Digital Enterprise Suite from Siemens – Part II
(In this part we look at the current scenario and how Siemens has transformed manufacturing through Digitalization)
Manufacturing Industry has been optimizing processes in product design, production planning and production. Software tools have aided in some parts of the processes. CAD and CAE in product design and validation. In production planning software applications have been used for factory layout, through put analysis, robotic simulation and programming, quality analysis. In production MES software applications aided the processes.
PLM software applications supported the underlying process threads and established the pervasiveness of a common digital thread from Product Design to Production. For example the BOM ( Bill of Materials ) can be generated as a conceptual BOM in Product Design and taken into Manufacturing and Requirements Planning. A virtual thread has been developed replicating in parallel to the physical thread in manufacturing industry. And in many areas the virtual and the physical threads were merging. Still in some of the areas there were disconnects between the virtual and the physical thread. One such area was prototyping and testing with physical models being built. This disconnect is compounded by products becoming increasingly complex with the use of embedded software and electronics. Moreover the market forces demanded products to have multiple variants to meet the personalized requirements of multiple customer segments.
The need is a common Digital Platform which is a comprehensive merger of the virtual and the physical world. Siemens PLM has introduced the Digital Enterprise Suite of Software forming such a platform. The inception of the platform is the merger of the Product Lifecycle Management (PLM) software with the powerful automation technologies in Totally Integrated Automation (TIA) portal. This merger of PLM and TIA built the thread from Product Design to Production Planning to Production Engineering to Production Execution.
Massive volume of data is generated across the platform. This data comes through IOT devices which will be inter-connected. The data can be used intuitively as a feedback loop. To this end Siemens has introduced Mindsphere , an open IOT operating system. Mindsphere provides an open Platform as a Service and is part of the Digital Enterprise Suite.
Thus the Digital Enterprise Suite is a fully integrated software solution across customers’ entire value chain from initial conceptual design, manufacturing planning and execution through services and support of both the products and plants that produce them.
The outcomes of the applications of the Digital Enterprise Suite will be in the form of:
- Connected Enterprises
- Smart Factory Digitalization
- Internet of Things
- Big Data, Intelligent Systems
- Additive Manufacturing
- Augmented Reality
- Cyber Physical Systems
- Robotics and Automation
The application of the Digital Enterprise Suite by customers is by building digital twins which are smart virtual models. Such a digital twin of a product will carry all the necessary information for their own production. Siemens has demonstrated the capabilities by setting up its own smart factory in Amberg.
The holistic view of digitalization in manufacturing in the Digital Enterprise Suite of Siemens PLM can be looked at from three stages of developments.
- The Ideation stage wherein product design is conceptualized. At this stage is the Digital Product Twin including all design elements of a product viz:
- 3D models ( using CAD systems )
- System Model ( using system engineering product development )
- Bill of Materials
- 1D, 2D, and 3D analysis models ( using CAE systems )
- Digital software design and testing ( using ALM systems )
- Electronic design
Such a digital product twin supports complete virtual product design and validation doing away with building physical prototypes.
- The Realization stage, wherein how a product will be manufactured through production planning is defined. At this stage is the Digital Production Twin. The digital production twin carries all information on the product’s :
- Manufacturing Process , how it will be produced
- Production facility model, carrying information on the plant , production and assembly lines
- Production facility automation model describing how the automation system ( SCADA, PLC, HMI etc. ) will support production
The Digital Production Twin will support throughput analysis, optimization of assets and quality parameters. It can be further simulated for virtual commissioning.
- The Utilization stage wherein the performance of the product once it is put to use is monitored. At this stage is the Digital Performance Twin which forms a feedback loop on the actual performance of the product. Performance data at this stage can be analyzed with the Digital Product Twin and Digital Production Twin for further optimization of the complete process. This also gives newer insights to innovation.
The Digital Enterprise Suite from Siemens PLM enables customers to leverage digitalization to gain benefits in terms of shortening time to market, greater production flexibility, reducing costs and improving quality.
Siemens has installed globally millions of devices ( 30 million automation systems, 70 million contracted smart meters, 800 thousand connected products). This is complemented by being the leading global provider of Product Lifecycle Management ( PLM ) and Manufacturing Operations Management ( MOM ) software, systems and services with over 15 million licensed seats and more than 140,000 customers worldwide.This successful legacy has enabled Siemens to be the only IOT provider to drive closed loop innovation on the Digitalization Enterprise Suite through Digital Twins of Product, Production and Performance. This is the Digitalization of Manufacturing.
Author – Mr. Abhijit A Barua, Director – at Siemens Industry Software ( PLM ) India
Mr. Abhijit Barua – profile - Linkedin - https://www.linkedin.com/in/abhijit-barua-b357682/
Note - The ideas expressed in Part I and Part III are personal. Ideas expressed in Part II are based on the digitalization initiatives and the resources thereof available in Siemens Industry Software.