The Digital EnterpriseEWA – Electronics Works Amberg

April 2017Unrestricted © Siemens AG 2017

Unrestricted © Siemens AG 2017Page 2 DF FA MF

Site AmbergPlants and Products

SIMATICPLC - Programmable Logic ControllerDP - Decentral PeripheryHMI - Human Machine Interface

SIRIUS

Contactors

Circuit board assembly/Electronic Products

Push buttons andsignal columns Production metal parts

and assembly groups

DF FA MF EWA

DF CP MF GWA

Unrestricted © Siemens AG 2017 All rights reserved.

Page 3

Excellence in Manufacturing – For our Customers

Dr. Gunter BeitingerVP of Manufacturing

Our Mission

67%15%

6%12%

VA contribution by Location( ~ 85% in Germany) SEWC Chengdu (China)

SE MF Fürth (Germany)Non FA (90% Germany)

1250 1000390 200

Number of MF Employees Per Location

Our Vision

Our Locations„

Be the Role Model for Excellence in Manufacturing to provide proven Value Add for our Customers and Business Unit, based on the methods of Digital Enterprise and Lean Industrial Engineering

Shape the Digital Future. Together.

Dr. Gunter Beitinger, Vice President Manufacturing (Lebanon)

(Nanjing)

(Karlsruhe)

Amberg

Fürth

EWA SEWCSE MF

EWA Amberg (Germany)

Non FA

Chengdu

(location) = non FA locations producing FA products*) approx. 200 MF employees producing FA products

*)

Frei verwendbar © Siemens AG 2017Seite 4 DF FA MF

Produkte des EWA – SIMATIC

Programmierbarer Logik-Controller SIMATIC S7

Bedien- und Beobachtungssysteme

SIMATIC HMI

Dezentrales IO System SIMATIC ET 200

Unrestricted © Siemens AG 2017 All rights reserved.

Page 5

Industrie 4.0: The Vision of the Future of Manufacturing

Electronic Works Amberg~1.260 Employees>15 Mio. Products per year

1 Product per Second>60.000 Customers worldwideQuality level of >99,9989%

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Digitalizationchanges

everything

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Page 7

The Answer to the Question:„How can I become a smart factory?“

Automation

• Automated Production• Smart Line Concepts• Industrial Engineering• Plug & Communicate Specification

Digitalization

• Digital Lifecycle Readiness• Horizontal and Vertical Integration• Identification and History for all Elements• Smart Data Management• Manual/ LCA Production

• Standardized Work Instructions• Ergonomic Workstation Design• Focus on Tact Time

Organization

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Page 8

The Totally Integrated Automation portfolio for factory automation

Enterprise Level

Management Level

Operator Level

Control Level

Field Level SIMATIC NETIndustrial

Communication

SIMATICControllers

SIMATIC IDENTIndustrial

Identification

SIMATIC Distributed I/O

SINAMICSDrive Systems

SIRIUSIndustrialControls

SINUMERIKCNC

SIMATICHMI

SIMOTIONMotion Control

TIA PORTALEngineering

Framework for Automation TasksTo

tally

Inte

grat

ed

Auto

mat

ion

SIMATIC ITIntelligence Suite

SIMATIC IT Production Suite

SIMATIC IT R&D Suite

PLMERP

MES

SCADA

SIMATIC WinCCSCADA System

TECNOMATIXDigital

Manufacturing

TEAMCENTERCollaborative

PDM

NXProduct

Development

Plant CloudServices

The Totally Integrated Automation portfolio for factory automation

Unrestricted © Siemens AG 2017Page 9 DF FA MF

Essential requirements –throughout the manufacturing industry

Security

Speed Flexibility Quality Efficiency

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Integrating and digitalizing the entire value chainis key to staying competitive in the future

