The way to make digital in the future

The way to make digital in the future--Siemens ' digital experience

Since ancient times, with "abundance" reputation of Chengdu is a good place to enjoy the ease of life. Ease of life may be a good friend invited to play a game of mahjong, or small groups in the narrow alley of the shadow staggered between a cup of tea. However, in addition to ease, Chengdu has also been changing, the national "West development" strategy after the start of the more than 10 years, it has grown into a regional GDP nearly trillion yuan of the economic strong city. According to statistics, more than 200 of the world's top 500 companies in Chengdu, manufacturing, electronic information industry, the rise of the city added a technology label.

In this fast-growing city, it is not difficult to feel the changes that technology brings to industry. In the high-tech West district of Chengdu, there is a factory that looks "humble". Its appearance is low-key and simple, but the interior hides a huge mystery. The whole plant has realized the digitalization from management, product development, production to logistics and distribution, and data interconnection with German production base and US research and development center through information technology. It is a complete digital enterprise platform-Siemens industrial automation products Chengdu production Research and Development base (hereinafter referred to as "Siemens Chengdu Plant").

Speaking of "digitization", it is not difficult to understand. We develop and produce a new product at the Siemens Chengdu Plant, which will have its own data information. These data are continuously enriched in research, development, production and logistics, and are kept in a data platform in real time. The operation of this plant is based on these data bases, ERP, PLM (Product Lifecycle Management System), MES (manufacturing execution System), control system and supply chain management, all achieve seamless information interconnection, thus creating a transparent factory picture.

What's more, the vast majority of the plant's technology comes from Siemens itself, a factory that "produces itself".

Digital Research and Development: collaboration and rapid

The Chengdu plant undertakes the role of Siemens Global industrial automation product development. The ability to do so is related to the full application of Siemens PLM Digital solutions such as NX and Teamcenter. Research and development is also the starting point of the digital chemical factory "data chain", the data produced by the research and development process will be transmitted in real-time between the various systems in the factory, and the synchronous updating of the data avoids the mistakes that the traditional manufacturing enterprises often appear due to miscommunication, and also makes the factory's efficiency greatly improved. Data statistics, due to the rapid development of digital chemical plant, can reduce the time to market the product 50%.

The new products developed by Siemens Chengdu Plant were born in the Siemens PLM product development solution NX Software. It supports all aspects of product development from design to engineering and manufacturing, integrates multi-disciplinary simulations, and offers solutions for a full range of advanced parts manufacturing applications that cannot be achieved by other computer-aided design software. Engineers in the Research and development department can simulate the design through NX software, and can also be assembled in the design process to achieve "visible". The digital design realized by the application of NX software can greatly shorten the iterative cycle of the product from design to analysis, and also reduce the programming time by up to 90%. The time for product development is correspondingly shortened.

Products that are designed in NX software will continue the "production journey" with their own data information. This data is delivered to the production line via CAM (computer-aided manufacturing systems), ready for the next manufacturing process, and simultaneously "written" into the Digital factory's data center--teamcenter software for sharing with departments such as quality, procurement and logistics. Procurement department will be based on product data information for parts procurement, quality department will be based on product data information for acceptance, logistics Department is based on data information to confirm the parts.

The shared database is the greatest feature of Teamcenter. When data is called from different departments, such as quality, procurement, and logistics, they use shared document libraries and are quickly connected to the responsible parties through the backbone. Even if the data is updated, different departments will be able to get the latest data in the first place, which makes the work of the research and development team of Siemens Chengdu Plant become simpler and more efficient, which avoids the barriers of information transmission between the research and development of traditional research and manufacturing enterprises or different departments due to different data platforms.

Digital production: easy and efficient

Wang Yunlong graduated from a university in Chengdu, the electronics and information professional, Siemens Chengdu Factory PLC (programmable Controller) assembly station, an ordinary employee. Compared to most of the colleagues around him, he is a new person, but the job is not complicated for him, thanks to the Siemens Digital Enterprise platform, will be boring manufacturing and production made easy.

Every day the electronic task order generated by the Siemens MES system is displayed on the computer display in front of the Wang Yunlong Workbench, and the real-time data exchange interval is less than 1 seconds, which means he can always see the latest version. Siemens MES system simatic it swept the traditional manufacturing enterprise production planning and scheduling functions. Without the manual copy of the task order, eliminating the different production line communication complex links. Production orders are released by MES, and in the high integration with ERP system, the real-time transmission of production plan, material management and other data can be realized. In addition, SIMATIC it integrates plant information management, production maintenance management, material traceability and management, equipment management, quality management, manufacturing KPI analysis and other functions, can ensure that the plant management and production of high synergy.

There are 5 different parts boxes on the Wang Yunlong Workbench, each with an indicator light on each case. When the auto-guide car to send a welcome to the assembly of the product, the computer display will appear on its information, the corresponding need for the box on the LED lights, Wang Yunlong know what parts to install. This is because the sensor scans the barcode information of the product, and transmits the data in real time to the MES system, and the MES system is replaced by a person to complete the thinking process by connecting with the Siemens TIA (fully integrated automation system) to manipulate the part box LEDs. This design can meet the needs of automation products "flexible" production (that is, the production of a variety of products on a production line), with the help of the LED, even if the other product Wang Yunlong will not be afraid of the wrong parts.

Siemens ' fully integrated Automation solutions (TIA) have largely replaced the human brain, vision and arm. Siemens uses a programmable controller (PLC) to guide the production process, using a vision system to identify the quality, and to use the Automatic Guide trolley to deliver the product. Connecting and transmitting data via profinet Fieldbus not only makes people's work easier, but also ensures the reliability, flexibility and efficiency of all aspects of production.

