future of manufacturing - driving the digital enterprise · manufacturing is getting more and more...
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© Siemens Ltd. Seoul 2014. All rights reserved
Future of Manufacturing
- Driving the Digital Enterprise18th of March, 2015 Günther Klopsch
Head of Digital Factory Division
and Process Industries & Drives Division
Siemens Ltd. Seoul
Page 2© Siemens Ltd. Seoul 2014. All rights reserved
Automation is one of the most efficient means to manage the limited natural
resources of this world for the continuously growing population
The growing population and the rise in the standard of
living cause a continuously growing need for all kinds of products
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The Internet is revolutionizing the business world
and creates major challenges for manufacturing companies
© Siemens Ltd. Seoul 2014. All rights reserved
The global challenges
Future of Manufacturing
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Korea into the top ranks of global manufacturing
Manufacturing output continues to grow by about 2.7 percent annually in advanced economies and 7.4 percent in large developing countries
(between 2000 and 2007)
South Korea’s economy has risen steadily in global manufacturing, ranked 11th in 1990, 8th in 2000 and 7th in 2010.
South Korea’s manufacturing share of GDP is 28% ranked in the world’s 2nd place.
Manufacturing share of GDP in percentRanking by share of manufacturing gross value added
1980 1990 2000 2010Average 17
Source: McKinsey Global Institute, IHS Global Insight, United Nations Statistics Division, BEA (Nov., 2012)
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Manufacturing is getting more and more important all around the world
Reform of
industrial policy
• Focus on IT integration
in industrial processes
• Energy efficiency
legislation
High-tech strategy
• Projects for the future
"Industrie 4.0" and
"Smart Services World"
Governments are launching initiatives to strengthen industry
Manufacturing
Renaissance
• Formation of a
"National Network for
Manufacturing Innovation"
• Research Center "Digital
Manufacturing and Design
Innovation"
Creative Economy
• Manufacturing Industry
Innovation 3.0 Strategy
• Plan to establish 10,000
Smart Factories by 2020
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Challenges for industry are growing worldwide
Shorter innovation cycles
More complex products
Larger data volumes
Individualized mass production
Volatile markets
High productivity
Energy and resource efficiency are
decisive factors of competitiveness
Increasing competitiveness
Increase efficiency Shorten time-to-market Enhance flexibility321
Manufacturing is changing faster than ever before
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Siemens Electronics Factory Amberg –
Increased productivity and energy efficiency through Plant Data Services
• At a glance: Automatically updated consumption values for
electricity, gas, water and other resources on the factory or
site level
• Reduction of energy consumption on machine level: Savings
in Christmas time of ~200,000 kWh (vs. previous year)
• Identification of unnecessary resource input in non-production
times: Annual savings of 100,000 liters liquid nitrogen
Energy Analytics –
Intelligent reports and dashboards
Page 9© Siemens Ltd. Seoul 2014. All rights reserved
Challenges for industry are growing worldwide
Shorter innovation cycles
More complex products
Larger data volumes
Individualized mass production
Volatile markets
High productivity
Energy and resource efficiency are
decisive factors of competitiveness
Increasing competitiveness
Increase efficiency Shorten time-to-market Enhance flexibility321
Manufacturing is changing faster than ever before
Page 10© Siemens Ltd. Seoul 2014. All rights reserved
Big Data – Data is growing exponentially
Source: IDC's Digital Universe Study, sponsered by EMC, December 2012
Exabytes
The digital universe will reach
40 zetabyte by 2020, resulting
in a 50-fold growth from the beginning
of 2010.
2010 2020
10.000
20.000
30.000
40.000
2000
Up to the year 2000, the world generated
appr. 2 exabytes of new information:
2.000.000.000.000.000.000.
Product development Product data of one camera increased from
1.8 terabytes to 296 terabytes
2015
2.000
Today, this amount is generated in
one single day.
