Plant Simulation Fact Sheet Book HQ-ilovepdf-compressed PDF

Answers for industry.
Plant Simulation
Simulation and optimization of production systems and processes
Benefits Summary existing production system or – when used

• Improve productivity of Tecnomatix® Plant Simulation software in the planning process – long before the
existing facilities by as enables the simulation and optimization of real system is installed. Extensive analysis
much as 20 percent production systems and processes. Using tools, statistics and charts let users evalu-
• Reduce investment in Plant Simulation, you can optimize material ate different manufacturing scenarios and
planning new facilities by as flow, resource utilization and logistics for make fast, reliable decisions in the early
much as 20 percent all levels of plant planning from global pro- stages of production planning.
• Cut inventory and duction facilities, through local plants, to
Plant Simulation helps users:
throughput time by as specific lines.
much as 60 percent • Detect and eliminate problems that oth-
In times of increasing cost and time pres-
• Optimize system erwise would require cost- and
sures in production, along with ongoing
dimensions, including time-consuming corrective measures
globalization, logistics has become a key
buffer sizes during production ramp-up
factor in the success of a company. The
• Reduce investment risks
need to deliver JIT (just-in-time)/ JIS (just- • Minimize the investment cost of produc-
through early proof of
in-sequence), introduce Kanban, plan and tion lines without jeopardizing required
concept
build new, sustainable production facilities, output
• Maximize use of manu
and manage global production networks
facturing resources • Optimize the performance and energy
(to name a few) requires objective decision
• Improve production line usage of existing production systems by
criteria to help management evaluate and
design and schedule taking measures that have been verified
compare alternative approaches.
in a simulation environment prior to
Plant Simulation helps create digital models implementation
of logistic systems (e.g., production) to
Modeling manufacturing processes
explore the systems’ characteristics and to
Plant Simulation enables you to create
optimize their performance. The digital
well-structured, hierarchical models of pro-
model enables users to run experiments
duction facilities, lines and processes. This
and what-if scenarios without disturbing an
www.siemens.com/tecnomatix
TECNOMATIX
Plant Simulation
Features is achieved through powerful object-ori- production variations. Statistical analysis,

• Optimize systems for ented architecture and modeling graphs and charts display the utilization of
reduced energy usage capabilities that enable you to create and buffers, machines and personnel. You can
• Simulation of complex maintain even highly complex systems, generate extensive statistics and charts to
production systems and including advanced control mechanisms. support dynamic analysis of performance
control strategies parameters including line workload, break-
Plant Simulation’s user interface follows
• Object-oriented, hierarchical downs, idle and repair time and proprietary
Microsoft Windows standards, making it
models encompassing key performance factors.
easy to get familiar and productive quickly.
business, logistics and
Simulation models can be created quickly Model visualization
production processes
by using components from application In addition to the highly efficient 2D model
• Dedicated application object
object libraries dedicated to specific busi- view of Plant Simulation, models may be
libraries for fast and
ness processes, such as assembly or visualized in a 3D virtual environment using
efficient system modeling
carbody manufacturing processes. Users Plant Simulation’s included libraries or your
• Graphical outputs for
can choose from predefined resources, own CAD data. The result is impressive 3D
analysis of throughput,
order lists, operation plans and control virtual models that are synchronized at all
resources and bottlenecks
rules. By extending the library with your times with their 2D counterparts, allowing
• Automatic bottleneck
own objects you can capture best-practice you the flexibility to choose the appropriate
detection, Sankey diagrams
engineering experiences for further simula- method of visualization without compro-
and Gantt charts
tion studies. mising simulation and analysis needs.
• 3D online visualization and
animation Complex and detailed simulations can be
• Integrated neural networks handled, understood and maintained much
and experiment handling better than in conventional simulation tools
• Automated system by using Plant Simulation architectural
optimization via genetic advantages like capsulation, inheritance
algorithms and hierarchy.
• Value stream mapping and
Simulating and analyzing system
simulation
performance
• Open system architecture
Plant Simulation models are used to opti-
supporting multiple
mize throughput, relieve bottlenecks and
interfaces and integration
minimize work-in-process. The simulation
capacities (ActiveX, CAD,
models take into consideration internal and
Oracle SQL, ODBC, XML,
external supply chains, production Contact
Socket, OPC, etc.) Siemens Industry Software
resources and business processes, allowing
you to analyze the impact of different Americas +1 314-264-8499
Europe +44 (0) 1276 413200
Asia-Pacific +852 2230 3308
© 2013 Siemens Product Lifecycle Management

Software Inc. Siemens and the Siemens logo are
registered trademarks of Siemens AG. D-Cubed,
Femap, Geolus, GO PLM, I-deas, Insight, JT, NX,
Parasolid, Solid Edge, Teamcenter, Tecnomatix
and Velocity Series are trademarks or registered
trademarks of Siemens Product Lifecycle Man-
agement Software Inc. or its subsidiaries in the
United States and in other countries. All other
logos, trademarks, registered trademarks or ser-
vice marks used herein are the property of their
respective holders.
Y3 7541 4/13 B
Tecnomatix Plant Simulation
Value Stream Mapping
Benefits Implementation
• Increase productivity of The Plant Simulation Value Stream Mapping Library (TN75096) is an optional
existing production facilities extension to the Plant Simulation Standard or Professional license.
by as much as 20 percent
• Reduce investment in Summary
planning for new production The Plant
by as much as 20 percent Simulation Value
• Reduce inventories and cycle Stream Mapping
time by as much as 60 library supports the
percent user, taking into
• Optimize the system account the
dimensions, including buffer dynamic relation-
sizes ships of complex
• Reduce investment risk manufacturing
through early feasibility sequences to
analysis increase the share
• Increase resource utilization of value-added pro-
• Better line planning and duction, variability,
allocation quality, speed and
efficiency for
Typical questions for the increased produc-
simulation: tion, while reducing
• How can we minimize the inventory and capi-
investment costs? tal commitment, and securing on-time delivery.
• Is the required output
achieved? Tecnomatix Plant
• What happens when quantity Simulation
changes? Plant Simulation
• How can stocks be reduced? helps you create
models of logistic
systems (e.g., pro-
duction) to explore
the systems’ charac-
teristics and to
optimize their per-
formance. The
digital model
enables users to run
experiments and
TECNOMATIX
TECNOMATIX
what-if scenarios without disturbing an Tecnomatix Plant Simulation

existing production system or – when used Value Stream Mapping
in the planning process – long before the Visualization, analysis and improvement of
real system is installed. Plant Simulation dynamic value chains
contains powerful object-oriented archi-
tecture and modeling capabilities that
enable you to create and maintain even
highly complex systems, including
advanced control mechanisms. Plant
Simulation’s user interface follows
Microsoft Windows standards, making it
easy for you to quickly become productive.
Simulation models can be created quickly
by using components from application
object libraries dedicated to specific busi-
ness processes. You can extend the library
with your own objects through a powerful
programming environment for the further-
ing of simulation capabilities. Tools for
automatic optimization, analysis of simula-
tion results and 3D visualization of
simulation models are also available.
Extensive analysis tools, statistics and
charts let users evaluate different manu-
facturing scenarios and make fast, reliable
decisions in the early stages of production
planning.
Plant Simulation helps users:

• Detect and eliminate problems that
otherwise would require cost- and time-
consuming correction measures during
production ramp-up
• Minimize the investment cost of
production lines without jeopardizing
required output
• Optimize the performance of existing
production systems by taking measures
that have been verified in a simulation
environment prior to implementation
• Easy to use through Plant Simulation allows for the creation of added in manufacturing and for identify-
Microsoft Windows complex production systems and processes ing, reducing and eliminating non-value
conformity in easy to understand computer models. added processes and operations.
• Block libraries for the fast Using Plant Simulation, material flow,
and efficient modeling of resource utilization and supply chains at all Value Stream Mapping is a modern method
typical scenarios levels of corporate planning may be of process optimization based on the
• Graphs and diagrams optimized. methods of lean management, as
• Analysis of throughput, described by the well-known Toyota
resource utilization and What is Value Stream Mapping? Production System and as applied by the
bottlenecks Value stream mapping is an established Siemens Production System.
method for studying the economic value
The goal is to easily and quickly map and
better understand the value chain for the
purpose of optimizing it.
Objectives and benefits

The traditional goals of the Value Stream
Mapping process are:
• Increase production variability
• Increase production quality
• Increase production rate
• Increase production efficiency
The aim is to optimize production

resources, the layout of the controls and
the lot sizes to guarantee a steady flow of
production without buffer stock build-up
while simultaneously maintaining quality
of order receipt and delivery.
Source: Value Stream Mapping – The Road to Lean
Manufacturing
Erlach, Klaus; Springer-Verlag, 2010
Tecnomatix Plant Simulation is Why perform value stream mapping in The traditional, static value stream analysis
part of the Plant Design and Plant Simulation? is extended to include the critical time ele-
Optimization solution offering • Reduction of cost for data collection by ment for stock availability.
from Siemens PLM Software. reducing the number of objects
describing the processes through pre- Thus, you can depict dynamic fluctuations
These are coordinated software defined logic blocks of the daily production due to lot sizes,
components that enable you to setup procedures, product variations, or
plan the complete production • Reduction in analysis effort through other disturbances.
of a plant by way of a computer automated analysis modules
model to visualize and simulate The dynamic material flow simulation in
the processes in production Through computer simulation, examine Tecnomatix Plant Simulation permits the
lines, warehouses and work- the dynamic effects of the value stream, reduction of the number of products in
shops, so as to quickly, easily which remain hidden in the static, paper- production and thus the capital investment
and safely achieve the required based mapping of the value chain required for robust production, ensuring
findings and results. that natural fluctuations in production do
not impair the ability to deliver.
The extensive portfolio allows
for an optimized manufactur-
ing process design lifecycle,
including planning, factory lay-
out design, and manufacturing
processes and factory simula-
tion, enabling the seamless
connection with higher-level
planning systems.
Approach
Traditional: Depiction of production by
manual, graphical sketch of the value
stream using symbols on a sheet of paper
showing the conditions, such as material
flow, information flow, inventories, value-
added and non-value adding activities.
Based on customer demand, inventory and
cycle times, analysis of the current state of
production is performed as a team.
Revision and improvement of the value
stream is then derived from this current
value stream mapping of the production
process.
Standardized method based on generally

accepted symbols
TECNOMATIX
Predefined core objects: Value Stream Mapping Library in Plant

• Process Simulation
• Supplier Predefined symbols based on the general
• Customer standard:
• Stock • Quick and easy to learn
• Supermarket • Predefined dialogs with configurable
• Internal and external user objects
transport • Control logics
• Predefined controls for • Analysis objects
mapping of:
- Kanban processes Application
- Heijunka Box The Plant Simulation Value Stream
- Compensation box Mapping Library allows users to quickly
and easily map and improve their supply
Predefined objects for analysis chains with real dynamic behavior.
and evaluation of:
• Throughput time The Plant Simulation Value Stream
• Loading/unloading or waiting Mapping Library was developed in collabo-
time ration with industry practitioners for use
• Value-added time by industry practitioners, providing the
• Analysis of the process necessary objects.
utilization
• Availability of resources
(time sensitive)
© 2012 Siemens Product Lifecycle Management Software

Contact Inc. All rights reserved. Siemens and the Siemens logo are
registered trademarks of Siemens AG. D-Cubed, Femap,
Siemens Industry Software
Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid
Americas +1 800 498 5351 Edge, Teamcenter, Tecnomatix and Velocity Series are
Europe +44 (0) 1276 702000 trademarks or registered trademarks of Siemens Product
Asia-Pacific +852 2230 3333 Lifecycle Management Software Inc. or its subsidiaries in
the United States and in other countries. All other logos,
trademarks, registered trademarks or service marks used
www.siemens.com/plm herein are the property of their respective holders.
X3 00000 7/12 B
Aerospace
Renovating Russia’s largest airport – virtually

Tecnomatix provides the tools to simulate optimum passenger and cargo handling workflows,
helping airport become a leader in the Russian civil aviation market
Business challenges
Plan for airport upgrade and MOSCOW DOMODEDOVO AIRPORT
passenger traffic increase
Moscow Domodedovo Airport is Russia’s largest airport. Handling 46 percent of air passengers in
Keys to success
Moscow, the airport is used by 74 airlines and serves 228 destinations across the globe, with 91
Use Tecnomatix Plant destinations exclusive to the Moscow region. The airport works with 46 foreign and 28 domestic
Simulation for modeling air airlines. This includes 11 countries from the Commonwealth of Independent States (CIS). In 2009
cargo handling, passenger Moscow Domodedovo Airport handled 18.7 million passengers.
flows in the international
terminal, as well as various The cooperation between Domodedovo and Siemens PLM Software began in 1999, when Moscow
terminal performance Domodedovo Airport implemented a major redevelopment program – among the largest European civil
scenarios aviation investment projects of the decade – with a proposed series of airport infrastructure upgrades
Start with single application; that required the development and evaluation of various designs.
with success, implement
simulation across projects Moscow Domodedovo Airport selected Siemens PLM Software as an instrumental technology provider
for its reconstruction program.
Results To effectively plan for the airport renovation, qualitative and quantitative efficiency indicators needed
to be set. In addition, the equipment, floor space and transport requirements needed to be determined.
Bottlenecks identified at the
Moscow Domodedovo Airport’s experts used advanced computer-aided design (CAD) tools and some of
design stage and timely
the best practices of airports
corrections made
globally to address these
Investment risks reduced for requirements. Among Moscow
reconstruction of the Domodedovo Airport’s strategic
international terminal tools for design and analysis is
Airport attained a the Plant Simulation solution,
leadership position in the part of Tecnomatix® software
Russian civil aviation market from Siemens PLM Software.
The first assignment for

Tecnomatix was a cargo
handling simulation project. The
objective was to model the
handling of incoming air cargo
in order to identify bottlenecks
and to improve overall
efficiency. Within three weeks
the model had been developed.
Key information included the
aircraft landing schedule, the
TECNOMATIX
Aerospace Tecnomatix
Solutions/Services number and specifications of cargo handling transports,

Tecnomatix the storage capacity and timeline. The model provided
an evaluation of both the cargo handling system “as is”
and with several proposed upgrades, which led to the
optimal solution for the air cargo terminal.
Client’s primary
business Next, using Tecnomatix, a series of joint projects were
simultaneously implemented, including a simulation
Moscow Domodedovo and evaluation of the international terminal’s
Airport is the largest Russian reconstruction plan. Since the airport anticipated a
airport and holds the sharp increase of international flights, it was important
leading position among to make sure that the design solutions were correct. It
Moscow area airports in was also essential that the investment risks related to
terms of passenger traffic. the terminal’s reconstruction be minimized and
Located 22 kilometers controlled.
southeast of Moscow, it is
the first passenger airport Using Plant Simulation, Moscow Domodedovo Airport
terminal in Russia to be produced a detailed model of passenger flows within
certified under ISO the terminal. Airport experts were able to experiment
9001:2000. with a variety of scenarios to evaluate and determine
www.domodedovo.ru/en/ the optimal approach. For example, extensive
parameters were entered to arrive at various solutions
that depended on a range of anticipated passenger
Client location situations. Parameters included flight
Moscow schedules and data, incoming passenger
Russia traffic, service regulations, passenger routes
across the terminal, equipment for check-in,
customs, security, luggage claim areas, the
“Thanks to Tecnomatix, locations of stores, food outlets, and duty
we have made consid free zones.
erable improvements
to everyday airport Peak loads were a special concern,
workflows, including especially relative to the equipment needed
check-in planning, to handle the high-traffic times. Plant
buses, gates, Simulation accounted for different
and boarding passenger flow patterns, considering both
management.” incoming and outbound flight schedules.
Bottlenecks were readily revealed and
Helen Galanova
corrective action taken.
Spokesperson
Moscow Domodedovo
“With such outstanding virtual planning,
Airport
Tecnomatix Plant Simulation has
significantly reduced the risks and
uncertainty associated with our airport
reconstruction planning,” says Helen Galanova, spokesperson for Moscow Domodedovo Airport.
“Thanks to Tecnomatix, we have made considerable improvements to everyday airport workflows,
including check-in planning, buses, gates, and boarding management.”
Galanova notes, “Using advanced technologies such as Tecnomatix, Moscow Domodedovo Airport has
become a leader in the Russian civil aviation market.”
© 2010 Siemens Product Lifecycle Management Software Inc.

