction and multiplication of the robotized stations.”
The simulation work in China is performed according to the customer’s requirements and in collaboration with car component design. The main goal of the simulation is to plan and validate the production line. In some cases, the simulation shows that the design of a specific part should be slightly changed due to the need to use specific welding tools.
“We simulate all the BiW workcells, start-ing from spot weldstart-ing, and continustart-ing with more advanced technologies, such as stud welding and laser welding,” Piegaia explains. “Laser welding, though being much more expensive than spot welding, is more appealing in those areas of the car that are visible once the car is manufac-tured. Using Robcad simulation, we delivered a roof welding workstation to one of our customers, in which two robots do spot welding and two robots do laser welding.”
Smooth transition from Robcad to Process Simulate
Comau (Shanghai) recently started using the Process Designer and Process Simulate solutions, both in the Tecnomatix portfo-lio, to deliver the 3D robotic simulation work it previously created using Robcad™ software, also in the Tecnomatix portfolio. The first project executed with these tools was a framing zone on a new production line for one of the European OEMs. Process Designer and Process Simulate data were among the initial deliverables submitted to the OEM.
“We believe Tecnomatix is the best tool set for the 3D simulation of robotized workcells.”
“Twenty engineers worked on this project, using Tecnomatix tools for nearly half a year, and delivered state-of-the-art simulations that supported the produc-tion line, which is now in operation.”
Riccardo Piegaia
Process Engineering Manager Mechanical Engineering Department
Comau (Shanghai)
Piegaia acknowledges the support Comau (Shanghai) received from Siemens PLM Software to get its engineers up to speed with the new tools. He already foresees a great benefit from them. “For a line builder like Comau (Shanghai), the engineering communication framework with the cus-tomer is always a challenge – what form of communication to use, which data to share with the customer, and how fre-quently to do so. Compared to a project done using Robcad, with Process Designer and Process Simulate, I see a clear saving in engineering manpower, since there is no need for a Comau (Shanghai) engineer, who functions as a technical mechanical leader, to be involved in this communica-tion. It is straightforward to communicate directly with the customer based on the Process Designer and Process Simulate data.”
“In addition, the engineering work pro-ceeds faster and visualization is improved,” notes Congjian (Kaiser) Liu, a process engi-neer in the Mechanical Engiengi-neering Department of Comau (Shanghai). “We can actually visualize the entire production line now. Other important features are the
multi-user capabilities, which ensure that no simultaneous conflicting changes can take place. The new functionality is also of great benefit, for example the Weld Distribution Center application, or the new concept of event-based simulation, which enables a much more realistic simu-lation. It is used, for example, in a welding gun tip dressing operation, which takes place only every so many cycles.” “Process Designer and Process Simulate also provide a good foundation for responding to requests for proposals,” says Qian Hawjia, a process engineer in the Proposal Department of Comau
(Shanghai). “We have already submitted a few proposals based on these solutions, and we believe that this methodology will grow. The previous method was based on a complex Excel worksheet, but we real-ized that a quotation process, more and more, includes both engineering and finance aspects. Process Designer/Process Simulate is the platform that supports both.”
“Another promising area would be Teamcenter Manufacturing Process Planner, integrated with Process Simulate, as it provides the means to over-come organizational and geographical barriers using global libraries and process plans.”
Mingzhi Ni
Manager, Mechanical Engineering Department Comau (Shanghai)
“The new functionality is also of great benefit, for example the Weld Distribution Center application, or the new con-cept of event-based
simulation, which enables a much more realistic simula-tion. It is used, for example, in a welding gun tip dressing operation, which takes place only every so many cycles.”
Congjian (Kaiser) Liu Process Engineer Mechanical Engineering Department
Comau (Shanghai)
The Process Designer/Process Simulate deployment is supported by a new concept of the virtual machine (VM) developed by the Comau (Shanghai) information tech-nology (IT) department. Richard Yan, Information and Communication
Technology manager at Comau (Shanghai) explains, “As the number of customers to which we deliver simulation data increased, we realized that we needed a smarter IT solution to support different data schemes. Therefore, we decided to use the VM environment and set up this innovative configuration with the support of Siemens PLM Software China. This con-figuration actually saved 60 percent of the hardware cost.” Yan notes that if this solu-tion is positively valuated, it might be adopted by Comau globally.
Tremendous growth
Comau (Shanghai) has experienced tre-mendous growth in China – an average of nearly 50 percent annual growth in a span of 10 years starting in 2002. “The Chinese market represents a huge opportunity for Comau (Shanghai),” notes Dr. Stefan Sack, CEO of Comau (Shanghai). “If we take the
automotive market, for example, there are only 45 to 50 cars per thousand people in China, which is still significantly lower than the ratio in developed countries, so one can expect a significant growth of this market.
