Driving the Digital Enterprise for discrete industries€¦ · •Outsourcing and globalization of supply chain •Industry 4.0, Internet of Things To be early in new markets Standardized

Driving the Digital Enterprise

and realizing the Digital TwinRené Wolf, Siemens PLM – Dan Hoz, Mentor

siemens.com© Siemens AG 2017

© Siemens AG 2017

April 2017Page 2 siemens.com

© Siemens AG 2017


Siemens continuously invests in the future

…which is increasingly Digital

1958

1958 - Start of production automation: Siemens receives the patent for SIMATIC

1996 - Totally Integrated Automation (TIA) enables inter-operability between all automation components

1995/96 2001 2008 2009

2009 - TIA Portal provides access to all automation tasks

2012 2014

2013 - Siemens is currently the only company whose technologies combine the real and the virtual production world under one roof

2007

2011

2012

2013

$10+ billion in investmentssince 2007

Production engineering and execution(Siemens Automation)

Product development(Siemens PLM)

2016

2015 / 16 - Siemens establishes leadership in product and process simulation to enable full digitalization

© Siemens AG 2017


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Digital Manufacturing Flow for Electronics

Future vision: Consolidated digital flow

© Siemens AG 2017


Electronics Industry

Trends and Challenges in the Manufacturing Execution

Shorter Product Life-Cycle

Speed up Indus-

trialization

Better product

quality

Reduce

production’s

costs

$

Market Trends

• Growing and

diversifying market

• Shorter Product Life-Cycles &

increasing frequency of new

innovations

• Cost and quality pressures

• Emerging technologies, production

processes, miniaturization

• Personalized products

• Regulations and compliance

industry driven at regional and global

level

• Outsourcing and globalization

of supply chain

• Industry 4.0, Internet of Things

To be early in

new markets

Standardized process

from design to

production

Flexible usage

of production

equipment

“Right the First

Time”

Fast Access to

product and

production data

Single device and

multi-level traceability

requirements

Fulfil

regulations and

compliance

Management of multi-

site supply chains

Online

Production

visibility

Multi plant data

and material

logistics

“Right the First

Time”

Reduced NPI

Cycle time

Challenges

© Siemens AG 2017


The business value of the Digital Twin

Focus on Manufacturing Process and Production System

Digital Twin of the

Product

Digital Twin of the

Manufacturing

Process & Production

System

Digital Twin of the

Production &

Performance

Digital Twin of the

Product

Digital Twin of the

Manufacturing


System

Both Box build

and PCB

assembly

processes are

defined,

simulated and

validated

together

© Siemens AG 2017


Production execution

Efficient

and secure

production

with TIA

SIMATIC, SINUMERIK,

SIMOTION, SIMOTICS,

SINAMICS and SIRIUS

1 2 3 4 5

© Siemens AG 2017



Advanced

Planning and

Scheduling

of manufacturing

operations in one

tool

Camstar Scheduling

1 2 3 4 5

© Siemens AG 2017



Import of BOM

/ BOP from

Teamcenter,

define

Workflow and

Dispatch Order

Camstar

1 2 3 4 5

© Siemens AG 2017



Run Manual

Assembly

Operation and

escalate

deviations to

Teamcenter

Camstar

1 2 3 4 5

© Siemens AG 2017



Run inspection

operations and

manage issue

for high quality

products

Camstar

1 2 3 4 5

© Siemens AG 2017


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ME

CH

AN

ICA

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RO

NIC

Digitalize the Entire Electronics Manufacturing Process

Leverage Digital Twins of the Product, Process and Production

to ensure continuous, optimized, high-quality process

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Dan

© Siemens AG 2017


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EL

EC

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ON

IC

Digitalize the Entire Electronics Manufacturing Process

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“Can I

Manufacture It?”

One tool running 950

Fabrication, Assembly,

Test and Reliability

checks

Intelligent hand-off

to manufacturing via

ODB++

“How to

Manufacture it?”

One tool covering all

manufacturing

engineering tasks,

creating the Digital

Twin of the Process

and production

system

“How Can I Do This

Better?”

© Siemens AG 2017


▪ Plug & Play data acquisition

and control

▪ Create a Digital Twin of

the Production

PCB assembly data acquisition

1 2 3 4 5

© Siemens AG 2017



and control


the Production

▪ Real-time manufacturing data

available to Enterprise Apps

▪ MES Agnostic


1 2 3 4 5SMT ICT, MANUAL INSPECTION, AUTO-TEST SYS. ASSEMBLY, SHIPPING

ERP/SCM ANALYTICS PLM MINDSPHERE MES

CAMSTAR

SIMATIC

3RD PARTY

© Siemens AG 2017



and control


the Production

▪ Real-time manufacturing data

available to Enterprise Apps

▪ MES Agnostic



ANALYTICS MINDSPHERE MES

CAMSTAR

SIMATIC

3RD PARTY

ERP/SCM PLM

✓ Maintain ERP inventory accuracy

✓ Enable accurate MRP ordering & planning

✓ Optimize material usage for

better material turnover

✓ Remove excess material WIP

from the shop-floor

PREDICTIVE MATERIAL FLOW PLANNING

© Siemens AG 2017


MINDSPHERE MESPLM

▪ Analytics as a competitive

advantage



CAMSTAR

SIMATIC

3RD PARTY

ERP/SCM ANALYTICS

© Siemens AG 2017



advantage


1 2 3 4 5

Valor IoT

Dashboards

What happened?