All rights reserved. Siemens and the Siemens logo are
Contact
Siemens PLM Software
Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge,
Americas 800 498 5351 Teamcenter, Tecnomatix and Velocity Series are trademarks
Europe 44 (0) 1276 702000 or registered trademarks of Siemens Product Lifecycle
Asia-Pacific 852 2230 3333 Management Software Inc. or its subsidiaries in the United
States and in other countries. All other logos, trademarks,
registered trademarks or service marks used herein are the
www.siemens.com/tecnomatix property of their respective holders.
X9 22973 11/10 B
Tecnomatix • NX • Teamcenter
ASML
Digital manufacturing tools support a world leader in a growing market
Industry A leading provider of lithography

Semiconductor equipment systems for the semiconductor
Industrial machinery industry uses Plant Simulation to
optimize production scenarios
Business challenges
Innovative consumer and industrial
Deliver new and innovative electronics products require state-of-
machines the-art microchips
Shorten machine delivery ASML is one of the world’s leading provid-
cycle ers of lithography systems for the semi-
Adjust production capacity conductor industry, manufacturing
to market conditions, while complex machines that are critical to the
maintaining cost control production of integrated circuits and
microchips. These advanced systems help
ASML’s customers, the chipmakers, to
Keys to success reduce the size and increase the function-
Simulate new production lines ality of microchips within consumer elec-
Evolving high-productivity TWINSCAN NXT platform,
before they are commissioned tronics equipment. As a result, ASML helps manufactured by ASML.
to create more powerful electronics
Analyze production
systems for consumers and industry
scenarios and recommend Amid the global financial crisis of 2009,
professionals.
best alternatives chipmakers sharply reduced capital expen-
Optimize the sequencing The “digital revolution” has been realized ditures. Halfway through the year, the
of production processes by the semiconductor industry and indi- semiconductor industry was among the
rectly by lithography: the process responsi- first to recover, and orders picked up, lead-
ble for imaging smaller features on silicon ing to two subsequent years of record
Results sales for ASML. Sales in 2010 were nearly
wafers and continuing “Moore’s Law,”
Created a pilot in which real- which predicts that technology will double three times those of 2009, followed by
world results were compared the number of transistors on a microchip another sales increase in 2011. During
against simulation models at regular intervals. Thanks to lithography, this strong rebound, ASML had to ensure
created using Tecnomatix, ever-shrinking microchips have brought that it would continue to deliver its
proving that actual production better, more affordable and energy-effi- machines on time and in accord with
performance/metrics can be cient electronics and services to everyone, the highest quality standards.
accurately imitated improving mobility, connectivity, safety
and digital entertainment.
www.siemens.com/plm
Results (continued)
Optimized a production line
configuration that supports
the needed throughput and
reduces the investment in
production resources for a
new EUV machine
Boosted production capacity
for a new design by using two
positioning module qualifica-
tion tools
Created library of simulation Production of the new EUV machine in a clean room.
objects, e.g. an optimization

algorithm object that As demand in the semiconductor industry Management (ISM) team manager at
identifies the most efficient is cyclical, ASML must continuously adjust ASML. “The production simulations that
sequencing of manufac- its production capacity to meet the we develop using Plant Simulation support
turing steps requirements of the market. This is a building a bridge between these groups.
sophisticated process that involves fore- We have to make many decisions regard-
Implemented Plant Simulation
casting demand, setting detailed output ing the establishment of new production
as part of the company’s pro-
plans and aligning with a large and facilities, or improving existing ones. Plant
duction process approach that
complex supply chain. This process also Simulation helps us make these decisions
enables continuous delivery
involves the use of the Plant Simulation after simulating what-if production scenar-
of the most innovative and
solution in the Tecnomatix® portfolio. ios. Our machines have to perform to high
cost-effective solution to
standards; they need to print very small
customers
Bridging the gap between product features on silicon wafers, printing 30-40
design and manufacturing layers exactly on top of each other, and do
“Maintaining world leader- ASML uses several Siemens PLM Software it extremely fast. Precision is measured in
ship is a tough task. You solutions, including Teamcenter® software nanometers. A relentless drive to innovate
must be innovative and for digital lifecycle management and NX™ is part of the ASML culture, and has
cost-effective. Plant software for product design. Recently, the allowed us to meet this challenge. In this
Simulation will be part of Industrial Engineering department of ASML context, we had the need for a discrete-
our engineering decision- began using Plant Simulation, a discrete- event software simulation tool to simulate
making process. A lot of event simulation tool. and optimize our production.”
production scenarios will
be simulated virtually using “The Industrial Engineering team
Plant Simulation, before we functions in between D&E (Development
will actually commission and Engineering) and M&L (Manufacturing
the production line.” and Logistics),” explains Andreas
Schoenwaldt, Industrial Specification
Andreas Schoenwaldt
Industrial Specification
Management Team Manager
ASML
Creating a Plant Simulation model for
the production phase, with a target
of shortening machine lead time
Machine testing is the production phase
that requires the longest duration, even
significantly longer than the final assembly
phase. ASML is constantly striving to
shorten lead times, increase production
capacity and lower costs in order to
increase its appeal as a go-to supplier. In
studying these challenges, data analysis
showed that one source of delays is the
late delivery of processed wafers. Joris
Bonsel, an industrial engineer on the
Industrial Specification Management (ISM)
team at ASML, notes, “These wafers are The Plant Simulation process lab model.
produced in our process lab, mainly for the
purpose of machine testing. We used data were impressed when we realized that
from a five-month period of actual wafer with Plant Simulation, we can build a
orders requested by the test department, model that will accurately imitate the per-
combined with the corresponding actual formance of a physical production line.”
delivery times. We then created a Plant
Simulation model that delivered the same A new generation of lithography
results that were collected, reflecting a systems
surprisingly high level of accuracy. ASML has developed a new generation of
lithography systems that uses extreme
“Once we knew that we had a simulation ultraviolet (EUV) light and will allow chip-
model that reflected reality, we started to makers to continue to shrink feature
do the industrial engineering analysis. It sizes on chips. The first systems intended
was clear that adding more manpower in
the lab would improve delivery perfor-
mance, but we were able to simulate the
actual production, and proved that there is
a clear financial benefit to adding one
employee to the process lab, rather than
invest, for example, in a new track. Just to
prove that this result is not trivial, we sim-
ulated and showed that adding a second
employee was not cost beneficial. This
analysis was previously done based on gut
feeling, rather than a simulation, and
therefore it was difficult to argue with the
simulation recommendation.” Bonsel
notes, “This was actually the project we
used to pilot Plant Simulation, and we The NXE:3300B.
“We were impressed when for volume manufacturing, dubbed Higher throughput through simulation
we realized that with Plant NXE:3300B, will ship in 2012, and the One of the key modules of the TWINSCAN
Simulation, we can build a engineering teams had to plan production NXT:1950i machine is the positioning
model that will accurately facilities to support the rollout. Maurice module (PM). As ASML was considering
imitate the performance of Schrooten, an industrial engineer on the how to boost production capacity for a
a physical production line.” ISM team at ASML, explains: “One of the new design, the team wanted to know
main questions was: ‘Which production how many qualification tools, that is, posi-
Joris Bonsel
resources were needed for manufacturing tioning module qualification tools (PMQTs)
Industrial Engineer
the MBMM (main body mid module), one would be needed, and how could the tool
of the major modules of this machine?’ utilization be maximized. The team also
Management
Naturally, we were looking for the most planned to compare deployment of two
ASML
cost-effective investment, and therefore parallel workstations with the same tasks
we have used Plant Simulation to analyze versus two serial workstations, each with
the implications of three different alterna- half of the tasks. Ron Clauwers, an indus-
“The Plant Simulation tives on clean room space consumption, trial engineer on the ISM team at ASML,
result is an optimized throughput variation, and labor and hard- notes: “To deliver the highest throughput,
production line configura- ware investment. The three alternatives four scenarios were compared with each
tion that supports the were: 1) cloning the current production other, and the Plant Simulation results
needed throughput and line, 2) outsourcing, called HLQB (high- showed that we should use two identical
reduces the investment in level qualified buy), some of the produc- PMQTs in a flexible (not fixed) manner, in
production resources.” tion and, 3) using a new production line other words, each PMQT can accommo-
methodology, which splits the assembly date any needed production step, com-
Maurice Schrooten
work between three different work areas. bined with priority rules, and use parallel
Industrial Engineer
The simulation showed that the cloning workstations (rather than serial worksta-
alternative required a higher investment tions), in front of the PMQTs.”
Management
in equipment, so we abandoned it.
ASML
Out of the other two alternatives, which
were largely equal, we selected the one
with the lowest risk for ASML. The Plant
Simulation result is an optimized produc-
tion line configuration that supports the
needed throughput and reduces the
investment in production resources.”
Plant Simulation result box plot: the time (in weeks)

needed to produce a specific volume of PMs is shown.
The highest throughput is obtained with two tools,
flexible utilization and parallel workstations.
Plant Simulation result chart: comparison of

investment in three production line alternatives.
Solutions/Services Plant Simulation becomes part “The GA optimization object uses the
of the decision-making tool kit genetic algorithm capability of Plant
Tecnomatix
www.siemens.com/tecnomatix “One of the strengths of Plant Simulation is Simulation to recommend a sequence of
the ability to create a library of objects process steps, taking into account all the
NX constraints, and to assign the steps to the
with certain logic, and re-use these objects
www.siemens.com/nx required production personnel.
in different models,” says Schrooten. “We
Teamcenter worked closely with the Siemens PLM
www.siemens.com/teamcenter Software deployment partner, cards PLM Another useful capability of Plant
Solutions B.V., and they have provided us Simulation we are using is the experiment
with an initial, useful library of objects. manager. With this, we run simulations of
Customer’s primary business
For example, we created the genetic several scenarios, and can very easily com-
ASML, one of the world’s algorithm (GA) optimization object in our pare the results of different alternatives.”
leading manufacturers of object library. When we simulate a manu-
chipmaking equipment and facturing process, we define a lot of Schoenwaldt concludes, “Maintaining
a key supplier to the chip constraints between the manufacturing world leadership is a tough task. You must
industry, designs, develops, steps, such as the precedence constraint, be innovative and cost-effective.” He
integrates and services which defines which step should be done notes, “Plant Simulation will be part of our
advanced systems to produce prior to another step; time constraint, engineering decision-making process.
semiconductors. The company which defines waiting time that is some- A lot of production scenarios will be
has manufacturing, customer times needed after executing some of the simulated virtually using Plant Simulation,
support centers and training manufacturing steps; and constraints before we will actually commission the
facilities in more than that are related to physical aspects, for production line.”
15 countries. instance, two steps that can’t be done
www.asml.com simultaneously, as they are done on the
same physical area of the machine.
Customer location
Veldhoven
Netherlands
Partner
cards PLM Solutions B.V.
Americas +1 800 498 5351 © 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are
Europe +44 (0) 1276 702000 registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge,
Asia-Pacific +852 2230 3333 Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle
Management Software Inc. or its subsidiaries in the United States and in other countries. TWINSCAN NXT, TWINSCAN
NXT:1950i, and NXE:3300B are trademarks of ASML Netherlands BV. All other logos, trademarks, registered trademarks or
service marks used herein are the property of their respective holders.
www.siemens.com/plm Z13 29753 4/12 A
Tecnomatix
Bühler
Leading process technology partner uses advanced tools
to increase value for its customers
Industry Plant Simulation enables the Bühler’s core technologies are in the
Processing technology delivery of complete solutions areas of mechanical and thermal process
engineering. With its expertise and over
Innovative automation solutions 150 years of experience, Bühler enables
Business challenges delivered with Swiss accuracy its customers to succeed by consistently
Increase completeness of the Did you know that 65 percent of the rolling out unique and innovative solutions.
solution offered to customers chocolate and 40 percent of the pasta Over the years, Bühler has acquired
manufactured globally is done so with the a reputation as a reliable partner, thanks
Deliver a cost-effective to its global presence and commitment
solution for unloading ships machines of the Swiss company Bühler
Group? Bühler is a specialist and global to customer value.
Increase effectiveness of technology partner for plant, equipment
food production equipment and services for processing foods and Bühler operates in over 140 countries,
operation manufacturing advanced materials. and has a global payroll of over 10,000
The organization holds leading market employees.
Keys to Success positions worldwide in the fields of

To increase its operational efficiency, Bühler
technology, such as processes for
Provide field engineers and uses product lifecycle management (PLM)
transforming grain into flour and animal
sales with a cutting-edge solutions from Siemens PLM Software: NX™
feeds, producing pasta and chocolate,
software to demonstrate software, and the Plant Simulation solution
and manufacturing die-cast components.
solution superiority in the Tecnomatix® portfolio.
Analyze different ship
unloading solutions
Select the optimal production
sequence
Results
Cut cost of unloading ships
by embedding proprietary
algorithm in a simulation
model
Reduced operational cost
of mixing plants by using
optimal production sequence
A Bühler chocolate production line.
siemens.com/tecnomatix
“We are very pleased Ship unloading solution validated When a company is interested in acquiring
with our usage of Plant with Plant Simulation a new ship unloading solution or modify-
Simulation, as it allows us As part of its grain handling products, ing an existing system, it must consider
to easily test different Bühler delivers ship unloading solutions to the number and type of unloaders that will
scenarios with little effort, its customers. The unloading process for a be needed. Naturally, there is a compro-
and embed it in the simula- ship requires many hours, and every hour mise between the number of unloaders,
tion of our own algorithms”. the ship is in the port is very expensive. As a the type and the unloading time. This
result, there is a high motivation to unload compromise can be optimized by analyz-
“When quantifying the
the ship as safely and quickly as possible. ing different scenarios.
expected improvements into
an economical benefit, we
During the unloading process, the ship’s Bühler field engineers and sales represen-
found an impressive cost
center of gravity shifts and the ship tilts. tatives had challenged the Bühler
reduction enabled by the
Any tilt above the allowed tilting angle Corporate Technology department with
usage of Plant Simulation
during unloading might break up the ship. finding a solution that would help pros-
for the production sequence
Therefore, the sequence of unloading the pects resolve this complex decision. Such
determination.”
different compartments of a ship is very a solution should enable a customer to
Dr. Mukul Agarwal important. Moreover, there is a need to easily define an unloading scenario for a
Expert for Intelligent Process balance the unloading of neighboring specific ship, simulate different scenarios
Operation compartments. and compare them.
Corporate Technology
Bühler
Bühler ship unloading solutions.

