Siemens
Leveraging digital transformation to shorten the time from designing to manufacturing production lines
Industria: Automotive & transportation, Electronics
Undertaking a digital transformation
Hirata Corporation (Hirata), headquartered in Kumamoto, Japan, is a global leader in constructing production lines. It has locations throughout Japan as well as plants in North America, Europe and across Asia, providing production equipment to automotive and semiconductor manufacturers worldwide.
Hirata provides transmission assembly lines, engine assembly lines, electrical vehicle (EV) and other automotive production equipment to numerous manufacturers.
When the 2016 Kumamoto earthquakes damaged the company’s plants, Hirata decided to contribute to the reconstruction effort by relocating its headquarters to Kumamoto City.
As sales increased, the company’s newly built plant was expanded to provide space for adjusting equipment test runs and enabling customers to conduct inspections inside the plant. Hirata has integrated design, manufacturing, assembly, electrical work and adjustment test runs. As the company constructed and subsequently expanded its plant, it also started a large-scale digital transformation.
After evaluating several simulation solutions, Hirata chose Siemens Digital Industries Software’s Process Simulate in the Tecnomatix® portfolio. It also decided to work with Siemens as its strategic partner to promote digital transformation, and as part of that initiative introduced the Siemens Xcelerator business platform of software, hardware and services to the company.
Strategically promoting digital transformation
By embracing digital transformation, Hirata has been able to shorten the time it takes to go from product design to manufacturing. Hirata has front-loaded its investment in resources early in the product development process, bringing forward work that was previously done in later stages.
As Hirata’s customers began to face shorter production times, they focused on how to compress the time between new products, handle low-volume, high-mix production and shrink the period required to modify production lines during operation.
Hirata knew the digital transformation would help them, but it was challenging to explain to senior management and on-site personnel what would change and what the simulations with Process Simulate would reveal. Describing the benefits of simulations was particularly difficult at first. Some personnel had the impression that simulations would require twice as much effort. However, as the implementation went ahead, workers were able to see the positive effects and started saying it made sense.
Simulation supports high-quality manufacturing
“Prior to introducing digital simulations, we were able to check for equipment interferences and conduct on-site verifications, but now we were able to teach robots offline,” says Shoichiro Seki, general manager of the engineering departments at Hirata. “Once that data has been downloaded, the robots can immediately be operated on-site, which is a huge advantage.
“Previously, we had to turn on the power, start up the robots and then perform the teaching work to check for interferences, cable twists and other issues. Now all of that can be performed offline, which is incredibly helpful for manufacturing.”
Leveraging Process Simulate
Hirata’s major customers have added 3D model validation to their equipment development process and most of them were using Process Simulate, which is part of Siemens Xcelerator. This also motivated Hirata to select Process Simulate.
“Previously we required three engineers to complete the verification process in three to 10 days, but one engineer using Process Simulate for cable simulation can complete the verification process in approximately two hours,” says Seki. “That reduced man-hours compared to conventional methods by 90 percent and manpower requirements by 66 percent.”
“After a year of simulation experience with Process Simulate, I was able to gain a deeper overall understanding of the work I had been doing for the past five years in my own area of expertise, human machine interface,” says Mami Hayata, chief of the control design group in the engineering department. “This enabled me to receive information from many different fields, including mechanical, control, instrumentation and robotics. The introduction of simulation has allowed me to learn so much more about the world of equipment.”
“I used to only talk to people in control,” says Kosuke Nishi, who is a mechanical design engineer. “But now I have connections with various people in mechanical, control, instrumentation and robotics. Initially, when simulations were introduced, my requests to mechanical designers to provide information for simulation were met with resistance, but now that awareness and demand have increased considerably, I feel that we are able to exchange useful information.”
“Previously, we determined the optimal cable routes and fixing methods by trial and error,” says Ryosei Sekiguchi, manager of the control design group in the engineering department. “With Process Simulate we can use simulations to verify multiple patterns of routes and fixing methods simultaneously, which significantly reduces the time spent on that.”