Descriptive Analytics

HINDSIGHT

© Siemens AG 2017



advantage


1 2 3 4 5 Why did it happen?

Diagnostic Analytics

Analytics Engine

Valor IoT

Dashboards

What happened?


HINDSIGHT

INSIGHT

Multiple issues affecting

few Assemblies

Few issues affecting

multiple Assemblies

© Siemens AG 2017



advantage

▪ Yield / quality / cost feedback

to Design and Engineering –

drive product and process

improvement


1 2 3 4 5

Example: Provide yield / quality / cost feedback to design

What will happen?

Predictive Analytics

Why did it happen?


Analytics Engine

Valor IoT

Dashboards

What happened?


HINDSIGHT

INSIGHT

FORESIGHT

© Siemens AG 2017


Example: Optimize material flow for improved material turnover

How can we make it happen?

Prescriptive Analytics


advantage




improvement

▪ Deep learning technologies

and regression techniques

to identify data correlation


1 2 3 4 5

Example: Provide yield / quality / cost feedback to design

What will happen?

Predictive Analytics

Why did it happen?


Analytics Engine

Valor IoT

Dashboards

What happened?


HINDSIGHT

INSIGHT

FORESIGHT

© Siemens AG 2017



advantage




improvement

▪ Deep learning technologies

and regression techniques

to identify data correlation

$3.93

$3.91

$0.05

$0.09

$3.98

$4.00$2,000per each 100K units

Average site (5 lines) places 50

Million components per month

PCB assembly data and analytics

Advanced Analytics is around the corner…

1 2 3 4 5

© Siemens AG 2017


DIGITAL TWIN OF THE

PRODUCT

DIGITAL TWIN OF THE

MANUFACTURING

PROCESS &

PRODUCTION SYSTEM

DIGITAL TWIN OF THE

PRODUCTION

Digitalization of PCB Assembly is the Key to

Industry 4.0 Enablement in Electronics

© Siemens AG 2017


Close Loop Digital Twin

Let your

products and

your production

speak to you

MindSphere –

the cloud-based, open

IoT operating system

1 2 3 4 5

MindSphere

© Siemens AG 2017


• Common NPI process,

Improve productivity and

throughput

• Standardized shop floor

documentation

• Full Traceability for Electronic

PCB and Box

• Powerful online Reporting

• Offer integrated NPI and MES,

WIP, Quality, traceability,

Repair, Reporting

Speed in product innovation:

New Product Introduction and MES in Electronics

• Shorter time to market

• Increase production uptime,

throughput and quality

• Provide standardized shop floor

documentation

• Provide Online Process Visibility

and control

• Fulfil Traceability and legal

requirements

• Increase manufacturing

effectiveness, best practices

BenefitsIndustry needs

© Siemens AG 2017


Closing the Loop – The Digital Twin in the Electronic Industry

Digital Twin of the

Product

Digital Twin of the

Manufacturing


System

Digital Twin of the

Production &

Performance

Digital Twin of the

Product

Digital Twin of the

Manufacturing


System

Digital Twin of the

Production &

Performance

feed back insights to continuously optimize product and production

MindSphere

© Siemens AG 2017


Video scribble:

Closed Loop Manufacturing and QualityClosed Loop

Manufacturing

Closed Loop

Quality

© Siemens AG 2017


Video scribble:

Closed Loop Manufacturing and Quality

© Siemens AG 2017


Product

DesignProduction

Planning

Production

engineering

Production

execution

Services

How Closed Loop

Manufacturing brings value

in the Process Industry

© Siemens AG 2017


Process Industry


Shorter Product Life-Cycle

Speed up Indus-

trialization

Better product

quality

Reduce

production’s

costs

$

Market Trends

• Glocalization –meet regional

requirements in global markets

• Shorter product innovation cycles

• Sustainability – make sustainable

products in a sustainable manner

• Health consciousness of consumers

• Price pressure (raw materials,

commoditization)

• Regulatory compliance complexity –

volatility

• Product & packaging variation –

convenience

• Technologization of products -

solutions, applications & services

• Personalized products


Product

complexity and

variety

Standardized process

with integrated

quality

Responsiveness

to market and

production

“Right the First

Time”