“When implementing the
suggested sequence identi-
fied using Plant Simulation,
we found there was a signifi-
cant reduction in the overall
production time and the
number of delayed order
deliveries was minimized.”
Dr. Mukul Agarwal
Expert for Intelligent Process
Ship unloading simulation with Plant Simulation.
Operation
“We analyzed several potential solutions In its drive to increase its competiveness Bühler
and realized that an event simulation tool and the completeness of the solution it
would be the most suitable for this task,” delivers to its mixing production equip-
says Dr. Mukul Agarwal, expert for ment customers, Bühler decided to check
Intelligent Process Operation, Corporate the feasibility of also offering a software
Technology at Bühler. “Since we were tool which would enable it to test differ-
already using Plant Simulation, we decided ent production scenarios. Therefore, it cre-
to use it for the ship unloading scenarios ated a model using Plant Simulation that is
analysis. So we created a simulation easy to use and identifies the recom-
model and embedded in it an unloading mended production sequence.
algorithm that we developed. We are
very pleased with our usage of Plant
Simulation, as it allows us to easily test
different scenarios with little effort, and
embed it in the simulation of our own
algorithms.”
Mixing production equipment operation

optimized with Plant Simulation
Bühler delivers a complete mixing solution,
including process definition, plant engi-
neering, process automation, manufactur-
ing, installation and start-up, as well as
customer service. An example of a
mixing application would be the blending
done by flour mills, which mix different
types of flour and sometimes add
additional ingredients. A Bühler mixing production line.
Solutions/Services
Tecnomatix
Plant Simulation
NX
siemens.com/nx
Client’s primary business

Bühler is the specialist and
technology partner for plant,
equipment and services for
processing foods and for
manufacturing advanced
materials.
www.buhlergroup.com Food production simulation with Plant Simulation.
Buhler conducted several pilots to validate “Offering a Plant Simulation model and
Client location
the benefit of this simulation model. methodology as a means to optimize the
Uzwil “We analyzed the performance of an exist- operation of the equipment our customers
Switzerland ing line, and compared the production are buying from us is an important step in
sequence that was used with an optimized increasing our competiveness and the
production sequence suggested by the completeness of our solution,” says Klaus-
“Offering a Plant Simulation analysis done with Plant Simulation,” notes Jochen Lisner, head of Intelligent Process
model and methodology Dr. Agarwal. “When implementing the sug- Control, Corporate Technology at
as a means to optimize the gested sequence identified using Plant Bühler. “It directly supports our slogan,
operation of the equipment Simulation, we found there was a signifi- ‘Engineering Customer Success.’”
our customers are buying cant reduction in the overall production
from us is an important time and the number of delayed order
step in increasing our deliveries was minimized. When quantify-
competiveness and the ing the expected improvements into an
completeness of our economical benefit, we found an impres-
solution.” sive cost reduction benefit as well.”
Klaus-Jochen Lisner
head of Intelligent Process
Control
Bühler
Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks,
registered trademarks or service marks used herein are the property of their respective holders.
siemens.com/plm Z8 32120 1/13 A
Tecnomatix
Comau (Shanghai)
Digital manufacturing tools support rapid growth
Industry Comau (Shanghai) simulates

Industrial machinery and more production scenarios in
equipment less time using Tecnomatix
Expanding innovative automation

Business challenges solutions to China
Acquire both domestic and Comau (Shanghai) Engineering Co., Ltd.
foreign automotive manufac- [Comau (Shanghai)] is a wholly owned
turing customers subsidiary of the Italian-based company
Support accelerated growth Comau S.p.A, a Fiat Group affiliate. Comau
(Shanghai) was established in 1997 as
Expand to new areas such as
Comau (Shanghai) Automotive Equipment
aerospace
Co. Ltd. but after 15 years in operation,
the company is no longer confined to the
Keys to success automotive industry. Having expanded its
Use Tecnomatix process plan- advanced automation technology into
ning and simulation tools to other areas of industrial manufacturing,
validate production lines the company officially changed its name
to Comau (Shanghai) Engineering Co., Ltd.
Leverage global knowledge in 2010.
and engineering
methodologies Comau (Shanghai) employs more than
Use Process Designer and 900 people at several facilities in China.
Process Simulate to generate In the Chinese auto market, Comau
quotations (Shanghai) is a major supplier of body
welding and powertrain assembly and
machining equipment. The company
Results started manufacturing robots in 2011 and
Tremendous growth – an has developed a well-balanced portfolio of
average of 50 percent annu- customers, including joint ventures of
ally in a span of ten years global brands. The company’s five business Comau (Shanghai) technicians setting up a production
line in its Shanghai facility.
One of the biggest and most units are Body Welding, Powertrain
talented 3D simulation teams Systems, Robotics, Aerospace, and
in China Adaptive Solutions. Comau (Shanghai) is often required by
customers to deliver line and workcell
Strategic decision to use the best simulations. For simplicity, the company
In building production lines for automotive typically uses the same planning and simu-
original equipment manufacturers (OEMs), lation system used by its customers.
Results (continued)
Delivered complete turnkey
automotive body welding
lines to leading automotive
OEMs
Improved proposal writing
More efficient resource
utilization
A physical, commissioned welding station delivered to Fiat, and the virtual workcell simulated using Tecnomatix.
“Most of our customers require us to use “Using the Tecnomatix tools, we are able
tools in the Tecnomatix portfolio, such as to simulate more production scenarios in
Robcad, Process Designer and Process less time.”
Simulate,” explains Riccardo Piegaia, pro-
cess engineering manager in the Comau Piegaia, who relocated from Italy, brought
(Shanghai) Mechanical Engineering to China his experience using the
Department. “But even for those few Tecnomatix® portfolio from Siemens
customers who use other tools, we have PLM Software. When he started with
taken the strategic decision to use only the Comau (Shanghai), he was the only person
Tecnomatix tool set. Why? Because we using 3D simulation, but as the company
believe Tecnomatix is the best tool set for was awarded more and more projects, he
the 3D simulation of robotized workcells. trained other engineers and significantly
increased the size of the team.
“The Tecnomatix tools not
only help us provide best-in-
class production lines to our
customers, but also elimi-
nate waste within our
organization by saving engi-
neering time and helping
minimize re-work on the
shop floor.”
“We currently employ the
biggest and best-skilled
3D simulation team in
China – dozens of simulation
engineers who use Robcad,
Process Designer and
Process Simulate.”
A car roof laser welding station simulated using Tecnomatix.
Dr. Stefan Sack
CEO
“This team must deliver value,” notes “We simulate all the BiW workcells, start- Comau (Shanghai)
Piegaia. “For example, in 2011, our biggest ing from spot welding, and continuing
project was a complete body-in-white with more advanced technologies, such as
(BiW) line for Fiat China, which included stud welding and laser welding,” Piegaia
around 250 Comau robots. Twenty engi- explains. “Laser welding, though being
neers worked on this project, using much more expensive than spot welding,
Tecnomatix tools for nearly half a year, is more appealing in those areas of the car
and delivered state-of-the-art simulations that are visible once the car is manufac-
that supported the production line, which tured. Using Robcad simulation, we
is now in operation. This project proved delivered a roof welding workstation to
our ability to collaborate across continents, one of our customers, in which two robots
as we used some welding guns that were do spot welding and two robots do laser
designed in Italy. Now, we are about to welding.”
simulate and commission the second
phase of this project, which almost dou- Smooth transition from Robcad to
bles the line throughput by means of a Process Simulate
cycle-time reduction and multiplication of Comau (Shanghai) recently started using
the robotized stations.” the Process Designer and Process Simulate
solutions, both in the Tecnomatix portfo-
The simulation work in China is performed lio, to deliver the 3D robotic simulation
according to the customer’s requirements work it previously created using Robcad™
and in collaboration with car component software, also in the Tecnomatix portfolio.
design. The main goal of the simulation is The first project executed with these tools
to plan and validate the production line. was a framing zone on a new production
line for one of the European OEMs.
In some cases, the simulation shows that Process Designer and Process Simulate
the design of a specific part should be data were among the initial deliverables
slightly changed due to the need to use submitted to the OEM.
specific welding tools.
“We believe Tecnomatix is
the best tool set for the 3D
simulation of robotized
workcells.”
“Twenty engineers worked
on this project, using
Tecnomatix tools for nearly
half a year, and delivered
state-of-the-art simulations
that supported the produc-
tion line, which is now in
operation.”
Riccardo Piegaia
Process Engineering Manager
Mechanical Engineering
Department
Comau (Shanghai)
Congjian (Kaiser) Liu of Comau (Shanghai) simulates a tip dressing operation using Process Simulate.
Piegaia acknowledges the support Comau multi-user capabilities, which ensure that
(Shanghai) received from Siemens PLM no simultaneous conflicting changes can
Software to get its engineers up to speed take place. The new functionality is also
with the new tools. He already foresees a of great benefit, for example the Weld
great benefit from them. “For a line builder Distribution Center application, or the
like Comau (Shanghai), the engineering new concept of event-based simulation,
communication framework with the cus- which enables a much more realistic simu-
tomer is always a challenge – what form of lation. It is used, for example, in a welding
communication to use, which data to gun tip dressing operation, which takes
share with the customer, and how fre- place only every so many cycles.”
quently to do so. Compared to a project
done using Robcad, with Process Designer “Process Designer and Process Simulate
and Process Simulate, I see a clear saving also provide a good foundation for
in engineering manpower, since there is responding to requests for proposals,” says
no need for a Comau (Shanghai) engineer, Qian Hawjia, a process engineer in the
who functions as a technical mechanical Proposal Department of Comau
leader, to be involved in this communica- (Shanghai). “We have already submitted a
tion. It is straightforward to communicate few proposals based on these solutions,
directly with the customer based on the and we believe that this methodology will
Process Designer and Process Simulate grow. The previous method was based on
data.” a complex Excel worksheet, but we real-
ized that a quotation process, more and
“In addition, the engineering work pro- more, includes both engineering and
ceeds faster and visualization is improved,” finance aspects. Process Designer/Process
notes Congjian (Kaiser) Liu, a process engi- Simulate is the platform that supports
neer in the Mechanical Engineering both.”
Department of Comau (Shanghai). “We can
actually visualize the entire production line
now. Other important features are the
“Another promising area
would be Teamcenter
Manufacturing Process
Planner, integrated with
Process Simulate, as it
provides the means to over-
come organizational and
geographical barriers using
global libraries and process
plans.”
Mingzhi Ni A rear floor welding line simulated using Tecnomatix.
Manager, Mechanical
Engineering Department
The Process Designer/Process Simulate automotive market, for example, there are
Comau (Shanghai)
deployment is supported by a new concept only 45 to 50 cars per thousand people in
of the virtual machine (VM) developed by China, which is still significantly lower
the Comau (Shanghai) information tech- than the ratio in developed countries, so
“The new functionality is also
nology (IT) department. Richard Yan, one can expect a significant growth of this
of great benefit, for example
Information and Communication market.
the Weld Distribution Center
Technology manager at Comau (Shanghai)
application, or the new con-
explains, “As the number of customers to “We are already a market leader in the
cept of event-based
which we deliver simulation data areas of automotive body welding and
simulation, which enables a
increased, we realized that we needed a powertrain machining and assembly,” Sack
much more realistic simula-
smarter IT solution to support different continues. “We are experiencing a very fast
tion. It is used, for example,
data schemes. Therefore, we decided to growth due to the excellent engineering
in a welding gun tip dressing
use the VM environment and set up this skills we have developed, our relentless
operation, which takes place
innovative configuration with the support effort for continuous improvement, and
only every so many cycles.”
of Siemens PLM Software China. This con- the big value we deliver to our customers.
Congjian (Kaiser) Liu figuration actually saved 60 percent of the This would not have been possible if we
Process Engineer hardware cost.” Yan notes that if this solu- were not using the Tecnomatix tools.
Mechanical Engineering tion is positively valuated, it might be
Department adopted by Comau globally. “We currently employ the biggest and
Comau (Shanghai) best-skilled 3D simulation team in
Tremendous growth China – dozens of simulation engineers
Comau (Shanghai) has experienced tre- who use Robcad, Process Designer and
mendous growth in China – an average of Process Simulate,” Sack adds. “The
nearly 50 percent annual growth in a span Tecnomatix tools not only help us provide
of 10 years starting in 2002. “The Chinese best-in-class production lines to our cus-
market represents a huge opportunity for tomers, but also eliminate waste within
Comau (Shanghai),” notes Dr. Stefan Sack, our organization by saving engineering
CEO of Comau (Shanghai). “If we take the time and helping minimize re-work on the
shop floor. One of our advantages, as a
line builder competing in the Chinese
Solutions/Services
Tecnomatix
Process Designer
Process Simulate
Robcad

Comau (Shanghai), a wholly
owned subsidiary of the Fiat
Group affiliate, Comau S.p.A,
supplies welding and pow-
ertrain machining and
assembly systems, as well as
robots, to automakers and Process Simulate Virtual Commissioning is used to troubleshoot cell controller program.
other manufacturers in China.
www.comau.com
market, is that we are truly a global line Planner in the Teamcenter portfolio,
builder, or as we say at Comau, ‘global integrated with Process Simulate, as it
Customer location strategy, local execution.’ Looking provides the means to overcome organiza-
Shanghai forward, I can foresee that our global tional and geographical barriers using
China operations will leverage the excellent global libraries and process plans.”
knowledge and skills we are developing.”
“Process Designer and Process “Comau (Shanghai) is now looking into the
Simulate also provide a good next promising manufacturing engineering
foundation for responding to solutions from Siemens PLM Software. An
requests for proposals. We example of this would be Process Simulate
realize more and more that a Virtual Commissioning,” explains Mingzhi
quotation process includes Ni, Mechanical Engineering Department
both engineering and finance manager at Comau (Shanghai). “The ability
aspects. Process Designer/ to test the virtual workcells with real
Process Simulate is the plat- controllers is a very promising area as it
form that supports both.” provides a real opportunity to shorten the
Qian Hawjia project duration. It may also involve some
Process Engineer, Proposal organizational changes, as control engi-
Department neers, who are now part of another
Comau (Shanghai) department, will have to work closely with
the simulation engineer. Another promis-
ing area would be Manufacturing Process
Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle
Management Software Inc. or its subsidiaries in the United States and in other countries. Excel is a registered trademark of
Microsoft Corporation. All other logos, trademarks, registered trademarks or service marks used herein are the property of
their respective holders.
Tecnomatix
Continental Automotive Group

Changing production requirements are handled easily with
digital factory software
Industry Tecnomatix Plant Simulation

Automotive and models give planners more
transportation flexibility; material flow
simulation also increases output
Business challenges and reduces waste
Frequent product alterations
Making driving safe and comfortable
and quantity changes
Continental Automotive GmbH is one of
Many production line the leading automotive suppliers in the
adjustments world. The company’s three divisions –
Chassis & Safety, Powertrain and Interior –
Keys to success develop and manufacture products that
make driving safer (air bags and sensors;
Digital material flow brake and chassis control systems), more
simulation fuel efficient (gasoline and diesel injection
What-if simulations to systems) and more fun (infotainment
compare alternate production systems and multifunctional displays).
line scenarios
The company’s Regensburg, Germany
facility is its biggest electronics plant.
Results In an area of 16,500 square meters A printed circuit board automatically mounted
Problems identified and (approximately 177,000 square feet), with components.
resolved faster nearly 2,000 employees produce about