“Prior to introduction, we used 2D drawings to confirm ergonomic areas and workability based on planar dimensions, which frequently led to insufficient verification of worker postures and product shapes,” says Seki.
“This often resulted in us discovering necessary adjustments only after the completed equipment started being used. However, with the introduction of human machine interface, we can now perform work verifications for various postures in 3D. The results are clear and easy to understand, allowing smooth consensus building with customers.
“We compared simulation software from various manufacturers, but ultimately chose to adopt Process Simulate due to its global market share and especially its widespread use among automotive manufacturers.
“As a result of this evaluation, we chose Siemens as our strategic partner to promote digital transformation. We also introduced Siemens Xcelerator as part of that effort.”
Future of Process Simulate
Hirata is implementing Process Simulate add-on features every year, including modules for robotics, virtual commissioning, safety and cable. They have also introduced Plant Simulation in the Tecnomatix portfolio in various departments.
Zanini Renk Embraces Industry 4.0 with Siemens Solutions
Industry: Manufacture
Introduction
Zanini Renk, a renowned player in the manufacturing industry, has embarked on a transformative journey towards Industry 4.0 with the help of Siemens solutions. By leveraging their integrated software, Opcenter Execution Discrete and Opcenter Advanced Planning and Scheduling (APS), Zanini Renkhas revolutionized their operations and achieved remarkable improvements in efficiency, visibility, and customer satisfaction.
Enhancing Efficiency and Visibility
Prior to implementing Siemens solutions, Zanini Renk faced significant challenges in their factory operations. A lack of visibility and accuracy in scheduling resulted in daily firefighting and missed deadlines. However, with Opcenter Execution Discrete, the company gained a real-time view of their shop floor, allowing them to track and document the transformation of raw materials into finished goods with precision and transparency. Opcenter APS further facilitated detailed production scheduling, enabling Zanini Renk to optimize their manufacturing process and allocate resources effectively.
Transforming Operations with Industry 4.0
The implementation of Siemens solutions enabled them to determine their Overall Equipment Effectiveness (OEE). Within two years, their OEE increased from 45% to an impressive 71%, showcasing significant improvements in productivity and efficiency. The production data collection software, Opcenter Execution, provided Zanini Renk with precise measurement of data for each part, ensuring quality control and informed decision-making.
Gaining Holistic Visibility and Cultural Shift
With the aid of Opcenter APS, Zanini Renk experienced a cultural shift within their organization. Their team embraced the new system, reaping the benefits of increased visibility, credibility, and accuracy in delivery timelines. The software offered a holistic view of operations, enabling the company to overcome local limitations and make data-driven decisions on a global scale.
Next Steps Forward
Integrating Engineering with Manufacturing: Zanini Renk recognizes that true integration between engineering and the factory is the next clear step in their Industry 4.0 journey. To achieve this, they plan to introduce engineering software, such as Product Lifecycle Management (PLM), that seamlessly integrates with their production software. By creating a greater integration between engineering and the factory, Zanini Renk aims to enhance collaboration, optimize processes, and further improve efficiency. They believe that this integration will unlock new possibilities and drive their competitiveness to new heights.
Leveraging Data Analytics: In the era of Industry 4.0, data analytics plays a crucial role in driving improvement and increasing competitiveness. Zanini Renk recognizes the importance of leveraging the vast amount of data they generate and utilizing it effectively to fuel continuous improvement. By harnessing the power of data analytics, they aim to gain valuable insights that will enable them to make data-driven decisions, optimize their processes, and identify opportunities for further enhancement. Zanini Renk firmly believes that by embracing data analytics, they will propel their organization forward and continue to thrive in the dynamic landscape of Industry,
Partner Siemens delivers 200 software licenses to Conalep, ITCH and UTCH
With the purpose of providing students with the necessary tools to develop their technological skills, the German company Siemens donated 200 software licenses to four higher education institutions in Chihuahua.