Page 11© Siemens Ltd. Seoul 2014. All rights reserved
Challenges for industry are growing worldwide
Shorter innovation cycles
More complex products
Larger data volumes
Individualized mass production
Volatile markets
High productivity
Energy and resource efficiency are
decisive factors of competitiveness
Increasing competitiveness
Increase efficiency Shorten time-to-market Enhance flexibility321
Manufacturing is changing faster than ever before
Page 12© Siemens Ltd. Seoul 2014. All rights reserved
Increasing complexity and product variety –
For example automotive industry
Engines 11
Gears 3
Bodypanels 2
Chassis 4
Tire/rim combinations 10
Colors 45
Multimedia systems 11
Phone options 6
Assistance systems 15
Other selectable options 43
Configuration options VW Golf
Source: Volkswagen Configurator VW Golf, 1)estimated
Several trillion possible combinations1)
© Siemens Ltd. Seoul 2014. All rights reserved
The way to Industrie 4.0
Future of Manufacturing
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Setting the pace for the next industrial "revolution"
1st Industrial revolution
Introduction of mechanicalproduction plants using water and steam power
2nd Industrial revolution
Introduction of mass production based on the division of labor using electricalenergy
3rd Industrial revolution
Introduction of electronics and ITto increase the level of automation
4th Industrial revolution
Introduction of cyber-physical systemsEnd of 18th century
End of 19th century
1970
2010
Mechanical loom
Siemens single-phase generator
Industrie 4.0
Programmable Logic
Controller
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The answer for the future of manufacturing –
Covering the entire product development and production process
Verify design and manufacturing processes virtually – validate and optimize real production
Productionengineering
3TIA Portal
Productionplanning 2
Teamcenter
Productdesign 1
NX
Productionexecution
4Integrated
Drive Systems
Services
5Energy
Analytics
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Example: Manufacturing industry
Consistency throughout the entire value added chain
ServicesProduction designProductionplanning
Productdesign
Productionengineering
Totally Integrated AutomationPLM Software
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Real and virtual worlds are converging thanks
to innovative software and powerful hardware
Virtualworld
Realworld
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“Digital Enterprise” Software Suite –
The Siemens answer to Industrie 4.0 requirements
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Our automation offering
for the manufacturing industry
PLM
TECNOMATIX
Digital
Manufacturing
TEAMCENTER
Collaborative
PDM
NX
Product
Development
SIMATICHMI
SIMATICControllers
SIMATIC IDENTIndustrial Identification
SIMATIC Distributed I/O
SINAMICSDrive Systems
SIMATIC WinCC
SCADA System
SIMATIC NETIndustrial
Communication SIRIUSIndustrial Controls
SINUMERIKCNC
SIMOTIONMotion Control
TIA PORTAL
Engineering
Framework for
Automation Tasks
SIMATIC IT Production
Suite SIMATIC IT
Intelligence
Suite
Field level
Control level
Enterprise level
Management level
Operator level
ERP PLM
MES
SCADA
Page 20© Siemens Ltd. Seoul 2014. All rights reserved
Faster Product design and Production planning
through PLM software
Productionengineering
3Productionplanning 2Product
design 1NX
Productionexecution
4Services
5
Virtual Development &
Planning with PLM Software
Reduced development times
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Today’s Product Challenges are
More Difficult Than Ever Before…
Landing on Mars
is one of the hardest
jobs on Earth.
On August 5, 2013, the Mars rover Curiosity landed successfully on
the surface of Mars. There was only one chance to get it right. For
this unprecedented challenge, NASA employed Siemens PLM
software solutions. The development team at NASA’s Jet
Propulsion Laboratory digitally designed, tested, assembled, and
simulated the entire Mars rover before a single physical prototype
was created.
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Faster Product design and Production planning
through PLM software
Productionengineering
3Productionplanning 2
TEAMCENTER and
TECNOMATIX
Productdesign 1
Productionexecution
4Services
5
Complete Simulation &
Optimized Production
Up to 50% reduced
time to market
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Where are we today in production planning and simulation?