Greater manufacturing 67 million electronic devices per year. The
the planners in this complex effort, the
flexibility plant operates 24/7, running 22 lines for
plant established an internal consulting
surface-mounted devices (SMDs) along
Higher output and less waste agency, called the “Lean Office,” that
with other product-specific assembly and
provides the business units with an expert
Optimized material flows inspection lines.
production infrastructure and manufactur-
Investment decisions ing expertise. “We offer our customers,
validated The company’s different business units
the individual business units, a kind of
demand quite a lot from the manufactur-
carefree package for the manufacturing of
ing planners at the Regensburg plant.
their products,” says Dr. Markus Fischer,
Frequent product alternations as well as
head of industrial engineering at
quantity changes require repeated
Continental Regensburg.
production line adjustments. To support
www.siemens.com/plm
“The possibilities of a
simulation are really great
for reducing costs.”
Stefan Lamken
Lean Office Process Consultant
Continental Regensburg
Electronic component on work-piece carrier. Customized laser marking of a manufactured

electronic assembly.
Identifying problems through simulation problems are easily fixed,” explains Stefan
The Lean Office increasingly relies on Lamken, a process consultant to the Lean
advanced technology, such as the Office and key user of Tecnomatix.
Tecnomatix® software from Siemens PLM
Software. This digital manufacturing Normally at Regensburg Plant, the manu-
solution was chosen after a rigorous facturing planners design lines with precise
benchmarking process – involving the and successive processing stations. In this
production process for side airbag satel- context, a simulation model is used to
lites (sensors used to detect an impact) – verify the planned performance of the line.
that turned out 120,000 parts per day, “For our planners, Tecnomatix Plant
covering more than 200 variants. The Simulation is a very interesting tool,” says
task was to simulate material flow Fischer. “An offline simulation shows solu-
between processing stations, starting with tions that sometimes surprise even the
preliminary assembly, through to SMD most experienced colleague.” For example,
mounting and all the way to customized a multi-product line with up to 100 vari-
packaging. After the process was modeled ants did not reach the theoretical targeted
in Tecnomatix Plant Simulation (in two output. An unforeseen bottleneck unbal-
weeks), the resulting simulation won over anced the material flow. The Tecnomatix
the plant’s management, and Tecnomatix simulation showed that a processing
software was quickly integrated into the station was operating too quickly, resulting
Lean Office’s technology portfolio. in jams at subsequent stations. The unex-
pected solution – slowing down the cycle
The office uses the Tecnomatix material for that particular station – would have
flow simulation functionality to examine been discovered much later had the simu-
and optimize new production lines, as well lation not been used.
as to optimize existing ones. The lines can
be evaluated and optimized for various Supporting sound financial decisions
parameters, such as throughput, cycle In another situation, the goal was to
times, performance limits, interferences, increase the output of a production line.
and so on. To make reliable predictions, Manufacturing planners developed four
simulation models must map the real line possible scenarios, noting the cost of each
as accurately as possible. Also, modifica- possibility. By evaluating the four alterna-
tions must be tracked carefully. Given the tives using Tecnomatix simulations, the
frequent product alternations, the goal is company was able to see that the most
to quickly identify potential problems in economical approach would meet the
software and fix them before the actual desired goal. “We were elated with the
process begins. “With a simulation, many software,” recalls Lamken. “With it, we
Solutions/Services could see that the cheapest concept deliv-
Tecnomatix Plant Simulation ered as much additional output as the
www.siemens.com/ most expensive one.” Overall, this is one of
tecnomatix the key advantages of the Tecnomatix
solution: accurate performance data on
which to base financial decisions.
Continental Automotive Tecnomatix also saves money by eliminat-
Group is one of the world’s ing the need for time-consuming tests on
leading automotive suppliers. actual production lines. For example, an
www.conti-online.com SMD line occasionally bottlenecked and
jammed, requiring operator intervention
Blister belt machine for packaging of SMD components.
to resolve the problem. This jeopardized
Customer location product quality and affected the line’s
Regensburg performance. A cooling buffer solved these various external conditions, such as poten-
Germany problems. A Tecnomatix simulation took tial supply disturbances and personnel
the solution a step further by showing how changes. “With Tecnomatix we are able to
the buffer could also enable higher output. evaluate various scenarios in the planning
“Material flows can be This was determined without performing stages,” says Fischer. “With this capability,
optimized in different ways, any physical tests. “The possibilities of a we have the necessary flexibility to per-
without having a single simulation are really great for reducing fectly meet customers’ demands.”
second of downtime.” costs,” says Lamken.
Currently, the Lean Office uses Tecnomatix
Stefan Lamken
In addition to verifying new and revised Plant Simulation models on approximately
Lean Office Process Consultant
production processes, the Lean Office uses eight projects per year, although that
Tecnomatix to minimize stock and to number is growing. “Every manufacturing
reduce waste. Questions regarding the planner who has experienced the benefits
ideal number of work-piece carriers in a of simulation comes back to us and our
“Tecnomatix simulations give
line are answered in detail by the soft- services,” says Lamken. “Digital material
us the flexibility we need in
ware. At the same time, simulation makes flow simulation with Tecnomatix has enor-
our production processes to
it possible to consider the effects of mous potential at our Regensburg plant.”
perfectly meet customers’
demands.”
Dr. Markus Fischer
Head of Industrial Engineering
www.siemens.com/tecnomatix Z1 25134 8/11 C
Tecnomatix
Siemens Drives
How the digital factory at Congleton supported a business turnaround;
use of Plant Simulation facilitates a significant reduction in factory lead times
Industry
Industrial machinery and
equipment
Business challenges
Establish the capability to
deliver product-to-warehouse
within a single day
Reduce factory and
warehouse inventory
Keys to success
Plant Simulation for discrete-
event simulation
Expertise of Siemens Warehouse inventory cut in half Siemens Congleton’s mission
Corporate Technology and cash freed up with the help “We provide our global customers with
of the Plant Simulation solution technically innovative, energy-efficient
Accurate data and under-
in the Tecnomatix portfolio products in a sustainable environment –
standing of manufacturing
on demand.” That’s the mission statement
processes
Dramatic improvement in productivity of the Siemens Congleton plant and the
Effective change management driving axiom behind a workforce of just
Much has been written about the digital
Shop floor buy-in over 500 employees who are producing
factory, but does it deliver in practice?
key models in the Micromaster and
One organization that knows the answer is
Sinamics range of drive inverters and
Results Siemens Industry Sector, Drive Technology,
distributed drive technology. Opened
Motion Control (Siemens Drives), based in
Delivering products to ware- in 1971, the factory and offices cover
Congleton in the United Kingdom (UK).
house in Germany within 12,000 square meters.
Tom Hattersley, who heads up the
24 hours Operational Supply Chain at Siemens
Target: product delivery within
Warehouse inventory cut Drives, notes, “These days, the digital
one business day
in half factory is a key component of competitive
Hattersley describes the process that led
Substantial cash freed up manufacturing and was a major factor in
up to his plant’s success: “I was production
the success of our Congleton 2011 project.
Lead time significantly engineering manager at the time, though
Between 2008 and 2011, we achieved a
reduced – up to 70 percent I came out of this role for six months to
dramatic improvement in productivity
work with the Congleton 2011 project
supported by the use of Plant Simulation.”
“I’d strongly recommend that
plants wanting to improve
their performance use Plant
Simulation. It gives you the
information – and the confi-
dence – to share your plans
with the relevant people,
show them what is possible
and get their buy-in.”
Tom Hattersley
Head of Operational Supply
Chain
Siemens Congleton
team full time. We were already rated “When we started the project in 2008,
within Siemens as a site of best practices. we were squeezing out what we could
Since the early ’90s, we’d used TQM (total in terms of multiple small productivity
quality management), quality circles and improvements. We knew we’d need a step-
continuous improvement teams to help change improvement if we were to make
improve our performance. We’ve been progress. We knew, too, that lean tools
lean in the office, as well as lean in manu- were not enough in isolation, and that we
facturing. As a result, we’ve seen an would need to model and test possible
improvement in our throughput times by factory layouts. We had to get it right the
a factor of ten and we have won numerous first time if we were to avoid irreversible
awards. However, we faced a real spending on inefficient layouts, unneces-
challenge in meeting the Congleton 2011 sary equipment and processes that would
objective of establishing the capability of not work. We needed a tool to achieve
delivering product to our Nuremburg this, and that tool was Plant Simulation.”
warehouse within a one-day window.
High-impact productivity tool:
“We also wanted to reduce inventory at the Plant Simulation
back-end and to increase flexibility. If you The Plant Simulation solution in the
can supply in one day or react in one day, Tecnomatix® portfolio is a discrete-event
instead of reacting in 5, 10 or 20 days, simulation tool that helps users to create
which is the standard lead time for similar digital models of logistic systems, such as
production organizations, you can hold factory layouts, so that they can explore a
less inventory in the factory and improve system’s characteristics and optimize its
delivery performance, or maintain delivery performance. These digital models allow
performance with less inventory in the users to run virtual experiments and what-
warehouse. That frees up cash, which is if scenarios without disturbing existing
very important in the current economic production systems, or do so when used in
climate. the planning process, long before the real
production systems are installed. Extensive
analysis tools, such as the bottleneck
analyzer, statistics and charts, enables
users to evaluate different manufacturing
scenarios. The results provide the informa-
tion needed to make fast, reliable and
smarter decisions.
It took six weeks to create the value “Between 2008 and 2011,
stream map and design, and one more we achieved a dramatic
week to pull it all together and decide improvement in productivity
what the factory had to look like. It took supported by the use of
another six weeks to build the model in Plant Simulation.”
Plant Simulation, validate it, test it and run
Tom Hattersley
a number of ideas. Hattersley explains,
Head of Operational Supply
“We were creating, in essence, a mathe-
Chain
matic model of the factory, which relies
Siemens Congleton
on data such as machine availability, MTBF
(mean time between failures), MTTR
(mean time to repair) and more. We would
then test each hypothesis by simulation.
From Tecnomatix we’d get a workplace
overview showing working time and wait-
Experience: Siemens Corporate ing time, off-shift time, break times and so
Technology on. We could also see utilization for each
Siemens Corporate Technology (CT) in work center/bench, structure of the prod-
Munich already had experience using Plant uct in VSM, throughput histogram for each
Simulation. In March of 2008, CT carried product and a buffers/Kanbans chart. I
out a factory assessment as a lead-in to the could then, for example, reduce five work-
project. The three main elements of the places to three and change the shift pat-
project were value stream mapping terns, rerun the simulation and get the
(VSM) and design, simulation and factory new results.”
re-layout. Hattersley was responsible for
the value stream mapping, value stream Lead time dramatically reduced
design and the implementation, while Hattersley quantifies the success: “In
CT led the simulation fully supported by one case, the average factory lead time,
Hattersley. based on the simulation, was four days.
We devised a new way of working, tested
Building the model to map the it, identified the bottlenecks, balanced
value stream the flows and, using Plant Simulation,
“Value stream mapping is a structured showed we could get lead time down to
process that supports the lean manufactur- an average of 1.5 days. That effectively
ing initiative, which promotes the means we could halve our inventory in the
elimination of waste and minimization of warehouse. For another product group,
non-value added activities. It can be we got down from 3.5 days to 2 days. “
very intuitively described with a Plant
Simulation model. We therefore created Plant Simulation can also flag bottlenecks
the value stream map showing how the resulting from demand volatility.
processes looked at that time: the current Hattersley points out, “In the past, we
steps, delays, and information flows used to create a spreadsheet to model
required to deliver the target product – some rough guesses, but with Plant
in this case the Micromaster 4, frame sizes Simulation we can virtually introduce
A, B and C. Then we produced the value proposed changes to the factory layout
stream design, how we wanted the factory through a simulation model. We can then
to look in the future, moving capital equip-
ment around the factory, and building the
mezzanine floor to accommodate the test
equipment from the shop floor to create
more space to move things around on
the shop floor.”
Solutions/Services
Tecnomatix
Plant Simulation

Siemens Drives provides
variable speed drives for the
motion control of electric
motors across a wide range
of industries.
www.siemens.com/drives
populate real operational data into the Effectively managing change

Customer location
simulation model, and compare the results “For a successful outcome, it is essential
Congleton of the simulation with the real production that you understand and prepare your
United Kingdom results. Since the simulation typically deliv- process planning data – your routings,
ers very close results to the real produc- your standard times and so on,” says
tion, the confidence in the simulation Hattersley. “It’s time-consuming but vital;
Partner
results, mainly by non-simulation experts, you have to input good data into the simu-
Siemens Corporate Technology is increased.” lation to get good information out. You
have to be reasonably analytical, and
Vision, agility understand your products, your processes
“With the help of Plant The project was initiated prior to the 2008 and your machines. Of course, you have
Simulation, we are now downturn when short-cycle business the usual issues of managing change and,
where our customers want essentially just stopped, as companies as is normal for us, the shop floor was
us to be; we deliver products across industries significantly reduced heavily involved.”
to our warehouse in spending, though long-cycle orders were
Germany within one day, maintained for a while. Siemens Drives Confidence that makes a difference
and continue to make wanted to be ready when the economy According to Hattersley, results are the
improvements as we push revived, so it continued with the project, bottom line: “We reduced lead time and
forward now for our next demonstrating vision and agility. “We had freed up cash by reducing inventory. With
project: Congleton 2015 – a firm justification for what we were the help of Plant Simulation, we are now
World Class provider.” doing,” says Hattersley. “We carried out the where our customers want us to be; we
Tom Hattersley simulation, and we had the data to back it deliver products to our warehouse in
Head of Operational Supply all up. By 2009, much of the factory reor- Germany within one day, and continue to
Chain ganization had been completed and the make improvements as we push forward
Siemens Congleton benefits started to flow throughout that now for our next project: Congleton
year, with more coming during 2010. 2015 – World Class provider.” Hattersley
Throughout 2011, we cascaded down this concludes, “I’d strongly recommend that
simulation methodology to our lower- plants wanting to improve their perfor-
volume products, so they benefited too.” mance use Plant Simulation. It gives you
the information – and the confidence –
to share your plans with the relevant peo-
ple, show them what is possible and get
their buy-in.”
Americas +1 800 498 5351 © 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens, the Siemens logo, Micromaster
Europe +44 (0) 1276 702000 and Sinamics are registered trademarks of Siemens AG.. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX,
Asia-Pacific +852 2230 3333 Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens
Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos,
trademarks, registered trademarks or service marks used herein are the property of their respective holders.
Automotive
Designing better factories, virtually

Plant design and optimization services based on Tecnomatix are proving to be cost-effective for India’s auto industry
EICHER ENGINEERING SOLUTIONS
Siemens PLM Software www.siemens.com/plm
Business initiatives Consultants to the auto

Production efficiency industry
Eicher Engineering Solutions
Business challenges (EES) is a unit of VE
Compete for business with in- Commercial Vehicles Limited, a
house experience significant player in India’s
automobile industry. EES was
Justify the cost of production
planning services established in 1997 as a center
of excellence to provide
Keys to success design, development and
Broad-based plant design and consulting expertise in the field
optimization solution of engineering services. This
250-member organization
3D virtual factory models
works from four different
Support from Siemens in India worldwide locations and is
divided into four practice
Results
areas: design, analysis, testing
Benefits to clients include: and digital manufacturing
30-35 percent increase in the solution services. EES’s client
utilization of space roster includes automotive OEMs and suppliers such as Nissan, Toyota, Daimler Chrysler,
20-25 percent saving in Peterbilt, Navistar, Kia Motors, GM, Harley Davidson and Johnson Controls.
material movement
EES’s Digital Manufacturing Solutions discipline is under the direction of Sachin Sanghi. With
Potential capital cost savings in eight years experience in industrial engineering at GM, Sanghi brings a familiarity with modern
the millions of dollars
scientific plant design and optimization practices to companies that are still using 2D factory
planning methods for the most part.“When I visit a prospective customer, my job is to convince
them that scientific methods for factory planning can improve their production processes
sufficiently to justify our services,” Sanghi explains. “Their other option is to rely on in-house
experience, as they have always done. The trouble with that is that it is not scientifically based
and can not provide the accurate predictions necessary for making informed decisions.”
Broad-based software solution