“We are already a market leader in the areas of automotive body welding and powertrain machining and assembly,” Sack continues. “We are experiencing a very fast growth due to the excellent engineering skills we have developed, our relentless effort for continuous improvement, and the big value we deliver to our customers. This would not have been possible if we were not using the Tecnomatix tools. “We currently employ the biggest and best-skilled 3D simulation team in China – dozens of simulation engineers who use Robcad, Process Designer and Process Simulate,” Sack adds. “The Tecnomatix tools not only help us provide best-in-class production lines to our cus-tomers, but also eliminate waste within our organization by saving engineering time and helping minimize re-work on the shop floor. One of our advantages, as a line builder competing in the Chinese
© 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. Excel is a registered trademark of Microsoft Corporation. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.
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Siemens Industry Software
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Customer’s primary business
Comau (Shanghai), a wholly owned subsidiary of the Fiat Group affiliate, Comau S.p.A, supplies welding and pow-ertrain machining and assembly systems, as well as robots, to automakers and other manufacturers in China. www.comau.com
Customer location
Shanghai China
“Process Designer and Process Simulate also provide a good foundation for responding to requests for proposals. We realize more and more that a quotation process includes both engineering and finance aspects. Process Designer/ Process Simulate is the plat-form that supports both.”
Qian Hawjia
Process Engineer, Proposal Department
Comau (Shanghai)
market, is that we are truly a global line builder, or as we say at Comau, ‘global strategy, local execution.’ Looking forward, I can foresee that our global operations will leverage the excellent knowledge and skills we are developing.” “Comau (Shanghai) is now looking into the next promising manufacturing engineering solutions from Siemens PLM Software. An example of this would be Process Simulate Virtual Commissioning,” explains Mingzhi Ni, Mechanical Engineering Department manager at Comau (Shanghai). “The ability to test the virtual workcells with real controllers is a very promising area as it provides a real opportunity to shorten the project duration. It may also involve some organizational changes, as control engi-neers, who are now part of another department, will have to work closely with the simulation engineer. Another promis-ing area would be Manufacturpromis-ing Process
Planner in the Teamcenter portfolio, integrated with Process Simulate, as it provides the means to overcome organiza-tional and geographical barriers using global libraries and process plans.”
Industry
Automotive and transportation
Business challenges
Frequent product alterations and quantity changes Many production line adjustments
Keys to success
Digital material fl ow simulation
What-if simulations to compare alternate production line scenarios
Results
Problems identifi ed and resolved faster
Greater manufacturing fl exibility
Higher output and less waste Optimized material fl ows Investment decisions validated
Tecnomatix Plant Simulation
models give planners more
fl exibility; material fl ow
simulation also increases output
and reduces waste
Making driving safe and comfortable
Continental Automotive GmbH is one of the leading automotive suppliers in the world. The company’s three divisions – Chassis & Safety, Powertrain and Interior – develop and manufacture products that make driving safer (air bags and sensors; brake and chassis control systems), more fuel effi cient (gasoline and diesel injection systems) and more fun (infotainment systems and multifunctional displays). The company’s Regensburg, Germany facility is its biggest electronics plant. In an area of 16,500 square meters (approximately 177,000 square feet), nearly 2,000 employees produce about 67 million electronic devices per year. The plant operates 24/7, running 22 lines for surface-mounted devices (SMDs) along with other product-specifi c assembly and inspection lines.
The company’s different business units demand quite a lot from the manufactur-ing planners at the Regensburg plant. Frequent product alternations as well as quantity changes require repeated production line adjustments. To support
Tecnomatix
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Continental Automotive Group
Changing production requirements are handled easily with
digital factory software
the planners in this complex effort, the plant established an internal consulting agency, called the “Lean Offi ce,” that provides the business units with an expert production infrastructure and manufactur-ing expertise. “We offer our customers, the individual business units, a kind of carefree package for the manufacturing of their products,” says Dr. Markus Fischer, head of industrial engineering at Continental Regensburg.
A printed circuit board automatically mounted with components.
Identifying problems through simulation
The Lean Office increasingly relies on advanced technology, such as the Tecnomatix® software from Siemens PLM Software. This digital manufacturing solution was chosen after a rigorous benchmarking process – involving the production process for side airbag satel-lites (sensors used to detect an impact) – that turned out 120,000 parts per day, covering more than 200 variants. The task was to simulate material flow
between processing stations, starting with preliminary assembly, through to SMD mounting and all the way to customized packaging. After the process was modeled in Tecnomatix Plant Simulation (in two weeks), the resulting simulation won over the plant’s management, and Tecnomatix software was quickly integrated into the Lean Office’s technology portfolio. The office uses the Tecnomatix material flow simulation functionality to examine and optimize new production lines, as well as to optimize existing ones. The lines can be evaluated and optimized for various parameters, such as throughput, cycle times, performance limits, interferences, and so on. To make reliable predictions, simulation models must map the real line as accurately as possible. Also, modifica-tions must be tracked carefully. Given the frequent product alternations, the goal is to quickly identify potential problems in software and fix them before the actual process begins. “With a simulation, many
“ The possibilities of a simulation are really great for reducing costs.”