• Starting with the product specific data
• The production process is planned i.e. welding points
are defined
• Production equipment planning from a predefined
library
• Process optimization i.e. robot movements are
simulated
• Tool design and validation
• Virtual commissioning based on the real automation
application software
Body shop: From product data to commissioning
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Cost savings through highest efficiency in production engineering
Productionengineering
TIA Portal
Productionplanning 2Product
design 1
Productionexecution
4Services
53
Smooth Communication
of all components
Integration of all Automation Functions
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Totally Integrated Automation Portal
Engineering framework for all automation tasks
One Engineering Framework
for all new Hardware components
TIA Portal
intuitive efficient proven
SINAMICS
SIMATIC HMI
SIMATIC NET
SIMATIC Controller
Safety Integrated
Distributed I/O
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Efficient engineering is crucial for successful automation
TIA Portal and new portfolio make the difference in Automation
1979 1996 2010 2012 2020
Totally Integrated Automation minimizes engineering time and reduces costs –
Through efficient interoperability of all automation components
Cost of engineering Complexity of automation Total automation costs
The TIA Portal isthe key for engineering efficiency
Engineering Efficiency
Engineering cost/hour
Automation complexity (time)
Total costs
Long-term development of automation costs
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Efficient Production based on one high performance network technology
Productionengineering
3Productionplanning 2Product
design 1
Productionexecution
4Integrated
Drive Systems
Services
5
Fully integrated
Product & System Portfolio
Data integration from
shop-floor to top-floor
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Energy consumption levels
in a body storage application
64% Energy saving
Calculated on a yearly production:
- 10 scissors lifts and 8 carriages
- 60s cycle time
- 250 production days
Reduction by feeding
back
10,67 MWh
New total
Energy consumption
5,89 MWh
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
Jan Feb März April Mai Juni Juli Aug Sep Okt Nov Dez
kWh
Zeit
Energy consumption without
feeding back
16,56 MWh
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Services throughout the lifecycle build upon the data base of previous
process steps
Productionengineering
3Productionplanning 2Product
design 1
Productionexecution
4Services
5Energy
Analytics
Services throughout the lifecycleThe Key to
Customer Satisfaction
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Data-Driven Services based on production data:
Reduce Service, maintenance and energy costs
Customer
Operation Center
Data collector
© Siemens Ltd. Seoul 2014. All rights reserved
What has to be done
Future of Manufacturing
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From serial to parallel processes
Common data model with consistent data
flows
PLM-Team collaboration and roundtrip
engineering
Faster from idea
to production…
Solution: Integrated Workflow from Product Design to Production
….based on integration of product-
and production design
Serial Process Parallel Process
Local
optimization
Integrated
optimization
time time
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Static Production Flexible ProductionIncreasing flexibility of
production…
…. based on modular production
units
From static to flexible production
Pre-defined production
process
Self optimizing
and autonomous
Solution: Use of Cyber-Physical Systems
Increase flexibility and reduce complexity
CPS
Intelligent, autonomous and self configuration/optimizing
Communicative and collaborative
Context aware
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Integrated industrial cyber security protection
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Our perspective of Industrie 4.0
What needs to be done!
Future: Industrie 4.0
Dynamic network of local controls
Extended complex communication
Digital models of the overall
process and participants
Process optimization in dynamic networks
Self-configuring security concepts
also for temporary requirements
Humans to define rules and frameworks
for decision making
Today: Industrie 3.8
Local controls
Realtime communication
Digital "copies" of products and production
Manufacturing Execution Systems
Industrial security concepts
Execution and decision making
mainly by humans
• Rule framework and
architecture for dynamic
topologies
• Integrated process simulation
• …
Today: Industrie 3.x
Future: Industrie 4.0
Page 36© Siemens Ltd. Seoul 2014. All rights reserved
Future of Manufacturing – Prepare for change!
Look for strong
partnerships1Train your
employees3Strengthen
R&D2
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Thank you for your attention!