Sanghi chose the Tecnomatix® digital manufacturing solution from Siemens PLM Software as his
group’s software foundation. “I chose this software in part because I was familiar with it from
my days at GM,” Sanghi says. “But more important to me was the support of the Siemens
Automotive
“It is very effective to show organization in India. They helped me justify my business plan to EES. Had they not made that
3D simulations of assembly investment in me, the formation of the Digital Manufacturing Solutions team would not have
processes, or material been possible.”
handling processes, or
Another attractive feature of the Tecnomatix solution was the breadth of its functionality. With
even a walkthrough of an
Tecnomatix, Sanghi and his eight-member team have virtual 3D factory design capabilities (in
entire facility.”
FactoryCAD), comprehensive analysis tools for factory logistics (FactoryFLOW) and simulation
Sachin Sanghi capabilities that provide an intelligent foundation for business decisions (Plant Simulation). They
Practice Area Head, Digital
also have a unified source of factory knowledge. “This is a real benefit,” Sanghi says. “The
Manufacturing Solutions
Eicher Engineering Solutions factories I create virtually contain all the data about the layout, the material handling devices, the
racks, the machines and so on. I take an inventory not by physically counting but by asking the
software for a report. This is a huge contrast to how internal groups handle their factory data,
and it demonstrates a clear advantage of our approach.”
Real-world examples
The group’s typical client is automotive and automotive component companies that are either
trying to expand their existing capacity or to install additional capacity. While the current focus is
on a specific sector, the tools and techniques are as relevant to sectors as diverse as aerospace,
infrastructure, white goods, retail, etc. When Sanghi and his team plan these expansions using
Tecnomatix software, the savings to the customer come in the form of better resource
utilization, higher productivity and capital cost savings, as the following examples show.
In a job for a sister company, Eicher Engineering Components, a global tier one gear
manufacturer in India, EES’s Digital Manufacturing Solutions team was called in to advise on an
expansion that needed to increase the company’s capacity by a factor of three. The company had
already done some planning when Sanghi’s group got involved and had determined that the
expansion would need to use most of the available land. Using FactoryCAD, he was able to
design the expansion in such a way that they could increase capacity by a factor of almost five
without additional land.
Because he had created a 3D virtual factory in FactoryCAD, one of the options that Sanghi
noticed right away was that a number of non-value-added activities could be moved to the
mezzanine of the existing facility. “This is the
sort of thing that becomes very clear when
you have that third dimension to work in,” he
explains. “Even the customer started
contributing ideas once he saw the layout in
3D.” Sanghi made a number of other changes
as well, and for this client increased overall
space utilization by 33 percent. In addition, he
used FactoryFLOW to reduce material flow in
the facility by 26 percent. “Previously they had
to move material an average of 1,000 meters
(3280 feet). Using FactoryFLOW, even though I
Automotive
Solutions/Services had increased the floor space, the average move was down
to 703 meters (2,300 feet),” says Sanghi. The duration of
Tecnomatix
that entire project was three months.
NX
In another example, a stamping supplier to the leading
Client’s primary business Indian automotive company hired EES’s Digital
Eicher Engineering Solutions Manufacturing Solutions team when it was building a new
Digital Manufacturing Solutions’ facility to meet a mandated production increase. Internal
services include: production calculations showed that the new facility would need to be
system optimization, warehouse equipped with 19 stamping machines, at a cost of about
design and optimization, in-plant $250,000 each, to achieve the target capacity. “Using Plant
logistics design, material flow
analysis and planning, 3D layout Simulation, we determined that they would only need 14
design and process machines,” says Sanghi. “At first they didn’t believe us but
documentation. eventually we were able to convince them of the accuracy
www.eicherengineeringsolutions.com/ of our calculations. They decided to purchase 15 machines (an extra one to have on a contingency
pdo-plant-simulation.html basis). Our work with Plant Simulation saved that company $1 million.”
Client location
Convincing demonstrations
Gurgaon For the most part, EES’s Digital Manufacturing Solutions’ customers do not supply digital data for
India their facilities or equipment. Sanghi and his colleagues create the necessary geometry using
FactoryCAD. They’ve found that this is the fastest way to work because the extensive libraries in
FactoryCAD eliminate the need for modeling items from scratch. At times, Sanghi has also used the
“More important to me was
NX™ digital product development system from Siemens PLM Software to create digital product
the support of the Siemens
models, such as tires and fuel tanks for a warehouse space optimization job.
organization in India.”
Sachin Sanghi The ability to do this work quickly is sometimes important to winning business. But a more
Practice Area Head, Digital important selling point is giving prospective clients the assurance that EES’s Digital Manufacturing
Manufacturing Solutions Solutions team knows what it is doing. The Tecnomatix solution is valuable in this regard. “It is very
Eicher Engineering Solutions
effective to show 3D simulations of assembly processes, or material handling processes, or even a
walkthrough of an entire facility. It meets an emotional need,” says Sanghi.
For most of India, the use of plant design and optimization software represents a new approach to
factory planning. With Tecnomatix and a growing body of case studies showing the cost-effectiveness
of this approach, EES’s Digital Manufacturing Solutions team is helping Indian manufacturers make
more knowledgeable decisions as how to expand their capacity to better compete.
Contact
Americas 800 498 5351
Europe 44 (0) 1276 702000
Asia-Pacific 852 2230 3333
www.siemens.com/plm
© 2008 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG.
Teamcenter, NX, Solid Edge,Tecnomatix, Parasolid, Femap, I-deas, Velocity Series and Geolus are trademarks or registered trademarks of Siemens Product
Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or
service marks used herein are the property of their respective holders. 8/08
Tecnomatix
Eisenmann
Developing an automated flight service cart system for New Doha
International Airport
Industry Eisenmann shortens project using computer systems, which simulate

Industrial machinery and delivery time by conducting in great detail the plant’s operation.
Eisenmann Conveyor Systems (Eisenmann)
equipment virtual commissioning using
is using Siemens PLM Software’s Plant
Plant Simulation Simulation solution in the Tecnomatix®
Business challenges portfolio to simulate such testing virtually,
Virtual commissioning enabled by hence the term, “virtual commissioning.”
Gain bigger market share Plant Simulation
through innovative products This process can save companies substan-
The process of testing a facility or plant to tial amounts of time and money by model-
Deliver a monorail system for verify that it functions according to specifi- ing and optimizing operations long before
food catering carts at the New cations is called commissioning. Advances construction or equipment installation
Doha International Airport in technology have made it possible to begins.
Shorten final onsite conduct significant portions of this testing
throughput testing
Keys to success
Simulate the automated
material flow of complete
operations
Virtually commission
electrified monorail systems
Optimize complex material
flow systems
Easily build a discrete event
simulation model
Eisenmann electrified monorail system.
Results
Designed and built the New
Doha International Airport’s
electrified monorail system
Determined optimal number
of trolleys and buffers
Shortened final throughput
testing through virtual
commissioning validation
This model created using Plant Simulation shows an inverted monorail system, including the monorail layout, a
bar chart showing the order queues, a circular chart showing the level of empty trolleys and a table showing the
hourly throughput values.
Eisenmann builds facilities for surface fin- independently on the rail system. Branch
ishing technology, material flow automa- points can be implemented on the line
tion, environmental technology and with the aid of switch points. The actual
ceramics firing lines, as well as special rails are typically attached to the shop
facilities for energy recovery, coating, ceiling. If a trolley fails, it can be slid from
thermal processing and recycling. the transport line into the maintenance
Eisenmann uses software tools from bay without major effort.
various product lines of Siemens PLM
Software. Hundreds of Eisenmann engi- Eisenmann uses Plant Simulation exten-
neers use NX™ software for product design sively in the company’s Conveyor Systems
and Teamcenter® software for product business unit. The expected target of each
lifecycle management (PLM). In the area simulation is defined with the customer.
of digital manufacturing, Eisenmann uses The objectives to be pursued differ,
Robcad™ software in the Tecnomatix port- depending on the project phase, and may
folio for 3D simulation of paint production include the development of new concepts
processes, as well as Plant Simulation for and visualization of material flow; project
discrete event simulation of paint and planning support by material flow confir-
logistic lines. mation and determination of the number
of trolleys; and execution support via
Electrified monorail system for fast, impact analysis of malfunctions and by
automated inbound logistics testing material flow strategies and contin-
Electrified monorail system
designed using NX. An electrified monorail system (EMS) is a gency concepts.
rail-bound means of conveyance with
individually driven trolleys that move The customer provides Eisenmann with
the required transport matrix, which is
actually the throughput that the facility will be processed on schedule and to “ We are very pleased with the
needs to support, and where applicable, a rigorous standards. discrete event simulation
working time model. Eisenmann develops capabilities we have devel-
the layout and defines the conveying With 130 trolleys and roughly 20,000 oped in Eisenmann through-
characteristics, for example, the conveyor transports per day, the 1.6 kilometer long out the years, especially our
speed (in straight rail and curves) and electrified monorail from Eisenmann lies use of Plant Simulation.”
routing strategies. at the heart of this logistical masterpiece.
Dr. Monika Schneider
The monorail will effectively and effi-
Simulation Expert
“We are very pleased with the discrete ciently link the various process steps
Conveyor Systems
event simulation capabilities we have involved in this delivery system, including
Eisenmann
developed at Eisenmann throughout the all the measures necessary to clean and
years, especially our use of Plant equip the carts.
Simulation,” says Dr. Monika Schneider,
simulation expert at Eisenmann Conveyor Carts arriving in the incoming area will be
Systems. “Typically, the results we get manually pushed onto the waiting EMS
from the simulation include confirmation trolleys and transported to the supply sta-
of the required throughput and the tion, where they are emptied. The empty
required number of trolleys, which have a carts on the EMS trolleys will pass through “ Using the joint work of the
strong impact on project costs; confirma- the cleaning zone, and then proceed to control programmer with
tion of the layout design; capacity utiliza- the various terminals. The corresponding the simulation expert who
tion of conveyor system components and destinations will be specified by the mate- configured and used Plant
stations; occupancy of buffers and queues; rial flow computer (MFC) from Eisenmann. Simulation, we created a
and the impact of planned routing strate- At the terminals, the carts will be loaded virtual commissioning
gies. Based on the simulation results, with fresh goods and food. Approximately setup, in which we were able
appropriate project documentation is 82,000 meals will be produced and distrib- to identify and solve real
generated. uted every day. problems of our routing
strategy control program.”
“Examples of Plant Simulation capabilities, “In the NDIA project, we have used Plant
“ Connecting Plant Simulation
which are fundamental for our usage, Simulation intensively,” Schneider says.
to the MFC, we were able to
include our own object libraries,” says “We started with the 2D layout of the
conduct some of this testing
Schneider. “These libraries allow us to catering building, and built a simulation
virtually, in the office. That’s
build a basic simulation model in half a model that runs an animated simulation
another project first. More
day, with the ‘Pack-n-Go’ functionality, on this layout. For the quotation phase, in
importantly, this means that
enabling us to deliver a dynamic simula- which we had to fix the number of trolleys
the real commissioning
tion model.” and lifting stations, the track length and
effort was smaller. Because
other parameters, we simulated a peak
real onsite commissioning is
Testing a logistical masterpiece – scenario. The material flow starts from
expensive, this capability
virtually the incoming area to the ‘main highway,’
has the potential to greatly
As a future hub of international air traffic, through which all the trolleys are going.
impact the competitiveness
the New Doha International Airport (NDIA) Special attention was given to the routes
of our offering in terms
in Qatar set out to create a smoothly func- of empty trolleys, according to priority
of cost.”
tioning, reliable logistics system. NDIA rules, in order to prevent blockage of
selected Eisenmann to install an EMS, trolleys by other trolleys during low profile Dr. Ullrich Ochs
linking all operational stations in the new times. Senior Manager
state-of-the-art catering wing and assuring Software Electrical
the airlines’ supply of flight service carts. “In this project, we practiced for the first Engineering
These carts will provide the airplanes with time with a virtual commissioning con- Eisenmann
food, drinks, duty-free articles and news- cept, by connecting the MFC to the simu-
papers. Within this exceptional airport, the lation model, and thus we were able to
carts of all arriving and departing airlines
“ The simulation model we virtual commissioning. Using the joint
create with Plant Simulation work of the control programmer with the
is often part of the deliver- simulation expert who configured and
able to our customers. used Plant Simulation, we created a virtual
Many of them also use Plant commissioning setup, in which we were
Simulation themselves, so able to identify and solve real problems
they know how to run the with our routing strategy control program.
simulation and change the The kind of issues we identified using the
needed parameters. This virtual commissioning setup included, for
is a big benefit for them, example, a trolley that didn’t arrive at the
because they get a virtual designated station and the size of the buf-
model of the physical line.” fers for empty trolleys (which was
incorrect).
Dr. Heiner Träuble
Simulation Expert
“In the final step of a project commission-
Automotive Paint Systems
ing, we usually conduct a throughput test,
Eisenmann
in which we physically run the line for
several hours, typically an entire shift, with
all the shop floor people. Connecting Plant
Simulation to the MFC, we were able, for
Food cart being loaded onto the trolley
the first time, to conduct some of this
testing virtually in the office. More impor-
identify and resolve most of the problems tantly, this means that the real commission-
in the MFC program. You can actually ing effort was smaller. Because real onsite
visualize any improper material flow in the commissioning is expensive, this capability
virtual simulation model. I worked on this has the potential to greatly impact the
side-by-side with a control programmer, competitiveness of our offering in terms
who developed and debugged the control of cost.”
programs. As we set up this connection for
the first time, we were rather impressed,
because everything worked as
documented.”
The complexity factor

“ We have a long legacy of “This project was complex in the sense
using Plant Simulation in the of the relatively many routing strategies
automotive business unit of that we had to develop,” says Dr. Ullrich
Eisenmann, and we are very Ochs, senior manager, Software –
pleased with it. We some- Electrical Engineering, Eisenmann
times use other solutions, as Conveyor Systems. Dr. Ochs, who manages
requested by our customers, the control aspects of the NDIA project,
but Plant Simulation really explains, “When developing that many
stands out as a superior routing strategies, the control programmer
solution that fits our needs.” needs to forecast virtually any possible
scenario, and this is a real challenge. So
Dr. Heiner Träuble
we decided to use Plant Simulation for the
Simulation Expert
Automotive Paint Systems
Eisenmann User terminal screen and model created using Plant
Simulation during the virtual commissioning of the
NDIA project.
Resolving complex challenges in “ In the Conveyor Systems
automotive paint lines – virtually business unit, we use Plant
Eisenmann also uses Plant Simulation in Simulation in nearly every
its automotive business unit to simulate project. We start by using
various kinds of production lines, such as Plant Simulation in the
paint shops and overhead monorail sys- quotation or pre-engineering
tems that deliver parts to assembly lines phase, as well as employ it
and automated guided vehicle (AGV) in the realization phase. We
systems. Typical input parameters for the typically create one new
simulations include the layout of the plant, simulation model per week.”
Automotive subassembly paint line delivered
such as geometry and topology; technical by Eisenmann. Ralf Weiland
parameters, such as speeds and accelera-
Senior Vice President
tion; and logistical parameters, such as
Conveyor Systems
requested throughput, shift pattern, mean The targets of the simulation in the auto-
Eisenmann
time to repair (MTTR) and availability. motive business unit typically include con-
firmation of throughput (jobs per day),
“In the automotive business unit, we are cycle time check of conveyors and in paint
using Plant Simulation to create simula- shops, a sequence check of the batches
tions at different levels of detail, depend- (sometimes called “pearl chain”). The typi-
ing on the project phase,” says Dr. Heiner cal challenge is that color sorting “dam-
Träuble, simulation expert, Automotive ages” the sequence, creating the need to
Paint Systems, Eisenmann. “In the concept measure the quality of the sequence.
phase, we mainly analyze the size of buf-
fers before and after the paint line. The Other targets include decoupling of
details of the conveyors won’t usually be conveying areas to analyze the impact of
handled at this phase. During the planning failures, checking conveying strategies,
phase, the generic buffers will be changed sorting for color blocks (in a paint shop),
to discrete conveyors. The scope of analy- sorting to rearrange a sequence (such as
sis will typically be the cycle time of the to support just-in-sequence production),
discrete conveyors and flow strategies. determining or estimating the number of
Sometimes, after several years of opera- skids and hangers, visualizing complex
tion, a production line will need to be re- material flow, and discussing or develop-
built. Then we use the simulation model ing conveying strategies in a layout or
we created when delivering the line to plant.
show the impact of the changes. “ With our virtual commission-
“We have a long legacy of using Plant ing capability, supported by
“The simulation model we create with Simulation in the automotive business unit creating realistic validations
Plant Simulation is often part of the deliv- of Eisenmann, and we are very pleased in a virtual environment
erable to our customers. Many of them with it,” says Träuble. “We sometimes use using Plant Simulation,
also use Plant Simulation themselves, so other solutions, as requested by our cus- we believe we can shorten
they know how to run the simulation and tomers, but Plant Simulation really stands delivery time on every
change the needed parameters. This is a out as a superior solution that fits our project.”
big benefit for them, because they get a needs. The software has unique features,
Ralf Weiland
virtual model of the physical line. Some such as defining a plant layout as a back-
Senior Vice President
customers require us to use their own sim- ground, highly flexible programming
Conveyor Systems
ulation standard. Moreover, selected auto- language, very useful ‘Pack-n-Go’ function-
Eisenmann
motive OEM customers provide us their ality to deliver simulation models to
own library of Plant Simulation objects, customers, and strong library capabilities
from which we create the simulation
model.”
Solutions/Services (including objects with logic), which
Tecnomatix enable us to use customer libraries as well
Plant Simulation as our own.”
Robcad
www.siemens.com/tecnomatix Using Plant Simulation for virtually
every project
NX
“In the Conveyor Systems business unit,
www.siemens.com/nx
we use Plant Simulation in nearly every
Teamcenter project,” says Ralf Weiland, senior vice
www.siemens.com/teamcenter president, Eisenmann Conveyor Systems. Eisenmann education center in Böblingen, Germany.
“We start by using Plant Simulation in the
quotation or pre-engineering phase, as
well as employ it in the realization phase. fulfills the requested throughput data.
Eisenmann is a leading global We typically create one new simulation But the benefit of Plant Simulation is far
provider of industrial solutions model per week.” beyond this. We actually reduce the risk
and services for surface finish- associated with a line delivery by simulat-
ing, material flow automation, Weiland explains the process: “During ing any potential operative scenarios.
thermal process technology, the quotation phase, the ability to present With our virtual commissioning capability,
and environmental engineer- a suggested concept to a potential supported by creating realistic validations
ing. A family-run business customer, supported by a simulation, is in a virtual environment using Plant
based in Southern Germany, unique. This helps us demonstrate the Simulation, we believe we can shorten
Eisenmann plans and builds proposed concept in a visually dynamic delivery time on every project.”
made-to-measure manufactur- manner, which gives the prospect more
ing, assembly and distribution confidence that our proposed concept
plants that are highly flexible,
energy- and resource-efficient,
and deployed by enterprises
throughout the world for
more than 60 years.
www.eisenmann.com
Customer location
Böblingen
Germany
Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle
Tecnomatix Plant Simulation for
the food and beverage industry
Benefits Summary
• Identify and fix bottlenecks Seasonal demands, high product turnover, high flexibility for new products
• Develop optimal cleaning and multi-variety packs, as well as quality and freshness are among the chal-
strategies lenges in engineering for food and beverage production plans. With highly
• Define quantified measures automated sophisticated technologies and expensive equipment, it is particu-
to optimize output up to larly important to ensure that manufacturing processes meet current and
30 percent future needs.
• Invest in the right equipment
• Determine feasible and
robust production plans
• Secure product quality by a
stable and harmonized
production flow
• Minimize discarded material
To manage these challenges, simulation is the tool to implement fully vali-