Stefan Lamken
Lean Office Process Consultant Continental Regensburg
problems are easily fixed,” explains Stefan Lamken, a process consultant to the Lean Office and key user of Tecnomatix. Normally at Regensburg Plant, the manu-facturing planners design lines with precise and successive processing stations. In this context, a simulation model is used to verify the planned performance of the line. “For our planners, Tecnomatix Plant Simulation is a very interesting tool,” says Fischer. “An offline simulation shows solu-tions that sometimes surprise even the most experienced colleague.” For example, a multi-product line with up to 100 vari-ants did not reach the theoretical targeted output. An unforeseen bottleneck unbal-anced the material flow. The Tecnomatix simulation showed that a processing station was operating too quickly, resulting in jams at subsequent stations. The unex-pected solution – slowing down the cycle for that particular station – would have been discovered much later had the simu-lation not been used.
Supporting sound financial decisions
In another situation, the goal was to increase the output of a production line. Manufacturing planners developed four possible scenarios, noting the cost of each possibility. By evaluating the four alterna-tives using Tecnomatix simulations, the company was able to see that the most economical approach would meet the desired goal. “We were elated with the software,” recalls Lamken. “With it, we
Electronic component on work-piece carrier. Customized laser marking of a manufactured electronic assembly.
© 2011 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.
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Solutions/Services
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tecnomatix
Customer’s primary business
Continental Automotive Group is one of the world’s leading automotive suppliers. www.conti-online.com
Customer location
Regensburg Germany
“ Material flows can be optimized in different ways, without having a single second of downtime.”
Stefan Lamken
Lean Office Process Consultant Continental Regensburg
“ Tecnomatix simulations give us the flexibility we need in our production processes to perfectly meet customers’ demands.”
Dr. Markus Fischer
Head of Industrial Engineering Continental Regensburg
could see that the cheapest concept deliv-ered as much additional output as the most expensive one.” Overall, this is one of the key advantages of the Tecnomatix solution: accurate performance data on which to base financial decisions.
Tecnomatix also saves money by eliminat-ing the need for time-consumeliminat-ing tests on actual production lines. For example, an SMD line occasionally bottlenecked and jammed, requiring operator intervention to resolve the problem. This jeopardized product quality and affected the line’s performance. A cooling buffer solved these problems. A Tecnomatix simulation took the solution a step further by showing how the buffer could also enable higher output. This was determined without performing any physical tests. “The possibilities of a simulation are really great for reducing costs,” says Lamken.
In addition to verifying new and revised production processes, the Lean Office uses Tecnomatix to minimize stock and to reduce waste. Questions regarding the ideal number of work-piece carriers in a line are answered in detail by the soft-ware. At the same time, simulation makes it possible to consider the effects of
various external conditions, such as poten-tial supply disturbances and personnel changes. “With Tecnomatix we are able to evaluate various scenarios in the planning stages,” says Fischer. “With this capability, we have the necessary flexibility to per-fectly meet customers’ demands.”
Currently, the Lean Office uses Tecnomatix Plant Simulation models on approximately eight projects per year, although that number is growing. “Every manufacturing planner who has experienced the benefits of simulation comes back to us and our services,” says Lamken. “Digital material flow simulation with Tecnomatix has enor-mous potential at our Regensburg plant.”
Industry
Industrial machinery and equipment
Business challenges
Establish the capability to deliver product-to-warehouse within a single day
Reduce factory and warehouse inventory
Keys to success
Plant Simulation for discrete-event simulation
Expertise of Siemens Corporate Technology Accurate data and under-standing of manufacturing processes
Effective change management Shop floor buy-in
Results
Delivering products to ware-house in Germany within 24 hours
Warehouse inventory cut in half
Substantial cash freed up Lead time significantly reduced – up to 70 percent
Warehouse inventory cut in half
and cash freed up with the help
of the Plant Simulation solution
in the Tecnomatix portfolio
Dramatic improvement in productivity Much has been written about the digital factory, but does it deliver in practice? One organization that knows the answer is Siemens Industry Sector, Drive Technology, Motion Control (Siemens Drives), based in Congleton in the United Kingdom (UK). Tom Hattersley, who heads up the Operational Supply Chain at Siemens Drives, notes, “These days, the digital factory is a key component of competitive manufacturing and was a major factor in the success of our Congleton 2011 project. Between 2008 and 2011, we achieved a dramatic improvement in productivity supported by the use of Plant Simulation.”Tecnomatix
siemens.com/tecnomatix
Siemens Drives
How the digital factory at Congleton supported a business turnaround;
use of Plant Simulation facilitates a significant reduction in factory lead times
Siemens Congleton’s mission
“We provide our global customers with technically innovative, energy-efficient products in a sustainable environment – on demand.” That’s the mission statement of the Siemens Congleton plant and the driving axiom behind a workforce of just over 500 employees who are producing key models in the Micromaster and Sinamics range of drive inverters and distributed drive technology. Opened in 1971, the factory and offices cover 12,000 square meters.
Target: product delivery within one business day
Hattersley describes the process that led up to his plant’s success: “I was production engineering manager at the time, though I came out of this role for six months to work with the Congleton 2011 project