Andreas Bukenberger, general manager of Siemens Chengdu Plant, gave specific figures for efficient production: "The first pass rate (FPY) of Chengdu Factory products can reach more than 99%." ”

Wang Yunlong confirmed his assembled products, press a button on the workbench, the sensor on the automation line will scan the barcode information of the product and record its data in this position. The MES system simatic it will use this data as the basis of judgement, to the control system issued instructions, command the car to send it to the next destination. ”

Before reaching the next operation, the product must pass the "strict" inspection procedure, take the programmable controller (PLC) product as an example, in the entire production process for this kind of product quality detection node is more than 20. Visual inspection is a unique quality inspection method of digital chemical plant, the camera will take the image of the product and the correct image in the Teamcenter data platform, a little flaw can not escape the "eye" of simatic it Quality Management module. Comparing the manual sampling of traditional manufacturing enterprises, this is obviously reliable and much faster. ”

After multiple assembly and acceptance of excessive quality inspection, the finished product will be sent to the packing station. After the manual packaging, packing and other links, a box of packaged automation products will be automatically transported to the logistics center or three-dimensional warehouse through the lift ladder and conveyor belt. ”

Such a complete production process, in the traditional manufacturing enterprises through the hands of dozens or even hundreds of people to complete, and in the workshop of Siemens Chengdu factory, but not see the dense assembly line staff, most of the process is automatic completion. ”

Using Siemens PLM and MES information interconnection, Siemens can also deploy production plans in real time between plants around the world based on material storage, delivery time and other information to achieve the best combination of resource utilization and material distribution. ”

"The Chengdu plant, which applied the Siemens Digital enterprise platform solution, compared to Siemens ' other plants in China, the delivery time of the product was reduced by 50%," Bukenberger said. The sister plant at Siemens Chengdu Plant, the Siemens Germany Amberg Electronics manufacturing Plant (EWA), now has an annual output of 1 million parts, an average of 1 seconds to produce a product, and the future Chengdu plant will be expected to hit this record. ”

Digital Logistics: precise and orderly

When it comes to the awe-inspiring location of the Siemens Chengdu Plant, it has to mention its precise and orderly digital logistics system. Assembly line staff such as Wang Yunlong, in the need for materials and even do not have to turn around, as long as the touch of the computer display on the workbench, three or four minutes later, the material he needs will be accurately from the workshop material Intermediate library output, and sent to him. ”

Behind this flow of automated logistics, it is known as the "automatic transportation" material conveying link. The sensor on the automatic assembly line will scan the barcode of the product on the Guide trolley, and the data will tell "software system" what is needed in the assembly link, the employee presses the button, the material will be automatically transported from the material library, and through the line of the Sensor "command", sent to the designated location, this process is " Fully transparent "and do not require human intervention. "This is the role of ERP, Siemens MES system simatic it and Siemens Warehouse management software. And all this, if in the traditional manufacturing enterprise, is to rely on the staff to look at the task list and personally to the material library to select the completed. Staff not only frequently to and from the work station and inventory location, but also inevitably because of the wrong task orders and inefficient; When the task order is updated, it is also difficult to ensure that employees are informed of the first time. ”

Material Intermediate Library is the station of the material in the workshop, in which the material is extracted from the material warehouse on a daily basis according to the principle of "need actual ability" in lean production. This has to mention the concept of "pull-type production", that is, in the process of production processes, only when necessary to receive goods, retailers will only receive the actual number of customers need to purchase from the supplier. Through this kind of management, can ensure that the factory can "timely, moderate, in the right place to produce quality products." ”

Larger quantities of material are stored in a compact, high-shelf warehouse. The purchased material is stored here after quality inspection and is connected to the workshop by two elevators. The warehouse has nearly 30,000 material storage boxes, material access is not used forklift truck handling, but through the "stacker Reclaimer" with digital positioning mode to crawl, do not have to consider the distance forklift through, material library design more compact, saving the space of the warehouse. Spare space for the expansion of the Siemens plant in Chengdu, leaving ample preparation. ”

Digital Enterprise: Manufacturing Future

In the high-tech Western District of Chengdu, where manufacturing is converging, many companies face similar challenges: when low labor costs are no longer labelled as "made in China" in the global market, manufacturing companies are more demanding for change. ”

In order to maintain the advantage in the fierce global competition, the manufacturing enterprises should make maximum use of resources, make production more efficient; In order to meet the changing customer demand, the manufacturing enterprises must shorten the time to market and respond to the markets more quickly, in order to satisfy the demand of market diversification, Manufacturing enterprises also need to quickly realize the flexible changes in the various links, the production becomes more flexible. Efficiency, speed and flexibility are the biggest changes that digital enterprises bring to the manufacturing industry. The emergence of a digital enterprise such as the Siemens Chengdu Plant provides a good reference for the future direction of China-made change. ”

Data show that through digital factory planning, you can reduce time to market by at least 30%, and by optimizing planning quality, you can reduce manufacturing costs by 13%. In many aspects, such as the ratio of new products to market, equipment production efficiency, product delivery capability and operating profit margin, the index of digital factory is much higher than that of traditional manufacturing enterprises. ”

Digital manufacturing brings not only dazzling technology, but also tangible benefits, as well as the competitiveness to support the long-term development of enterprises. This will be the foundation of sustainable development in China in the future. ”

Using its technology and experience in the digital enterprise platform, Siemens industry is helping China's manufacturing enterprises to achieve this transformation and will continue to influence China's manufacturing. The Siemens plant in Chengdu is a microcosm, and the digital blueprint for Chinese manufacturing is slowly unfolding. ”

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The way to make digital in the future