dated new processes that are “right the first time.” Using simulation, you can
determine the most cost effective and future-proof planning solution. Alter-
nate planning scenarios can be compared to select the best balance between
performance, flexibility and investment. By using simulation, it is easy to
identify bottlenecks and to plan the best strategy for increasing plant output.
TECNOMATIX
Tecnomatix
Tecnomatix Plant Simulation for the food and beverage industry
Simulation of food and beverage produc- The iSILOG solution breaks down the bor- mated and reproducible production flow.
tion processes helps you answer the fol- ders between continuous batch processing For example, the WIP level in the tanks will
lowing questions: and discrete production processes com- decrease depending on the production of
• What are the existing bottlenecks at mon in food and beverage production. It the connected filling line. The animation
the plant? covers special functions such as cleaning, allows you to follow the material flow and
• What are best strategies (e.g. cleaning, batch- and recipe-management. It makes it to observe tank levels, orders, equipment
changeovers, batch sizes, production possible for you to model the complete status and enhanced statistics like tank
planning and control) to increase flow, from incoming goods over batch pro- levels over time or Gantt charts for all
output? cessing in tanks and special equipment, equipment with detailed order informa-
• What are the existing limits of the plant filling, packing and palletizing up to stor- tion. Simulation serves as communication
regarding expected future products ing the finished goods in a warehouse. platform for all parties on existing or
and demands? Plant Simulation provides interfaces to planned manufacturing system behavior.
• What is the best approach for Excel, XML, data bases, etc. to integrate
harmonizing customer demands, the simulation into an existing software Use cases
incoming goods, batch sizes and environment. Plant Simulation can even Using this solution, one manufacturer was
packaging lines? help you cover the complete lifecycle of able to reduce by one the number of tanks
food and beverage production plants. required, reducing their investment by
In complex systems with large interdepen- From designing the manufacturing plant, 400,000 Euros. Other companies have
dencies such as in food production plants, through virtual commissioning of produc- tracked such improvement as:
it is nearly impossible to manually esti- tion control to the solution helps you • The ability to improve service reliability
mate how the system will perform. That is advance online production planning and and due data quality from 85 to
why simulation is an essential planning scheduling application. 100 percent without any additional
solution for a successful future. investment
This food and beverage solution can be • A 70 percent reduction in onsite
iSILOG has developed an additional solu- applied in all areas of food production for commissioning
tion for the food and beverage industry products such as: • Reduced energy consumption by more
based on Tecnomatix Plant Simulation • Brewing, soft drinks and milk processing than 5 percent, leading to reduced costs
from Siemens PLM Software. The solution • Fresh and frozen food and higher profitability
includes industry-specific objects such as • Instant soup
tanks, mixers, pipes, grinder, filling sta- • Snacks and candy Solution specific objects:
tions, packing, palletizing and storage. • Animal food • Tank
Using these standard objects makes it easy • Agricultural raw materials • Mixer
for you to model an existing or planned • Pipes
production process in the food and bever- A model based on the food and beverage • Grinder
age industry. solution can vary from a single production • Filling station
line to a complete plant including raw • Packing
material intake and final product storage. • Palletizing
The simulation model compasses an ani- • Storage

www.siemens.com/tecnomatix herein are the property of their respective holders.
X3 31104 8/12 C
Plant Simulation for Warehousing
and Logistics
Design, analyze and optimize warehousing and logistics operations
Benefits Summary
• Reduced time for designing Tecnomatix® Plant Simulation for Warehousing and Logistics software
warehousing and logistics enables you to rapidly create realistic simulation models of dynamic
operations warehousing and logistics operations. Plant Simulation lets you evaluate the
• Optimal utilization of characteristics and performance of design alternatives long before they are
resources, including implemented in real-life processes, thereby enabling you to make smarter
personnel, docks, storage decisions, minimizing design rework.
and other factors
• Extensive what-if analysis Challenges in warehousing and logistics
and evaluation of scenarios In today’s global economy, warehousing and logistics involve more than just
• Optimal return on “shoving boxes.” Warehouses now operate in dynamic global supply chains. A
investments in equipment highly competitive global marketplace requires rational approaches to
and WMS implementation designing dynamic warehousing and logistics operations. Speed, efficiency
• Unmatched accuracy and and quality all need to be improved simultaneously, not only at the
realism of results operational level, but also during design and implementation.
• Set of predefined
control rules Dynamic simulations of operations have become an indispensable aid for
• Visualization and animation achieving these strategic goals. To address these goals, Tecnomatix Plant
of operations and their Simulation provides a solution that enables you to evaluate the warehouse
performance performance from a comprehensive, “fact-based” perspective.
• Powerful tool to
communicate design
alternatives and their
performance
Features
• Simulation of complex
production systems and
control strategies
• Object-oriented hierarchical
models of warehouses,
encompassing business,
logistics and production
processes
• Graphs and charts for
analyzing throughput,
Source image: DB Schenker.
TECNOMATIX
TECNOMATIX
Plant Simulation for Warehousing and Logistics
Features continued applications support the analysis and re-

• Comprehensive analysis use of existing data, such as data from an
tools, including automatic existing warehouse management systems
bottleneck analyzer, Sankey (WMS). Plant Simulation comes with a
diagrams and Gantt charts clever toolset that enables you to run and
• 3D online visualization optimize various operational scenarios and
and animation different warehouse designs. Performance
• Integrated neural networks metrics are displayed in a transparent
and experiment handling manner in standard and customizable
• Automated optimization of reports/ dashboards. Operations are
system parameters visualized through the use of aesthetically
• Open system architecture appealing 2D and 3D animations.
supporting multiple
interfaces and integration Application areas
capabilities (ActiveX, C, CAD, Speeding up design and implementation
MS Excel, Oracle SQL, OPC) Plant Simulation offers functionality to Conceptual warehouse design
address all areas that influence the Conceptual design simulations should be
performance of a warehouse. It provides easy to use and facilitate effective commu
basic capabilities, such as the ability to nications. During this design phase, many
represent storage racks, layout and options remain open including site and
Ready for today’s and lift trucks. It also provides features for warehouse layout, delivery schedules and
tomorrow’s questions facilitating order-picking and value- operating hours. Unfortunately, historical
Traditionally, companies had to make added logistics. data often is not available, let alone
“best guesses” about their warehousing detailed equipment specifications.
and logistics operations. Now, Plant Plant Simulation objects are capable of However, the extensive capabilities of
Simulation leverages material flow reflecting real-world dynamics, such as Plant Simulation support conceptual
simulation to enable you to make “fact- varying order volumes, downtimes of simulations that facilitate quick warehouse
based” decisions about: resources and varying picking times. The design, process flow animation and the
• Capacity requirements for personnel, simulation’s unmatched realism sharply visualization of key performance indicators.
storage and handling equipment differs from solutions that rely on common
• Site and warehouse layout, including spreadsheet-based calculations. Detailed warehouse design Accuracy and
position, length, number and width of extensive what-if analyses are most
aisles and other considerations You can easily extend Plant Simulation important for detailed warehouse design.
• Storage, including ABC storage, zone with custom objects or control strategies. Conceptual warehouse designs need to be
storage, dedicated storage, random Data interfaces to most common detailed further with more specific data
storage and cross-docking
• Order-picking, including batching,
optimized routing, sorting and
consolidation algorithms
• Effects of automation, including robots,
AGVs, AS/RS and carrousels
• Planning and control, including
consideration of schedules, order release
and other factors
• Inventory management, including
ordering policies, cycle counting and
other considerations
• Value-added logistics
TECNOMATIX
about equipment and flow of goods. Plant Redesigning operations At various

Simulation provides a range of fully intervals, every warehouse operation
configurable equipment types and control requires a redesign. For example, redesign
policies to support accurate simulations. usually becomes necessary when new
The solution’s automated experimentation customers have to be served or
capability enables you to analyze and technological innovations are introduced.
optimize a wide range of scenarios, Simulation is extremely valuable in these
including completely different layouts. instances. Accurate data is readily available
for existing operations. Plant Simulation is
Optimizing existing operations the perfect tool to address even the most
Benchmarking a warehouse’s operation challenging redesign efforts. You can
against a simulation model is an objective quickly and accurately build simulation
way to optimize warehouse performance. models, as well as communicate
Simulation models also can be used for alternative designs and results in clear
operational planning. Re-use of data and reports and 3D animations.
flexibility are the keys to efficient
benchmarking. You can easily feed various
kinds of data into Plant Simulation,
including past orders, inbound and
outbound flows, equipment breakdowns
and other kinds of information, without
regard to their source. Simulations provide
accurate benchmarks with clear
visualization of the operation and key
performance indicators.

X9 16794 9/11 B
Tecnomatix Plant Simulation for the
high tech and electronics industry
Virtually build, test and optimize plants to find and fix production issues
before they happen
Benefits Summary
• Enhance productivity by 20 The high tech and electronics industry is rapidly growing, agile and global.
to 40 percent Manufacturers face massive price pressure, extremely short product lifecycles
• Reduce investment up to 20 and high numbers of variants. This requires ongoing changes in the
percent production infrastructure. Tecnomatix® Plant Simulation software from
• Reduce work in progress up Siemens PLM Software helps production managers and planners model,
to 75 percent simulate, visualize, analyze and optimize complex production scenarios. It is
• Cut throughput time up to critical to the return on your R&D investment that you be able to re-use
60 percent intellectual property for new products.
Features Plant Simulation enables you to simulate and optimize material flow,
• Simulation of complex resource utilization and logistics for all levels of operations planning from
production systems and global production facilities through local plants to specific lines and
control strategies processes. With increasing cost and time pressures in production, along with
• Object-oriented, hierarchical ongoing globalization, logistics management has become a key factor
models encompassing for success.
business, logistic and
production processes Plant Simulation enables you to detect and eliminate problems early in
• Dedicated application object the planning process that otherwise would have required costly and
libraries for fast and efficient time-consuming
modeling of typical scenarios correction measures
• Graphs and charts for during actual
analysis of throughput, production ramp-
resources and bottlenecks up. The software
• Comprehensive analysis helps you minimize
tools, including automatic your investment in
bottleneck detection, Sankey production lines
diagrams and Gantt charts without jeopar
• 3D online visualization and dizing the required
animation output. It also helps
• Integrated experiment you optimize the
handling performance of
• Automated optimization of production systems
system parameters by implementing
measures that have been verified in a simulation environment prior to
implementation.
Manufacturing optimization with Tecnomatix Plant Simulation enables you to

optimize assembly plants to achieve successful product launches, reduce
TECNOMATIX
TECNOMATIX
Tecnomatix Plant Simulation for the high tech and electronics industry
Features continued production ramp up and shorten time-to- Plant Simulation in action: higher
• Open system architecture market. Siemens PLM Software solutions efficiency, faster throughput, reduced
supporting multiple make it possible to re-use existing work in progress
interfaces and integration production data and process information A manufacturer of printed circuit board
capacities (ActiveX, CAD, more effectively. control units was producing parts in 35
Oracle SQL, ODBC, XML, variants. Before using Plant Simulation, the
Socket, OPC, etc.) PC assembly can be simulated using Plant company was producing 1,380,000 parts
Simulation, including all resources such as every 1.8 days. After using Plant
personnel, machines, materials and Simulation, they produced 1,400,000 parts
transport systems. The goal is to check the every 1.3 days, a 40 percent improvement
feasibility of production plans generated in efficiency. The plant enjoyed 29 percent
by a production planning system. faster throughput time – what used to take
Production plan execution for each shift is 40 hours can now be done in 31 hours.
optimized in a realistic manner that
considers the current circumstances in the What’s more, the plant has reduced work
plant. Measures can be checked before in progress and capital burden. The
they are carried out in practice. Plant average number of units in production
Simulation helps to develop and verify new before simulation was 120,000. After
shift models, work organizations and other simulation, it was 85,000, a reduction of
changes in production. 42 percent.

www.siemens.com/plm herein are the property of their respective holders.
X2 30714 6/12 B
Tecnomatix
KUKA Systems do Brasil

Leading automotive line builder delivers state-of-the-art
robotics production lines
Industry Use of Process Simulate Virtual than 15 countries, each of the KUKA
Systems Group’s companies is focused on
Industrial machinery and Commissioning enables early
providing the most advanced and high-
equipment detection of production issues value production solutions.
Innovative automation solutions KUKA Brazil was founded in 1998. Having

