Future of Manufacturing - Driving the Digital Enterprise 18th of March, 2015
Gü nther Klopsch Head of Digital Factory Division and Process Industries & Drives Division
© Siemens Ltd. Seoul 2014. All rights reserved
Siemens Ltd. Seoul
The growing population and the rise in the standard of living cause a continuously growing need for all kinds of products
Automation is one of the most efficient means to manage the limited natural resources of this world for the continuously growing population
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The Internet is revolutionizing the business world and creates major challenges for manufacturing companies
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Future of Manufacturing
The global challenges
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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.
Ranking by share of manufacturing gross value added
1980
1990
2000
Manufacturing share of GDP in percent
2010
Average 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
High-tech strategy
Creative Economy
•
•
Manufacturing Industry Innovation 3.0 Strategy
•
Plan to establish 10,000 Smart Factories by 2020
Projects for the future "Industrie 4.0" and "Smart Services World"
Manufacturing Renaissance • Formation of a "National Network for Manufacturing Innovation" • Research Center "Digital Manufacturing and Design Innovation"
Reform of industrial policy •
Focus on IT integration in industrial processes
•
Energy efficiency legislation
Governments are launching initiatives to strengthen industry
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Challenges for industry are growing worldwide
Increasing competitiveness
1
2
Increase efficiency Energy and resource efficiency are decisive factors of competitiveness
Shorten time-to-market Shorter innovation cycles More complex products
3
Enhance flexibility Individualized mass production Volatile markets High productivity
Larger data volumes
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
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© Siemens Ltd. Seoul 2014. All rights reserved
Challenges for industry are growing worldwide
Increasing competitiveness
1
2
Increase efficiency Energy and resource efficiency are decisive factors of competitiveness
Shorten time-to-market Shorter innovation cycles More complex products
3
Enhance flexibility Individualized mass production Volatile markets High productivity
Larger data volumes
Manufacturing is changing faster than ever before
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© Siemens Ltd. Seoul 2014. All rights reserved
Big Data – Data is growing exponentially The digital universe will reach
40.000
40 zetabyte by 2020, resulting in a 50-fold growth from the beginning of 2010. 30.000
Today, this amount is generated in
one single day. 20.000
Up to the year 2000, the world generated appr. 2 exabytes of new information: 2.000.000.000.000.000.000.
Product development
10.000
Exabytes
Product data of one camera increased from 1.8 terabytes to 296 terabytes 2000
2010
2015
2.000
2020
Source: IDC's Digital Universe Study, sponsered by EMC, December 2012 Page 10
© Siemens Ltd. Seoul 2014. All rights reserved
Challenges for industry are growing worldwide
Increasing competitiveness
1
2
Increase efficiency Energy and resource efficiency are decisive factors of competitiveness
Shorten time-to-market Shorter innovation cycles More complex products
3
Enhance flexibility Individualized mass production Volatile markets High productivity
Larger data volumes
Manufacturing is changing faster than ever before
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Increasing complexity and product variety – For example automotive industry Configuration options VW Golf Engines
Gears Bodypanels Chassis Tire/rim combinations Colors Multimedia systems Phone options Assistance systems Other selectable options
11 3 2 4 10 45 11 6 15 43 Several trillion possible combinations1)
Source: Volkswagen Configurator VW Golf, 1)estimated Page 12
© Siemens Ltd. Seoul 2014. All rights reserved
Future of Manufacturing
The way to Industrie 4.0
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Setting the pace for the next industrial "revolution"
2010 Siemens single-phase generator
End of 19th century Mechanical loom
End of 18th century 1st Industrial revolution Introduction of mechanical production plants using water and steam power Page 14
2nd Industrial revolution Introduction of mass production based on the division of labor using electrical energy
1970
Programmable Logic Controller
3rd Industrial revolution
Introduction of electronics and IT to increase the level of automation
4th Industrial revolution Introduction of cyber-physical systems
Industrie 4.0
© Siemens Ltd. Seoul 2014. All rights reserved
The answer for the future of manufacturing – Covering the entire product development and production process
Production engineering Production planning Product design
1
2
Production execution
3
Services
4
5 Energy Analytics
Integrated Drive Systems TIA Portal Teamcenter NX
Verify design and manufacturing processes virtually – validate and optimize real production
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Example: Manufacturing industry Consistency throughout the entire value added chain
Product design
PLM Software
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Production planning
Production engineering
Production design
Services
Totally Integrated Automation
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Real and virtual worlds are converging thanks to innovative software and powerful hardware
Virtual world
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Real world