Each license, valued at more than one million pesos, was donated by Siemens and will be distributed among Conalep, ITCH, ITCH II, UTCH and UTCH Sur, benefiting more than 3,000 students. The symbolic delivery of these licenses was presided over by José Jesús Jordan Orozco, Director of Economic Development and Competitiveness, who highlighted the importance of this collaboration between the State Government, the Municipal Government and the educational institutions, considering it a significant step in the modernization of education. He also mentioned that the donated software, which is part of the 4.0 hardware automation technology, will be used in universities for students to learn how to integrate technology with physical reality, which will improve their skills and facilitate their labor insertion after graduation.
“We are convinced that these licenses will have a great impact on students and that, once they graduate, they will find employment more easily thanks to what they have learned,” said Jordán.
For his part, Jaime Luciano Fernández Chávez, Director of Linkage of the Secretariat of Innovation and Economic Development, noted that the delivery of these licenses will open new job opportunities for young people. He added that the Secretariat is working on strategies so that students not only develop their skills, but also decide to stay in Chihuahua, contributing to turn the city into a technological center.
Improving technical education to prepare students for Industry 4.0 and to create complex thesis topics
Industry: Education
Leveraging the Siemens Xcelerator business platform, the Smart Factory Research Center became a key development for improving the university’s training quality.
Dr. Tran Duc Quy, Rector
Hanoi University of Industry
Keeping up with engineering education standards
Established in 1898, Hanoi University of Industry (HaUI) was one of Vietnam’s first technical schools. With a focus on delivering a comprehensive education and supporting Vietnam’s national industrial revolution, the university envisions becoming an institution of applied scientific research and training since many of their students aim for a career in either engineering or manufacturing. This has led the university to continually improve and develop its academic offerings to keep up with industry standards.
HaUI gradually built a series of modern laboratories to provide students with comprehensive, real-world training. For this, the university investigated solutions within the Siemens Xcelerator business platform.
Solving outdated technology limitations
As engineering and manufacturing industries shift toward smart factories and digital software solutions, such as using a digital twin for product development, the university found that graduates needed extensive on-the-job training.
To prepare students for Industry 4.0, the university needed a digital overhaul. Thus, they examined a range of potential digital tools and chose to implement Siemens Digital Industries Software solutions.
The university enlisted Vietbay, a Siemens partner, to collaborate on updating its training laboratories, leveraging their consultation, installation, integration and training services.
Creating the Smart Factory Research Center
By collaborating with Vietbay, HaUI was able to create the Smart Factory Research Center, which includes five research and practice labs, all connected using the Teamcenter® portfolio. These labs allow students to gain experience in all areas of production before graduation, with each corresponding to a specific product development stage, including research and development (R&D), mold and die, digital manufacturing, basic automation and advanced automation.
One of the biggest challenges was integrating the university’s requirements, such as its 3-axis and 5-axis computer numerical control (CNC) machining centers, with advanced technology. However, leveraging the user-friendly design of Teamcenter and Vietbay’s expertise, they were able to fully onboard the university’s machinery to facilitate information sharing across all production stages.
Vietbay also offered extensive training as part of its support package to the university. This included 40 courses delivered over 170 working days and introductions to tooling design in NX™ software, advanced planning and scheduling (APS) in Opcenter™ APS software, the internet of things (IoT) and low-code programming in the Mendix™ platform and application lifecycle management (ALM) in the Polarion™ portfolio. Teamcenter, NX, Opcenter, Mendix and Polarion are all part of the Siemens Xcelerator business platform of software, hardware and services.
Students and instructors participated in this training, paving the way for future course improvements.
“Leveraging the Siemens Xcelerator business platform, the Smart Factory Research Center became a key development for improving the university’s training quality,” says Dr. Tran Duc Quy, rector at Hanoi University of Industry. “Thanks to Siemens and Vietbay, we can provide thousands of lecturers and students the opportunity to practice using the latest technologies prevalent in Industry 4.0.”
“The Smart Factory Research Center, using the Siemens Xcelerator business platform, provides a powerful set of tools for teaching, researching and training engineering students,” says Hoang Tien Dung, head of the Faculty of Mechanical Engineering.