Business challenges
expanding in South America made an important investment in engi-
Increase competitiveness of KUKA Systems Group is one of the world’s neering capacity, the company’s solutions
services offering leading providers of engineering services are now present at virtually every automo-
Improve margin on delivered and manufacturers of flexible automatic bile manufacturer’s site throughout Brazil.
projects production systems. Its customers come Recently KUKA Brazil introduced its
from a diverse array of industries, includ- automation technologies to small and
ing automotive, aerospace and solar. The medium-sized companies in the aerospace
Keys to Success solutions of KUKA Systems do Brasil (KUKA and general industry markets. As a result,
Deploy Process Simulate Brazil) encompass comprehensive applica- the company doubled its size in just three
Virtual Commissioning for tions for the industrial processing of years. With 170 employees, KUKA Brazil is
improved production metallic or non-metallic materials. With now one of South America’s top produc-
equipment utilization approximately 3,500 employees in more tion-line integrators.
Bring more line installation
know-how back into the
organization
Remove barriers between
mechanical, electrical and
control engineers
Results
Robotics workcells 98 percent
ready before ever going to
the shop floor
Reduced number of issues
found on the shop floor
An automotive body-in-white production line delivered by KUKA Brazil.
Results (continued)
Continuously improving
operational efficiency;
lower costs
Outsourcing of start-up
work substantially reduced
Improved profitability
“Due to the superiority of the

robotics simulation tools in
the Tecnomatix portfolio,
we decided to use them
KUKA framing in body shop.
exclusively.”
Marcio Sampaio Tubini Moving from Robcad to Process Simulate “In 2012, we delivered a project to one of
Digital Manufacturing
KUKA Brazil has been harnessing the value the automotive OEMs (original equipment
Project Leader
of solutions in the Tecnomatix® portfolio manufacturers) using Robcad. For evalua-
KUKA Brazil
for years, including Plant Simulation and tion purposes, we performed some of the
Robcad™ software, and recently Process work with Process Simulate, and then
Designer and Process Simulate for automo- demonstrated its value. The customer
“The use of Process Simulate
tive robotics, body-in-white (BIW) produc- was very pleased with the results, so we
Virtual Commissioning
tion lines. As the advantages of Process decided to deliver the next project in its
brings together engineers
Simulate became more evident, the entirety using Process Simulate.
with different kinds of
company began transitioning from Robcad
expertise. The fact that
to Process Simulate. Tubini notes that his team is especially
electrical, mechanical
impressed that migrating data from
and control engineers sit
Robcad to Process Simulate is a non-issue.
together in the same room,
working on the same
Virtual commissioning for
scenario, is a big advantage.
higher competitivenes
Marcio Sampaio Tubini KUKA Brazil had been looking for ways to
Digital Manufacturing increase its competiveness. As part of this
Project Leader initiative, it evaluated Process Simulate
KUKA Brazil Virtual Commissioning in the Tecnomatix
portfolio, which enables connecting a 3D
robotics simulation with a physical cell
controller. Use of Process Simulate Virtual
A Kuka Brazil engineer using Plant Simulation
Commissioning provides the ability to
to analyze production capacity. control a virtual simulation using the
operator’s human machine interface (HMI),
“Due to the superiority of the robotics exactly as it is done on the shop floor.
simulation tools in the Tecnomatix portfo-
lio, we decided to use them exclusively,” “There is substantial benefit in doing the
says Marcio Sampaio Tubini, digital manu- robotics cell optimization, as much as pos-
facturing project leader, KUKA Brazil. sible, at the engineer’s desk, rather than
“For years we have been using Robcad, doing it on the shop floor,” notes Gilmar
and we are very satisfied with its Miranda, engineering manager, KUKA
capabilities. Brazil. Using Process Simulate Virtual
“We estimate that approxi-
mately 70 percent of the
start-up work is robotics-
and control-programs tun-
ing; we believe that by using
Process Simulate Virtual
Commissioning we can
reduce that by 20 to 30
percent.”
Gilmar Miranda
Engineering Manager
KUKA Brazil
“Process Simulate Virtual

A BIW production line simulated using Process Simulate Virtual Commissioning. Commissioning also enables
a higher level of cycle-time
Commissioning proved to be beneficial in Another important benefit is a more effi- productivity, as the robotics
several ways. Miranda explains, “With cient start-up in terms of equipment oper- cell interlocks are optimized.
Process Simulate Virtual Commissioning, ation. Tubini explains, “The use of Process This means producing more
we can get the robotics workcells 98 per- Simulate Virtual Commissioning brings units with the same equip-
cent ready before ever going to the shop together engineers with different kinds of ment or, as the experts in
floor. expertise. The fact that electrical, mechan- the automotive companies
ical and control engineers sit together in say, ‘higher jobs per hour
“Typically, after the initial production-line the same room, working on the same (JPH),’ which is a huge bene-
installation, we outsource the line start-up scenario, is a big advantage. Instead of fit for our customers.”
to suppliers. We estimate that approxi- troubleshooting the cell control program
Marcio Sampaio Tubini
mately 70 percent of the start-up work is by reviewing lines of code, the control
robotics and control-programs tuning; we engineer can now easily visualize
Project Leader
believe that by using Process Simulate any scenario.
KUKA Brazil
Virtual Commissioning we can reduce that
by 20 to 30 percent. This results in two “In the past, many of our technical discus-
significant benefits. First, a financial sav- sions took place only on the shop floor;
ings, as the amount of work outsourced is now they are conducted in a virtual-line
smaller; in fact, we have created a table environment. Using our previous
that maps those tasks that are moved from approach, sometimes we encountered
the line installation team to the virtual physical collisions, resulting in damage to
commissioning team. Second, KUKA Brazil equipment (such as robots and grippers)
is now much more knowledgeable regard- and the prototype part itself. When using
ing such scenarios. Greater start-up Process Simulate Virtual Commissioning,
know-how means improved operations the risk of such incidents is significantly
and fewer issues on the shop floor from reduced. For example, in a recent
project to project.” project using Process Simulate Virtual
Commissioning, we identified a problem
in the sequential plan: a clamp was not Glass material handling.
opening on time, thus causing the part to
crash into the equipment.
Solutions/Services
Tecnomatix
• Robcad
• Process Designer
• Process Simulate
• Process Simulate Virtual
Commissioning
• Plant Simulation

KUKA Systems Group (KUKA) Kuka Brazil engineers use Process Simulate in the company’s virtual commissioning lab.
concentrates on advanced
solutions for the automation “Process Simulate Virtual Commissioning
of industrial production pro- also enables a higher level of cycle-time
cesses. Since the company’s productivity, as the robotics cell interlocks
founding more than 100 years are optimized. This means producing more
ago, KUKA solutions have units with the same equipment or, as the
been known for quality and experts in the automotive companies say,
innovation. KUKA, with its ‘higher jobs per hour (JPH),’ which is a
Robotics and Systems divi- huge benefit for our customers. For
sions, is one of the world’s instance, robotics hemming processes
leading companies in the require maximum interlocks optimization,
field of mechanical and because the robots are working simultane-
systems engineering. ously very close to each other. Automatic measurement.
www.kuka-systems.com/brazil
“We were also impressed that we
Customer location can engage Process Simulate Virtual
Commissioning perfectly with non-
São Bernardo do Campo
Siemens controllers – for example,
Brazil
Allen Bradley controllers – using an
OPC (OLE for Process Control) server.
“With Process Simulate This highlights Siemens PLM Software’s
Virtual Commissioning, strength as a solutions provider with
we can get the robotics open tools.”
An automotive body-in-white production line tested by
workcells 98 percent ready KUKA Brazil prior to shipment.
before ever going to the
shop floor.”
Gilmar Miranda
Engineering Manager
KUKA Brazil
Americas +1 800 498 5351 © 2013 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of
Europe +44 (0) 1276 702000 Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and
Asia-Pacific +852 2230 3333 Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its
subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks
used herein are the property of their respective holders.
Tecnomatix
Siemens Magnet Technology

Improving capacity planning with digital factory software
Industry Siemens Magnet Technology

Life sciences uses Plant Simulation to optimize
complex production lines
Business challenges
The search for accurate production
Wide range of component forecasting
combinations Did you know that 30 percent of the MRI
Changing customer scanners installed in hospitals worldwide
demand contain a superconducting magnet manu-
factured by Siemens Magnet Technology?
The company accounts for about 45 per-
Keys to success cent of the total market, and 100 percent
Digital models simulate of the magnets produced at its facility
flow and critical interfaces near Oxford are exported overseas for
What-if simulations enable final assembly into imaging systems.
clear analysis and evidence- The business has been awarded several
based decision-making Queen’s Awards; most recently it was the
recipient of the Manufacturing Excellence
Awards (MX) 2010, sponsored by the company plans its workload based on cus-
Results Institution of Mechanical Engineers for tomer forecasts, any increase in demand
Product Innovation. Siemens Magnetic from one customer may affect other
Optimized flow of
Technology won the Cranfield School of customers.
components and assemblies
Management Best Factory Awards: Most
Problems identified Improved Plant and Innovation (Process The challenge is always to find a balance.
and resolved faster and Design). In November 2011, Siemens “This has been an ongoing issue for us,”
Greater manufacturing Magnet Technology also picked up one of says Michael Burke, project manager
flexibility Siemens’ Environmental Awards for its logistics at Siemens Magnet Technology.
pioneering work in minimizing the “As demand has risen, complexity has
More efficient production
consumption of helium. increased and our products have become
line with less waste
more sophisticated as well. In addition,
Each magnet is manufactured for custom- final testing can only be done when a
ers who incorporate it into an end-user magnet is fully assembled and ready to go:
product. Given the nature of healthcare the point of its highest value. Whilst we
procurement, both the sales process and have an extremely low failure rate, any
the logistical chain leading up to installa- glitches at the testing stage can have an
tion can be long and detailed. As the impact throughout production.”
Siemens Magnet Technology produces volume going through the factory has
nine models, each one comprising a increased significantly over a number of
distinct assembly of components and years, yet we are still using separate
undergoing a specific series of processes spreadsheets. We know that we need an
within four main stages of manufacturing. overview of products, skills and possibili-
These are coil manufacture; magnet ties, so that we can adapt production more
termination; assembly and weld; and test. quickly and easily. If we had an accurate
The manufacturing journey involves model of our production line, we’d be able
numerical and cyclical complexity as to see how everyone is affected by even
components and assemblies are grouped the slightest change. To resolve this, we
together in varying combinations as went to the board with a proposal and
they pass through each stage on the a clear business case to implement
factory floor. simulation software.”
Shining a light on manufacturing The Plant Simulation solution in the

complexities Tecnomatix® portfolio was an obvious
At each stage of manufacturing, managers candidate. Burke explains: “We’d previ-
maintain independent sets of capacity ously installed such an application and
data. This means that there is a critical although we’d never really got it to work
supply and inventory interface at the point properly, we were familiar with this type
of handover to the next process manager. of software. Plant Simulation really
“We do a lot of capacity modeling, but cur- impressed us: it is logical, easy to under-
rently cannot integrate this,” notes Burke. stand and we could immediately see
“Knowledge remains relatively isolated what it could do for us.”
within each process. When predicting
whether we can cope with a particular Industrial engineer Peter Taylor is
surge in demand, managers must make a now taking the lead on the modeling
judgement based on their own analysis project, which began in October 2010.
and experience. This has worked well so “We have excellent support from Siemens
far but can be time-consuming, and there PLM Software, so we thought we would
is no real backup system. It is impossible to develop a sound knowledge of Plant
verify our decisions, because there is no Simulation by beginning with the
overview of the complete manufacturing most challenging department, coil
journey.” manufacture – where each magnet begins
life as an array of superconducting wire.
Kevan Straughan, PLM software analyst at Even our consultant confessed to sleepless
Siemens Magnet Technology, adds, “The nights over its complexity.”
“Plant Simulation really
impressed us: it is logical,
easy to understand and we
could immediately see
what it could do for us.”
Michael Burke
Project Manager Logistics
Siemens Magnet
Technology
Consistent and indisputable analysis Forecasting potential bottlenecks

“We are creating the 2D building blocks of through simulation
our many processes by defining hierarchy, Siemens Magnet Technology aims to
showing relationships between individual run simulations for the manufacturing
resources, logging skill sets and indicating team that will clearly show an object
the cycle times and usage of tools and moving along the production line; high-
machines,” says Taylor. “There is a massive light blockages where there is a finite
amount of statistical information to enter. amount of tooling capacity and demon-
As we build the model, we are identifying strate the potential consequences of
what level of detail we require. We are bal- any decisions made at that point. Taylor
ancing what individual process managers explains, “We aim to develop a protocol,
want to see in terms of their own section’s so that we do not run simulations at ran-
output and what the business needs to see dom; there is an inbuilt mechanism that
from the overall manufacturing perspec- acts rather like a control experiment.
tive. We also aim to be consistent, so that It is very important to go through a logical
the company can utilize the same method- sequence of events. We are taking the
ology in other areas. Coil manufacturing is time to document all these processes
the most complicated, but once we get it and create a comprehensive handbook.”
right, other models should follow
similar formats.” Burke notes that the model includes stand-
alone methodology. “Our Siemens PLM
The coil manufacture model was ready for consultant has explained how to interface
its first proper review by the middle of coding of the different processes, so that
2011. “The most important aspect is to we can control how far we see a change
ensure that we are modeling as close to ripple down the line. The benefit is that
reality as possible and that process and when one inbuilt function does not quite
manufacturing managers agree on the do what we want it to do, it is very easy to
content. When they give their approval, change the code without unduly affecting
we’ll know that all the information in the other aspects of the model.”
model is correct; and once we have a valid
model, it will underpin constructive debate
about internal processes.”
Solutions/Services
Plant Simulation
(Tecnomatix portfolio)