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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
Enterprise level ERP
NX Product Development
PLM
TEAMCENTER Collaborative PDM
TECNOMATIX Digital Manufacturing
Management level SIMATIC IT Production Suite
SIMATIC IT Intelligence Suite
MES
Operator level SIMATIC WinCC SCADA System
SCADA TIA PORTAL Engineering Framework for Automation Tasks
Control level
SIMATIC Controllers
SIMATIC HMI
SINUMERIK CNC
SIMOTION Motion Control
SIRIUS Industrial Controls
SIMATIC IDENT Industrial Identification
SIMATIC Distributed I/O
SINAMICS Drive Systems
Field level SIMATIC NET Industrial Communication
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Faster Product design and Production planning through PLM software
Production engineering Production planning Product design
1
2
Production execution
3
Services
4
5
NX
Virtual Development & Planning with PLM Software
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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
Production engineering Production planning Product design
1
Complete Simulation & Optimized Production
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2
Production execution
3
Services
4
5
TEAMCENTER and TECNOMATIX
Up to 50% reduced time to market
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Where are we today in production planning and simulation? Body shop: From product data to commissioning • 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
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Cost savings through highest efficiency in production engineering
Production engineering Production planning Product design
1
Smooth Communication of all components
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2
Production execution
3
Services
4
5
TIA Portal
Integration of all Automation Functions
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Totally Integrated Automation Portal Engineering framework for all automation tasks SIMATIC Controller
One Engineering Framework for all new Hardware components
SINAMICS
TIA Portal
SIMATIC HMI
Distributed I/O
Safety Integrated SIMATIC NET
intuitive
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efficient
proven
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Efficient engineering is crucial for successful automation TIA Portal and new portfolio make the difference in Automation
Long-term development of automation costs
The TIA Portal is the key for engineering efficiency
Total costs Engineering cost/hour Automation complexity (time)
1979 Cost of engineering
1996 Complexity of automation
2010 Total automation costs
2012
2020 Engineering Efficiency
Totally Integrated Automation minimizes engineering time and reduces costs – Through efficient interoperability of all automation components
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Efficient Production based on one high performance network technology
Production engineering Production planning Product design
1
Fully integrated Product & System Portfolio
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2
Production execution
3
Services
4
5 Integrated Drive Systems
Data integration from shop-floor to top-floor
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Energy consumption levels in a body storage application
Calculated on a yearly production: - 10 scissors lifts and 8 carriages - 60s cycle time - 250 production days
64% Energy saving
kWh 18000
Energy consumption without feeding back 16,56 MWh
16000 14000 12000
Reduction by feeding back 10,67 MWh
10000 8000 6000
New total Energy consumption 5,89 MWh
4000 2000 0 Jan
Feb
März
April
Mai
Juni
Juli
Aug
Sep
Okt
Nov
Dez
Zeit Page 28
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Services throughout the lifecycle build upon the data base of previous process steps
Production engineering Production planning Product design
1
2
Services throughout the lifecycle
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Production execution
3
Services
4
5 Energy Analytics
The Key to Customer Satisfaction © Siemens Ltd. Seoul 2014. All rights reserved
Data-Driven Services based on production data: Reduce Service, maintenance and energy costs
Customer
Data collector
Operation Center
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Future of Manufacturing
What has to be done
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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
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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 Context aware
CPS Increase flexibility and reduce complexity Page 33
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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 Future: Industrie 4.04.0 Dynamic network of local controls Extended complex communication
Digital models of the overall process and participants
Today: Industrie Today: Industrie 3.8 3.x Local controls
• Rule framework and architecture for dynamic topologies
Realtime communication
• Integrated process simulation
Digital "copies" of products and production
• …
Process optimization in dynamic networks Self-configuring security concepts also for temporary requirements Humans to define rules and frameworks for decision making
Manufacturing Execution Systems Industrial security concepts Execution and decision making mainly by humans
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Future of Manufacturing – Prepare for change!
Look for strong partnerships
1 Page 36
2
Strengthen R&D
3
Train your employees
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Thank you for your attention!
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