Digitalizing to improve student education
By collaborating, HaUI and Vietbay were able to revitalize the university’s hands-on training while eliminating the need to invest in new equipment. For example, using 3D computer-aided design (CAD) tools such as NX, students were able to practice using a digital twin without needing access to physical machinery. This shift toward virtual spaces resulted in budget savings of an estimated 15 percent since the university was able to reduce its outlay on electricity and miscellaneous upkeep.
With the Vietbay training courses, combined with increased accessibility to technology, the university expanded its educational offerings to over 200 courses, making use of the Smart Factory Research Center.
“Lecturers are now trained to use the Siemens Xcelerator business platform,” says Trinh Van Long, director of the Smart Factory Research Center at HaUI. “This means educators can access a treasure trove of the most advanced technology currently available for teaching students.”
By improving access to high-quality testing environments and tools, students can pick increasingly complex topics for their graduation theses and essays, reducing the need for post-graduation training. These improvements are also attracting new students, with student enrollment increasing year-over-year (YoY) by 10 percent since finalizing the Smart Factory Research Center.
Virtual commissioning with Siemens solutions reduces launch time by three weeks
Industry: Intralogistics
Experts in intralogistics and warehousing operations
Intelligent Distributed Controls (IDC) was founded in 2003 to support customers with intralogistics and warehousing operations in the U.K. and Europe. The engineering, management and IT team at IDC have a broad range of skills including HV Control Panel Design, PLC Software Development, with C# .NET and Android supporting the WCS and WMS development. The team is also supported by project managers with an in-depth knowledge of intralogistics and warehousing and advises customers on automation and warehouse control and management systems (WMS).
One of IDC’s customers, a retail distribution center serving major mail order and e-commerce businesses, had begun planning in spring for the upcoming Christmas seasonal peak. One of the key machines in the distribution center is a high-speed tilt-tray sortation machine that processes more than 6,000 items per hour. The customer wanted to update the machine’s systems due to unsupportable SCADA and controls systems, and asked IDC to complete the upgrade in a narrow two-month window during May and June.
Besides its short time frame, the project posed additional challenges for IDC. IDC wanted to explore how much work could be completed remotely, to reduce the time required for final commissioning checks at the customer site.
Partnership with Simsol
IDC decided to use a combination of virtual and on-site commissioning techniques to reduce lead time on the project, and for this purpose partnered with Simsol, a Siemens Digital Industries Software solution partner.
Simsol is focused on Siemens’ Tecnomatix® portfolio of digital manufacturing solutions, and has gained recognition as a Expert partner, providing specialized expertise in digital manufacturing technologies and production simulation. Simsol trained IDC on the Tecnomatix software and offered best-practice advice on how to use and construct its models throughout the project.
Leveraging the digital twin
IDC used Plant Simulation in the Tecnomatix portfolio to build a comprehensive digital twin of the retail distribution center – a complete and accurate 3D model of the logistics systems and their processes, including control logic. The digital twin gives a strategic overview of the entire operation, rather than just a single cell or line. This gives more opportunity to focus on key areas identified for investigation and to continually improve across the whole production. IDC used the digital twin to explore and optimize the distribution center for performance, and to accurately simulate the tilt-tray sortation machine and more importantly the induction logic, which is critical to optimizing the throughput.
To make the most of the time available, the IDC team focused on the more complex areas of the machinery, investigating the dynamics and relationships among components and simulating mechanical changes to moving parts.
With the digital twin, the team was able to consider oversized (or “ugly”) items. Instead of building from the general throughput rate for standard items, the team generated virtual stock data in a range of item sizes that closely represented the packages to be processed by the distribution center. The dynamic data yielded a more realistic view of machinery performance. Performing this work remotely was crucial to meeting the customer’s deadlines.
“Without access to the actual sortation machinery, we had to use standard warehouse control system design models to construct code for testing,” says Richard Towne, Managing Director at IDC. “With the simulation model that IDC created, we could simulate almost all aspects and know that the code was validated against the system design, so we didn’t need major changes when we got on site.”
Tangible results
IDC realized tangible results from the use of digital twin plant simulation. The company was able to upgrade the controls and commission the tilt-tray sortation machine in just five weeks, well within the time frame proposed by the customer. With remote commissioning, IDC also minimized costly on-site time, reducing overall commissioning time by three weeks as compared to a similar upgrade project that required eight weeks using on-site commissioning only. The controls upgrades also increased the throughput of the sortation machine.