Cloud-based, open IoT operating system: MindSphere

Third party applications

Suppliers and logistics

Collaboration platform: Teamcenter

ServicesProductionexecution

Productionengineering

Productionplanning

Productdesign

Unrestricted © Siemens AG 2017Page 11 DF FA MF

Creating a Digital Twin of the entire value chainIntegrating and digitalizing the entire value chainis key to staying competitive in the future

Productdesign

Productionplanning

Productionengineering

Productionexecution

Services

Collaboration platform: Teamcenter

Suppliers and logistics

Third party applications

Cloud-based, open IoT operating system: MindSphere

Productdesign

Productionplanning

Productionengineering

Productionexecution

Services

Unrestricted © Siemens AG 2017Page 12 DF FA MF

And only the holistic automation approach……can cover all Industrie 4.0 requirements

REAL WORLDDIGITAL WOLD

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Product Lifecycle ManagementBring ideas faster to life

„Digital Twin”

Integration of digital and real

world of product and production

Seamless data flow from product idea to production

Consistent data management for all PLM toolsLeverage Big Data to gain insights into complex, global processes

Customer Challenge PLM Portfolio

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Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Reducing time-to-market

• Shorter innovation cycles• More complex products

• Bigger but smarter data volumes

Reducingtime-to-market

~ 5,000 work plan changes per year(> 20% due to component discontinuation)

> 120 variations are built per day based on 75% automation

~ 50 mill. process & product items entered per day

Unrestricted © Siemens AG 2017Page 15 DF FA MF

Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Enhancing flexibility

Enhancingflexibility

• Mass customization• Volatile markets

• Highest productivity

~ 350 changeovers per day to handle more than 1,000 different products

> 99.5% delivery reliability to assure 24h delivery time

± 20% personal capacity flexibility to meet customer demand on time

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Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Ensure stable quality

Ensure stablequality

• Decreased production failure• Increased product quality

Production process defect dropped to11dpm (99.9989% built in quality)

Field return rate decreased by 79% in last decade

Unrestricted © Siemens AG 2017Page 17 DF FA MF

Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Increasing efficiency

Increasingefficiency

• Optimal capacity utilization • Efficient resource utilization

> 75% line utilization to serve 60,000 customers

~ tenfold of shop floor utilization till start of production (1990) equals 1pc./ sec.

Unrestricted © Siemens AG 2017Page 18 DF FA MF

Siemens: Realization of our own Digital FactoryElectronics Works Amberg: Security in production

Security inproduction

• System Protection• Network Protection

• Plant Protection

Secure production environment:- separated networks for production- secure cell principle in use

Protection level 3 in selected areas

Integrity: The software we developed is exactly what is in your product!

Regularly Security Awareness training

Unrestricted © Siemens AG 2017 All rights reserved.

Page 19

Perfection and Productivity through Automation @ EWA

More than 75% Automation• Production• Material- and• Information flow

More than 1,000 SIMATIC applications

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Electronics Works Amberg Consistency from design to production

Simatic IT

Customer

NC-ProgrammgeneratorRouting ERP

Teamcenter

Templates SMT SPI AOI ICT / FP

X-Ray THT Labels IFT Inspection

Supplier

Production order

Capacity

Inventory Mgmt.Process interlocking

Traceability

Serial number report

Test protocol

BOM

Ressource

Routing

Relevant productdata information

Intelligent preprocessing

Material forecastAutomatic order

Delivery

Immigration …

Legacy Systems

PLM Software (NX)

Recipe

Unrestricted © Siemens AG 2017 All rights reserved.

Page 21

A maximum of transparence for logistics and quality

Identification of all objects and process• All products, parts,…• All machines, adapters• All programs, data, …

Record of all process values• Soldering temperature• Pass or fail• Torque …

Autonomous process analysis• Real-time• All employees• All processes

Record big data and push smart data

EWA-Unified Label

Unrestricted © Siemens AG 2017 All rights reserved.

