Rick Dries, Director of Engineering Support, Digital Factory Division, Siemens USA
The Digital Factory – Enabling a Holistic Approach to Automation
MIT Industrial IoT Workshop – October 7, 2014
Unrestricted © Siemens AG 2014. All rights reserved.
Challenges:
Manufacturing is changing faster than ever before
Increasing
competitiveness
1
Increase efficiency
• Energy and resource efficiency are
decisive competitive factors
2
Shorten time-to-market
3
Enhance flexibility
• Shorter innovation cycles
• Individualized mass production
• More complex products
• Volatile markets
• Larger data volumes
• High productivity
Industry Software should help to solve manufacturing challenges
© Siemens AG 2014. All rights reserved.
Growing business process complexity is impacting automation systems
On Board Memory (OBM) SIMATIC controller
Code volume SIMATIC Engineering Software
16,384
~ 55’
50’
31’
2,000
Mbyte
0,03
S5
CPU100
1987
Lines
of Code
0,25
S5
CPU945
1993
S7
CPU319
2010
S7
CPU1518
2013
~ 7’
Step7 Prof
Classic
2010
TIA Portal
V11
2011
TIA Portal
V12
2013
TIA Portal
V13
2014
(current status)
Software content of automation solutions is continuously rising
Page 3
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Hourly rates / Engineering hours / Total engineering cost
Complexity is driving up engineering costs
Total engineering cost
Engineering hours per project
Hourly rate of engineers
time
Page 4
© Siemens AG 2014. All rights reserved.
Hourly rates / Engineering hours /
Total engineering cost
TIA Portal – Mitigating the fast growing cost of automation engineering
Total engineering cost
Engineering hours per project
Hourly rate of engineers
time
Total engineering cost
TIA Portal
One engineering tool for all
automation engineering tasks
time
Page 5
© Siemens AG 2014. All rights reserved.
Reference: BMW
Integrated industry software optimizes production at BMW
Electrical and mechanical turnkey solution in BMW assembly factory
• PLM software, MES and TIA Portal
• All BMW cars can be produced on one manufacturing line
• Ergonomic adjustments to production plant and high safety standards
• 99%+ availability – helping assembly
plant to avoid bottlenecks: Low downtimes, High quality
• BMW sees the greatest potential cost savings in engineering
• TIA Portal concepts delivers this savings through:
• Fewer interfaces
• A common database
• Less errors through consistent system support
• TIA Portal creates the conditions for reducing engineering costs by creating more effective
and automated engineering; contributing significantly to cost reduction in time and quality.
Automotive manufacturers reach the next level of production with industry software
© Siemens AG 2014. All rights reserved.
A holistic automation approach must include the entire value chain
4 Production execution
3 Production engineering
2 Production planning
1 Product design
1
2
3
4
5 Services
5
Increasing productivity and efficiency in the individual process steps
© Siemens AG 2014. All rights reserved.
Siemens Digital Enterprise Platform
Digital World
Physical World
Product design and
virtual production
Real production
Production
planning
Product
design
PLM
TIA
Product
Lifecycle
Management
Totally
Integrated
Automation
Production
engineering
Production
execution
Best in class digital representation of the physical world.
Page 8
© Siemens AG 2014. All rights reserved.
The 3 core aspects
1
Production Network
 Flexible supply chains with cross-company just-in-time
decisions
2
Product and Production Design
 Reducing time to market by the integration of both
processes
3
Cyber-Physical Systems
 Flexible production based on
modular, autonomous production units
Cyber-physical systems
© Siemens AG 2014. All rights reserved.
From static production chains to flexible network
Production chain
More flexible and dynamic production
Production network
…. based on just-in-time decisions
More dynamic
relations
Long-term and
static relations
Solution: Optimized production with Manufacturing Operations Management
 Seamless Integration of PLM, ERP, MES and Automation
 Dynamic decisions regarding supply of dedicated resources, vendor parts, logistic services and
production sites
© Siemens AG 2014. All rights reserved.
The 3 core aspects
1
Production Network
 Flexible supply chains with cross-company just-in-time
decisions
2
Product and Production Design
 Reducing time to market by the integration of both
processes
3
Cyber-Physical Systems
 Flexible production based on
modular, autonomous production units
Cyber-physical systems
© Siemens AG 2014. All rights reserved.
From serial to parallel processes
Faster from idea
to production…
Serial Process
time
Local
optimization
….based on integration of productand production design
Parallel Process
time
Integrated
optimization
Solution: Integrated Workflow from Product Design to Production
 Common data model with consistent data
flows
 PLM-Team collaboration and roundtrip
engineering
© Siemens AG 2014. All rights reserved.
The 3 core aspects
1
Production Network
 Flexible supply chains with cross-company just-in-time
decisions
2
Product and Production Design
 Reducing time to market by the integration of both
processes
3
Cyber-Physical Systems
 Flexible production based on
modular, autonomous production units
Cyber-physical systems
© Siemens AG 2014. All rights reserved.
From static to flexible production
Static Production
Pre-defined production
process
Increasing flexibility of
production…
…. based on modular production
units
Flexible Production
Self optimizing
and autonomous
Solution: Use of Cyber-Physical Systems
 Intelligent, autonomous and self configuration/optimizing
 Communicative and collaborative
CPS
 Context aware
Increase flexibility and reduce complexity
© Siemens AG 2014. All rights reserved.
Rick Dries, Director of Engineering Support, Digital Factory Division, Siemens USA
The Digital Factory – Enabling a Holistic Approach to Automation
MIT Industrial IoT Workshop – October 7, 2014
Unrestricted © Siemens AG 2014. All rights reserved.