Tecnomatix solutions help improve steel foundry plant planning
Industry: Industrial machinery
Leading the world in roll production
Sinosteel Xingtai Machinery and Mill Roll Co., Ltd. (Sinosteel Xingtai) is the world’s largest producer of mill rolls with an annual output of 180,000 tons and a global market share of more than 20 percent. Pursuing the China 2025 national industrial manufacturing strategy, the company began upgrading its plants in 2018. The company moved to the Xingtai economic development zone to build new plants, investing nearly 10 billion RMB. Xingtai Machinery and Mill Roll aims to become the world’s first intelligent digital roll production enterprise.
Implementing Tecnomatix digital manufacturing
In the earliest phase of new plant planning, the company adopted the Tecnomatix® portfolio of digital manufacturing solutions, part of the Siemens Xcelerator business platform of software, hardware and services. With the assistance of IPS, a Siemens Smart Partner consultancy, Xingtai Machinery and Mill Roll collected production and logistics data and imported a new plant blueprint into the Tecnomatix Plant Simulation 2D/3D simulation environment.
Tecnomatix Plant Simulation includes tools for simulating, exploring, and optimizing logistics systems and their processes. The plant models enable analysis of material flow, resource utilization, and logistics for all levels of manufacturing planning, well in advance of production execution. Using these tools, Xingtai Machinery and Mill Roll conducted the plant simulations, verified the layout and logistics, and optimized the total manufacturing plan.
An effective way to discover plan deficiencies after the static design phase
By simulating the production and logistics processes, the Xingtai Machinery and Mill Roll team effectively discovered several problems that are otherwise difficult to detect at the static design phase. For example, the simulation results revealed that the inventory of pig iron and steel scrap was negative when studying the cross-region material distribution. By checking the input data table, the team found that the daily demand for pig iron and steel scrap was greater than the planned capacity of the storage tanks.
In another example, the team used Plant Simulation to discover that a flat car did not return to the waiting position for the next batch of material according to the batching schedule. The flat car was still in the melting span, and the material on the flat car had not been consumed, so the next batch of material could not be distributed on time. The error in the logistics design was easily understood when the team compared the simulation data with the input data table. The problem was finally solved by adding a spare material plate. Simulation has helped to accurately identify and correct other problems, such as the interference of a moving crane with other cranes and equipment. The ability and efficiency of Plant Simulation to help discover problems introduced at the static planning phase is highly valued by the company.
A powerful platform for plan optimization
Using Plant Simulation, Xingtai Machinery and Mill Roll optimized the plant plan. For example, one of the optimization considerations for a steel sand box area was whether to add a flat car track. Plant Simulation helped the team to easily verify the option by running the simulation and comparing the results. The simulation determined that adding a flat car track would reduce the moving distance of the overhead traveling crane by 1,600 meters and reduce working time by 27 minutes per day. Similarly, in a cast crossing and other areas, the team proposed a series of optimization solutions that were quickly verified by the simulation. These optimizations helped eliminate logistics collisions and increase the efficiency and utilization rates of high-value equipment. By the end of the first phase of the plant simulation project, the team had found six important design deficiencies and proposed two important optimization solutions for layout and logistics.
“With the help of Tecnomatix solutions and IPS consultants, we have improved the plan of the new plant in a relatively short time at a limited cost,” says Wang Jingjun, director of information management at Sinosteel Xingtai Machinery and Mill Roll. “The project not only helped avoid several important design deficiencies, but also helped save 100 million RMB in equipment investment by optimizing the layout and logistics.”
Leading automation machinery manufacturer improves safety with Process Simulate Safety Robots Manager
Industry: Automation
Hear from Ondřej Pažout, Benthor head of robotics and simulation, about how the leading automation machinery innovator uses Siemens Process Simulate software to help elevate robotic safety and efficiency. Benthor is a leading innovator in the manufacturing industry, specializing in the design and integration of advanced robotic systems.