Page 22

Gapless monitoring of the entire value chain

Intuitive drilldownAnalyzing and management informationWatchdog and push mails

Big data to smart data

Two mouse clicks fromplant view to unicum

Unrestricted © Siemens AG 2017Page 23 DF FA MF

Our employees are integrated into the Digital Factory

Fully digital supported work

Test instruction/Data Collection

Packaging

Label Printing

History

MonitoringPack parts

Product provision

Scanning

Product provision

Scanning

Label Printing

Entry in history

Conditionssatisfied

Selection: CV, Test instruction

Check & collect

Historycheck

Monitoringpacking list

Unrestricted © Siemens AG 2017 All rights reserved.

Page 24

0

100

200

300

400

500

600

90/91 91/92 92/93 93/94 94/95 95/96 96/97 97/98 98/99 99/00 00/01 01/02 02/03 03/04 04/05 05/06 06/07 07/08 08/09 09/10 10/11 11/12 12/13 13/14

Our Success with “Design to Quality”

dpm-A

08/09 09/10 10/11 11/12 12/13 13/14

19 171416

12,5 11,5

Success through quality

Perfection for our customers

Unrestricted © Siemens AG 2017 All rights reserved.

Page 25

Success through logistics performance

Highest Quality and Efficiency

89.0%

94.0%

97.0%98.0% 98.0%

99.4% 98.9% 99.4%98.0% 98.6% 98.0% 98.9%

99.9% 99.8% 99.6% 99.6%

0,0

0,5

1,0

1,5

2,0

2,5

3,0

3,5

60%

65%

70%

75%

80%

85%

90%

95%

100%

105%

99/00 00/01 01/02 02/03 03/04 04/05 05/06 06/07 07/08 08/09 09/10 10/11 11/12 12/13 13/14 14/15

Delivery items [mio.]

Logistic performance [1. BLT]

Unrestricted © Siemens AG 2017 All rights reserved.

Page 26

The Answer to the Question: „Why should I become a smart factory?“

Interpretation -Ability

Pattern RecognitionMeasure -Ability

Information Gathering

Prognostication -Ability

Stabilization

Decision -Ability

Adaptation

REALITYREALITY PLANINGSIMULATIONSIMULATION

… to increase “-abilities”!

Reactive Proactive

Unrestricted © Siemens AG 2017 All rights reserved.

Page 27

Industrial Data Management ExampleEnergy Management with SIMATIC

Field Level Control Level Operator Level Management Level

Measure-Ability… of Energy data

Interpretation-Ability…of Energy consumption

Prognostication-Ability…of Energy hot spots

Decision-Ability… Energy management

ET200-Energy meter, SIRIUSSIMOCODE, SENTRON PAC, …

Energy Box

S7-1200, S7-1500, S7-300 Basic Panels, Comfort Panel, … SIMATIC WinCC V7, PCS7,

SIMATIC powerratePROFIenergy

TIA PortalWinCC V12, STEP7 V12

SIMATIC B.Data (On-Site)Energy Analytics (als Managed

Service)

S7-300, S7-400, Industrial PC

Observe Analyze Predict Prevent

Unrestricted © Siemens AG 2017 All rights reserved.

Page 28

Industrial Data Management ExampleLogistic Management with SIMATIC

Field/ Control Level Operator Level Operator Level Management Level

Automation-Ability… of Logistic Systems

Interpretation-Ability…of Logistic Systems

Prognostication-Ability… of Logistic behavior

Decision-Ability… Logistic Planning

S7-1200, S7-1500, S7-300, ET200S SP; Basic Panels, Comfort

Panel, …

Plant Simulation PreactorWinCC

Observe Analyze Predict Prevent

Unrestricted © Siemens AG 2017Page 29 DF FA MF

Siemens: Realization of our own Digital FactoryElectronics Works Amberg

Thank You!April 2017Unrestricted © Siemens AG 2017

Unrestricted © Siemens AG 2017Page 31 DF FA MF

Information and Rules

Brochures in the foyer

Personal protective equipment for shopfloor visits, if required:

Button up the coats1 stripe per person

Don’t interfere with running machinesand systems!