Real-time product and

production status

data availability

End-to-end product

and production

traceability

Comply with

regulations and

standards

Efficiencies across

multi-site supply

chains

Integrate

Process and

Discrete parts

Production line

agility -

planning

Asset and

material

optimization

Collaborative

R&D for

fast NPI

Challenges

© Siemens AG 2017


Validating the Process Plant of the future

Simulation and

validation of

the process

plant

Tecnomatix Plant

Simulation

© Siemens AG 2017


Quality testing of the product samples from production

Share a

common

system

platform with

production

processes

SIMATIC IT R&D

Suite

© Siemens AG 2017


Production execution and integration with batch systems

Production

execution

integrated with

Batch System

SIMATIC IT UA

Process Industry

© Siemens AG 2017


Efficient analysis of Production KPIs

Analytical and

visualization

tools to support

decision-

makers

© Siemens AG 2017


• Faster new product introduction

(NPI)

• Increased throughput by

scheduling optimization

• Increase Product Quality

reducing scrap and rework

• Enhance the process

reliability and repeatability

• Enable Product Recall

• Provide full visibility on

Production KPIs


New Product Introduction and MES in Process

• Shorter Time To Market

• Production Optimization through

detailed scheduling

• Synchronize Production with

OffLine and AtLine Quality

Execution

• Integrated Production execution:

Batch and manual tasks

• Backward and forward Product

genealogy

• Production KPIs Management

BenefitsIndustry needs

© Siemens AG 2017


Closing the Loop – The Digital Twin in the Process Industry

feed back insights to continuously optimize product and production

MindSphere

Formulated Product

Design

Manufacturing

simulation and

validation

Production &

Performance

© Siemens AG 2017


Great Wall Wine Yantai Co Ltd –

Consistently highest quality with MES

• Maintain high quality standards

• Carefully manage vineyards

• Apply advanced technologies to the craft of winemaking

• Optimize complex, sensitive processes

Production executionSIMATIC IT

Proof from practice

Production executionSIMATIC IT R&D Suite

Gruppo Campari -

Initial steps towards the Digital Enterprise

• Product specification management on a global scale

• Simplify and standardize data collection and validation

• Responsiveness to information requests (market and

government)

© Siemens AG 2017


Product

DesignProduction

Planning

Production

engineering

Production

execution

Services

How Closed Loop

Manufacturing brings value

in the Discrete Industry

© Siemens AG 2017


Discrete Industry


Speed up Indus-

trialization

Better product

quality

Reduce

production’s

costs

$

Market Trends Shorter Product Life-Cycle

• Supply chain globalization / OEM

landscape to be shaken by new players

• R&D competitiveness and manufacturing

flexibility

• OEMs reducing in-house manufacturing to

focus on integrated systems assembly

• Global competition in lower tiers is

becoming very fierce

• Compliance to standards and regulations

across different countries

• Skill shortage vs technology changes

• Aircraft production backlog steadily

increasing

• Cost and quality pressures


Proliferation of

process

variations

Increased pressure on

time to market & cost

effectiveness

Agile

management of

engineering

Quick ramp-up of

know-how and

skills

Balance existing

programs and new

opportunities

New manufacturing

technologies per

innovation needs

Fulfil regulations

and compliance

Increasing pressure for

supply chain

transparency

Visibility into

non-conformance

costs

Localize

production to

reduce costs

“Right the First

Time”

Optimize quality

assurance

processes

Challenges

© Siemens AG 2017


Discrete Manufacturing – Closed Loop Manufacturing

Import of BOM

/ BOP from

Teamcenter,

define

Workflow and

Dispatch Order

SIMATIC IT UA

Discrete

Manufacturing

© Siemens AG 2017


Discrete Manufacturing – Production execution

Run inspection

operations and

manage issue

for high quality

products

SIMATIC IT UA

Discrete

Manufacturing

© Siemens AG 2017


• Smooth introductions of new

products

• Easy handling of product

changes / revision management

• Paperless manufacturing for

streamlined operation and

compliance

• More visibility on production

progress

• Reduction of scraps

• Production feedback for

continuous improvements

Industry needs


New Product Introduction and MES in Discrete Manufacturing

• Removes the barriers between

Manufacturing Engineering,

Planning and Execution

• Enables streamlining business

processes with holistic systems

approach

• Enables collaboration between

engineering and execution for

issue & non-conformance lifecycle

• Enables paperless factory with full

manufacturing transparency and

operational visibility

Benefits

© Siemens AG 2017


MOM Portfolio evolution to maximize value and address

industry-specific needs within the Digital Enterprise SW Suite

CloudOn-premises

SIMATIC IT

R&D/MES

SIMATIC IT

Preactor APSCamstar MES QMS Mentor Graphics - Valor

ManufacturingEffective cross-functional collaboration

Quality

Consolidated Products and Process Quality

Engineering

Integrated and automated Production System Engineering

The value of MOM portfolio integration:

Teamcenter

MindSphere

SIMATIC IT

Preactor APS

© Siemens AG 2017


Thank you!

Documents

Driving the Digital Enterprise for discrete industries€¦ · •Outsourcing and globalization of supply chain •Industry 4.0, Internet of Things To be early in new markets Standardized