Automation solutions for machines and production facilities
Benthor Automation, based in Mladá Boleslav, Czech Republic, develops automation and information technology (IT) systems for industrial manufacturing. The company’s customers are primarily in the automotive industry and include domestic and foreign car makers. Benthor’s core competencies include automation solutions for machines and production facilities with superior control technology and material flow management, and it offers services throughout the process chain, including consulting, technical solutions, hardware planning, software development, system deployment and after-sales service.
At Benthor, we prioritize the safety of robotic systems, and thanks to our collaboration with safety experts, we are able to design cutting-edge manufacturing equipment with integrated safety elements from the very first concepts of the workstations. This way, we provide our customers with transparency — visualizing the future workstation while eliminating additional costs caused by misinterpretation or misunderstanding of functionality.”Ondřej Pažout, Head of robotics and simulation for Benthor automation s.r.o.
In the industrial automation space and as robotic systems become more prevalent in densely populated automated lines, functional safety remains crucial to prevent human injury and equipment damage. When planning a new robot station or lines, whether implementing changes for new products or layout adjustments, prioritizing robot safety is paramount. The intricacies of addressing robot safety in production systems started only as a discussion between Benthor and Siemens team, and now it has evolved into a strategic business priority for Benthor. That is when the leading automation machinery manufacturer realized the value of using Process Simulate Safety Robots Manager to address the safety of robotic workstations.
Meet the robot safety experts part of this collaboration:
Product Manager Siemens Digital Industries Software
Director of Advanced Robotics Simulation
Siemens Digital Industries Software
Hear from Ondřej Pažout, Head of robotics and simulation for Benthor
Priority at Benthor
At Benthor, we fully recognize the crucial importance of safety in the integration of robotic systems. We design robotic workstations with the goal of minimizing risks for both operators and the equipment itself. Our integrations include not only physical barriers, but also sophisticated software tools for simulation and safety management. We address safety right from the start of the project by using simulations that consider all possible scenarios and potential safety incidents arising from risk analysis.
This approach allows us to eliminate potential risks even before the construction of the workstation begins. This helps us avoid costly adjustments to equipment or software during or after deployment. Thanks to our collaboration with the Siemens team responsible for Tecnomatix Process Simulate Safety Robots Manager, Benthor is able to implement advanced simulation technologies and methodologies that ensure detailed analysis and optimization of robotic workstations.
Solution: Process Simulate Safety Robots Manager
One of the key tools we use at Benthor is Process Simulate Safety Robots Manager (SRM). This application enables detailed management of robot safety functions and helps us simulate safety scenarios before physical implementation. With SRM, we can set up safety zones, define allowed movements, and monitor the status of robots in a simulated environment where there is no risk of injury or hardware damage. This allows us to quickly respond to any safety deviations and take appropriate measures during the design or virtual commissioning phase. This approach not only increases safety but also the efficiency, reliability, and profitability of automated systems.
Robot safety use cases
By utilizing solutions from the Tecnomatix Process Simulate portfolio, we have integrated more than 2,000 robots at Benthor, with nearly half of the installations using Safety Robots Manager to simulate safe robot behavior at the software level. Recently, we successfully implemented a robotic system project for the production of interior textile linings in the automotive industry. The core focus was the safety of operators when handling materials and preventing collisions with pressing tools. This resulted in more than 40 safety zones were successfully deployed and simulated across three robots. Thanks to simulation with SRM, Benthor was able to optimize robot movements and the production cycle without compromising safety standards.Ondřej Pažout, Head of robotics and simulation for Benthor automation s.r.o.
A robust partnership and the future of robot safety
The collaboration between Benthor and Siemens has proven invaluable in advancing the safety and effectiveness of our robotic workstations. By leveraging advanced simulation tools like Process Simulate Safety Robots Manager, Benthor continues to innovate and ensure that its systems meet the highest safety standards. Looking ahead, Siemens and Benthor are excited about future projects and the ongoing improvement of advancing safety protocols, which will further strengthen Benthor’s commitment to providing next-level solutions for its customers.