is the world’s leading
designer and manufacturer of
superconducting magnetic
resonance imaging magnets
for medical applications.
www.siemens.co.uk/magnet-
technology Preparing for the future Straughan adds, “Plant Simulation takes
“We’ve achieved a lot,” says Taylor. “Plant away manual updating and gives us a clear
Simulation allows us to view what we’ve overview and analysis, something we’ve
Customer location done to model demand and throughput.” never had before. We are also looking to
Oxford With a significant success completed, a implement Teamcenter in the future,
United Kingdom new project is already underway. “We are and all the work we are doing now to
using the main model as the starting point document and model our processes will
in order to visualize different scenarios be of huge benefit further down the line.
“Plant Simulation takes away two or three levels down,” notes Taylor. The objective is to integrate manufactur-
manual updating and gives “That will inform our decision-making in ing systems and link them into SAP,
us a clear overview and certain areas, for example, the potential which we use for enterprise resource
analysis, something we’ve for reprocessing helium lost during planning. This will give us complete
never had before.” manufacture.” control and flexibility within a fully
Kevan Straughan optimized production line.”
PLM Software Analyst
Management Software Inc. or its subsidiaries in the United States and in other countries. SAP is a trademark or registered
trademark of SAP Aktiengesellschaft. All other logos, trademarks, registered trademarks or service marks used herein are
the property of their respective holders.
www.siemens.com/tecnomatix Z6 26056 2/12 A
Teamcenter • Tecnomatix
Mahindra Vehicles
Mahindra rises with digitally planned new vehicle manufacturing facility
Industry Mahindra Vehicle Manufacturers themselves, their families and their com-
Automotive OEM Limited (Mahindra Vehicles) uses munities. In the spirit of “Rise,” a new
Mahindra manufacturing facility recently
Tecnomatix to establish a state-
rose in the Chakan corridor near Pune,
Business challenges of-the-art automotive India.
manufacturing plant
Manage global markets and
competition Mahindra Group’s Automotive Sector man-
A world leader in vehicle manufacturing ufactures and markets light commercial
Shorten the vehicle develop- rises in South Asia and utility vehicles, including auto rick-
ment lead time to reduce Mahindra Group (Mahindra) is among the shaws (three-wheelers). The sector has
time-to-market biggest and most powerful publicly listed been the leader in India’s utility vehicles
Minimize manufacturing companies in the world. It operates in the market since its inception, and currently
launch issues to accelerate key industries that drive economic growth, accounts for about half of India’s utility
production ramp-up enjoying a leadership position in tractors, vehicle market. The company exports its
utility vehicles, information technology products to Europe, Africa, South America,
Meet increasing demand for
(IT) and vacation ownership. Mahindra South Asia and the Middle East.
highly customized vehicles
focuses on enabling people to “Rise,” a call
to action to unite the many companies Mahindra decided to expand its lineup to
Keys to Success within the Mahindra Group to a common include a new range of medium and heavy
Get the new Chakan plant up purpose. More specifically, Mahindra commercial vehicles, including SUVs,
and running quickly employees are encouraged to rise, to suc- trucks and buses. This expansion required
ceed and to create a better future for a new plant, so Mahindra decided to
Improve quality and consis-
tency in manufacturing,
supporting “first time right”
approach
Analyze the impact of product
mixes on production through-
put and optimize facilities
layouts
Virtually analyze complex
assembly scenarios of the new
product lines
Share best practice process
data between multiple sites
and with suppliers
The new Maxximo light commercial vehicle, manufactured at the Final Assembly of the Mahindra Navistar
Mahindra Chakan plant. truck in the Mahindra Chakan plant.
www.siemens.com/plm
Results
Reduced lead time and the
overall duration of a vehicle
project
Decreased capital investment
in machines and conveyors
Substantially shortened lead
time for concept design of
production facilities
Reduced bottlenecks in
production
Increased re-use of manufac- A Mahindra manufacturing engineer uses Manufacturing Process Planner.
turing tools
Maximized production establish a new manufacturing facility in meeting the criteria we had defined,“ says
resource utilization Chakan. Mahindra’s challenge was how to Nagesh Nidamaluri, senior general man-
assess, design and build the facility, plus ager, Assembly Systems, MES and Digital
get it running and producing vehicles Manufacturing, Chakan plant, Mahindra
“In 2007, we selected and
according to the aggressive schedule that Vehicles.
introduced the Tecnomatix
management had defined.
solution, because it offers a
Mahindra uses the Manufacturing Process
full range of digital manu-
As of 2012, 1,500,000 cars are produced Planner solution in the Teamcenter
facturing tools that serve
annually in the Chakan corridor by portfolio for the planning of various pro-
our needs, integrates
Mahindra, Volkswagen, General Motors, duction processes; as well as Plant
smoothly with our existing
Mercedes Benz and other automotive man- Simulation, FactoryCAD™ software and
product data management
ufacturers. Mahindra is one of the largest FactoryFLOW™ software, all in the
systems and clearly stands
manufacturers in this area, producing light Tecnomatix portfolio, for plant design and
out in meeting the criteria
commercial vehicles (LCV), pick-up trucks, optimization; Process Designer and Process
we had defined.“
SUVs and the Mahindra Navistar heavy Simulate and Jack™ software, also all in
Nagesh Nidamaluri duty trucks. the Tecnomatix portfolio, for assembly
Senior General Manager planning and validation.
Assembly Systems, MES and Revisiting engineering processes to
Digital Manufacturing establish “state-of-the-art” plant The establishment of a new plant was a
Mahindra Vehicle Mahindra is a long-time customer of good opportunity to revisit Mahindra’s cur-
Manufacturers Limited Siemens PLM Software. Designers, data rent engineering processes. “We have
administrators and some of its product realized that in order to shorten a vehicle
assembly suppliers use Teamcenter® soft- manufacturing project, we need to deploy
ware for product lifecycle management concurrent engineering methods,”
(PLM). The company also uses NX™ soft- Nidamaluri says. “This means that manu-
ware for some of the powertrain product facturing engineering needs to work
design, and a few years ago Mahindra concurrently with product design. Digital
started using Tecnomatix® software for manufacturing tools provided by Siemens
digital manufacturing. PLM Software facilitate this approach. This
is a dramatic change to our current engi-
“In 2007, we selected and introduced the neering processes.
Tecnomatix solution, because it offers a
full range of digital manufacturing tools “We have a gate system, and one of the
that serve our needs, integrates smoothly gates is the virtual validation gate. In the
with our existing product data manage- past, mostly the product design group was
ment systems and clearly stands out in actually doing validations for this gate; but
‘smart objects’ to represent their factory “Providing the essentials
resources,” says Anupam Patil, senior man- needed to create detailed
ager, IT and PLM, Chakan plant, Mahindra and intelligent factory mod-
Vehicles. els, FactoryCAD allowed our
Truck cargo mounting Engine docking station planners to use ‘smart
analysis created with simulation created with Jack “This was especially advantageous because objects’ to represent their
Jack human human simulation.
the objects provided the ability to snap a factory resources.”
simulation.
layout model together, instead of wasting
“We use the workflow mecha-
time drawing the individual equipment.
nism of Teamcenter which
now, with the help of Tecnomatix digital Using FactoryCAD, we were able to
ensures that every change
manufacturing tools, the manufacturing resolve many issues before erecting and
goes through a pre-defined
engineering group is very active in prepa- commissioning of the factory, such as
sequence of events and an
rations for this gate.” interferences of process and utility equip-
authorized approval. These
ment with the civil structure, for example,
capabilities are unique, and
Mahindra decided to execute the digital as well as a monorail system that caused
provide us the ability to put
manufacturing journey at the Chakan plant interference with the supporting beams at
a lot of structure into the
in a series of steps, deploying point solu- a specific area and a robot that caused
MBOM creation process.”
tions to address specific needs, followed interference with the building column in
by the manufacturing bill of materials another area.” Anupam Patil
(MBOM) and finally the bill of process Senior Manager
(BOP). Mahindra plans to clone proven A planned production line, virtually IT and PLM
methodologies developed in the Chakan simulated Mahindra Vehicle
plant at other plants. Before building the production line, Manufacturers Limited
Mahindra completed a number of simula-
Laying out the new Chakan plant in 3D tion projects that helped to make
While constructing the new plant in important decisions in configuring the
Chakan, Mahindra decided to significantly production line. One of the projects
upgrade the way it creates and manages addressed the inter-connections of the
plant layout data. There were a number of body-in-white (BIW) welding shop, paint
issues to deal with, including the fact that line and the TCF assembly line, where all
there was no uniform plant layout method the parts are assembled to form a com-
across the enterprise. Each site was man- pleted vehicle.
aging plant layout separately. Plant layout
drawings were not maintained in a central The goal of the simulation project was to Interference of a robot and a column
repository, which made it very time-con- find out the optimal buffer storage capac- found using FactoryCAD.
suming to locate them when they were ity in between these production lines. The
needed. There was no revision manage- challenge arose because there were three
ment system and only one engineer at a BIW planned production lines (for the
time could work on any given layout. Maxximo, Genio and XUV vehicles) going
Drawings provided by suppliers were main- into a single paint line, which then goes
tained in different layers in the same file, into three separate TCF assembly lines.
resulting in duplication of data and unnec- Tecnomatix Plant Simulation was used to
essarily large files, which degrade conduct a what-if simulation to determine
visualization performance. the best scenarios for the plant’s inter-
shop conveyor system. Several scenarios
To resolve these issues, FactoryCAD was of mixed-model production volumes were
used to create 3D plant layouts for all of simulated and the optimal size of central
the Chakan plant production lines, includ- painted body buffer storage and individual
ing body and trim, chassis and final (TCF). BIW shop storage was determined. This
“Providing the essentials needed to create simulation project substantially reduces
detailed and intelligent factory models, the lead time in designing the storage.
FactoryCAD allowed our planners to use
“So, we decided to use dedi- goal of getting the implementation right
cated tools for this task, the first time. Detailed throughput exami-
and developed a robust nation notably reduced bottlenecks, and
MBOM creation and update what-if analysis capabilities substantially
methodology using decreased unnecessary capital investment
Manufacturing Process Plant Simulation model – routing with no cross-over. in machines and conveyors.
Planner.”
MBOM creation means no part is
Anupam Patil
forgotten in the production
Senior Manager
The engineering bill of materials (EBOM) is
IT and PLM
created and managed using Teamcenter.
Mahindra Vehicle
Then manufacturing engineers create the
Manufacturers Limited
MBOM using Manufacturing Process
Planner by consuming parts from the
EBOM. The MBOM is then sent from
“Manufacturing engineers
Manufacturing Process Planner to SAP®
used Process Simulate to
software, the enterprise resource planning
validate hanger design that
(ERP) system Mahindra uses.
could support sufficient door
Plant Simulation model – routing with a cross-over for
opening. The limit to which
empty skids. “In the previous method, planners used
the doors can be opened
Microsoft Excel to define and maintain the
was calculated based on the
MBOM,” Patil says. “While the tool is intui-
virtual 3D simulation,
Another project was to determine the tive, it was clear to us that this is not
instead of waiting for actual
optimal routing method of painted vehicle sustainable for handling large BOMs and
parts to arrive at plant. This
bodies from the single paint line to the sharing engineering data. So, we decided
resulted in cost and saving
three TCF assembly lines. “The simulation to use dedicated tools for this task, and
of time and iterations of the
helped to identify bottlenecks, and developed a robust MBOM creation and
hanger design.”
verify the robustness of the selected update methodology using Manufacturing
Amit Jahagirdar option,” says Amit Jahagirdar, digital man- Process Planner. Using this methodology,
Digital Manufacturing ufacturing manager, Chakan plant, planners adjust the EBOM and add relevant
Manager Mahindra Vehicles. “One simulated option production information such as a ‘make or
Mahindra Vehicle was a clockwise flow of bodies with no buy’ definition for each item and the point
Manufacturers Limited cross-over. The simulation showed that in of consumption along the production line,
the event that one of the three TCF lines is which is later used by the shop floor logis-
shut-down, the respective bodies in the tics management system.”
main line would create blockage in moving
bodies to the other TCF lines. The second “The MBOM will include the car parts in
option was a counter-clockwise flow, with their form through the entire production
a cross-over for the empty skids to flow process. For example, in the paint line, the
back to the paint shop. This is a more chassis will be represented by a bare chas-
robust option because each TCF feeder line sis, cathodic electrocoat deposition body
is practically independent of others. So, and painted body. These forms, which we
there is little or no impact on the overall call ‘semi-finished parts,’ appear as a single
performance of the line shutdowns.” assembly in the EBOM, but as different
assemblies in the MBOM. Another example
Using Plant Simulation, Mahindra gained of MBOM-specific information is the addi-
critical insight regarding its factory layout tion of scrap weight to the stamped parts,
and installation processes across vehicle as this information is used downstream in
lines. Accurate and fast validation of pro- the recycling process.
cesses enabled the company to achieve its
daily update to synchronize any incremen- “We have defined a workflow
tal changes to the EBOM. In a similar using Teamcenter to classify
manner, Teamcenter integration for SAP our existing and new tools
synchronizes the MBOM daily with SAP by part number, so that
based on make or buy attributes. For eventually we will have a
example, any assembly node with chil- structured library of tools
dren, which was identified in the MBOM across the Mahindra auto-
as a purchased assembly, will be automati- motive sector.”
cally exported and will appear in SAP as a
Amit Jahagirdar
single node.
Manager
Dynamic 3D simulation supports
Mahindra Vehicle
analysis of complex assembly scenarios
for the new Maxximo Manufacturers Limited
The painted body of the Maxximo mini-
truck is transported inside the new
assembly shop for operations. The car
body is moved along using a hanger sys-
tem in the underbody areas and on
transfer lines. The system was initially
designed to carry the car body with the
MBOM in Manufacturing Process Planner with “make
or buy” definitions. doors closed. After analyzing the concep-
tual flow of assembly, other possible
assembly operations were analyzed. It was
“Handling the MBOM changes throughout found that in order to reduce production
the development lifecycle is crucial for us. time, some assembly operations could be
Therefore, the engineering notifications executed when the car body is on the
are transferred along with the EBOM from hanger, as long as the doors could be
Teamcenter. The notifications are put into opened to a certain extent, which will
a common pull, and from there they are enable operators to work inside the
assigned to the relevant MBOM planner. In cabin area.
addition, once an initial MBOM is created,
all subsequent changes in the MBOM are
done in a controlled configuration, using
the incremental change mechanism, which
enables us to analyze very clearly the
impact of any EBOM change on the MBOM.
Within the incremental change, we use the
workflow mechanism of Teamcenter which
helps ensure that every change goes
through a pre-defined sequence of events
and an authorized approval. These capabil-
ities are unique, and provide us the ability
Process Simulate is used to simulate the doors
to put a lot of structure into the MBOM
opening while the truck is on a hanger.
creation process.”
Due to the importance of maintaining an “Manufacturing engineers used Process

accurate MBOM, starting from the engi- Simulate to validate hanger design that
neering team and down to the shop floor, could support sufficient door opening. The
Mahindra uses Teamcenter to execute a limit to which the doors can be opened
“The benefits of the was calculated based on the virtual 3D The next step is the development of the
Tecnomatix digital manufac- simulation, instead of waiting for actual BOP using Manufacturing Process Planner.
turing tools for Mahindra are parts to arrive at plant. This resulted in Assembly operations and their duration are
already invaluable. This tool- cost and time savings and reduced the defined, and then linked to the parts that
set deployment strengthens number of iterations of the hanger should be handled and to the specific tools
the ‘first time right’ mindset design,” says Jahagirdar. required to carry out the work. This meth-
we have in Mahindra, as it odology enables Mahindra manufacturing
enables us to conduct differ- The assembly process for the Maxximo was engineers to re-use best practices and cap-
ent ‘what-if’ analyses of planned so that the engine assembly from tured knowledge in planning or modifying
production scenarios.” the engine production unit is transferred a production line.
to the final assembly shop from a logistic
Nagesh Nidamaluri
area. It moves on a predefined track and “The digital manufacturing tools play a key
Senior General Manager
gets synchronized with the conveyor carry- role in the first steps of a car project,” says
Assembly Systems, MES and
ing the Maxximo car bodies on hangers. Nidamaluri. “These tools are already used
Because this is a complex scenario, which in the requirements definition phase of a
Mahindra Vehicle
involves many parameters, manufacturing new or modified production line. This
Manufacturers Limited
engineers also performed a dynamic 3D enables us to provide more mature engi-
simulation of this scenario. “The main neering information upfront to our system
objective of this simulation was to validate suppliers, and will therefore reduce lead
the planned process and its duration esti- time and the overall duration of a car proj-
mation. The ergonomics of operators was ect. I also expect that our production
also evaluated based on Mahindra stan- facilities and tools suppliers will interact
dards,” Jahagirdar says. with the system, and introduce their
inputs.”
Tools management lowers cost by
enabling re-use Mahindra Vehicles receives top award
Mahindra plans to use the resource classifi- Mahindra Vehicles received the top honor
cation capability of Teamcenter to manage in Siemens PLM Software’s Asia Pacific
its many production tools. According to Innovation Awards 2012, which places a
Jahagirdar, “The objective of this initiative spotlight on how PLM technology enables
is to lower costs, reduce lead time and companies to make smarter decisions that
improve quality by helping the manufac- lead to the creation of better products. The
turing engineer/planner select the proper top award is presented to the company
resource, increasing the re-use of manu- that uses PLM technology in a way that
facturing tools, reducing tool inventory, enables it to be a hallmark of success in
maximizing resource utilization and deliv- the manufacturing industry, maximizing
ering digital models for verification and the value derived from its products
simulation.” throughout the entire lifecycle to stream-
line its productivity and performance.
“We have defined simple categories for any
tool we have in our production plants, Implementing Tecnomatix portfolio
including a tool suitable to a specific part, enabled Mahindra Vehicles to come closer
such as fixtures or specific gauges. There than ever before to real-time digital manu-
are also more generic tools, such as robots facturing. Other benefits included a 25
and torque wrenches. Based on this, we percent reduction in the green field plant
are defining a workflow using Teamcenter set-up time, a 28 percent improvement in
to classify our existing and new tools by effective working time by validating and
part number, so that eventually we will reducing non-value added activities and an
have a structured library of tools across the overall increase in flexibility, which
Mahindra automotive sector.”
Solutions/Services
Teamcenter
Manufacturing Process Planner
www.siemens.com/teamcenter
Tecnomatix
Process Designer
Process Simulate
Plant Simulation
FactoryCAD
FactoryFLOW
Jack
Robotic simulation created with Tecnomatix to reduce cycle time of welding operations.
Mahindra Vehicle produced more product model mixes and progress in the digital manufacturing jour-
Manufacturers Limited manu- reduced time-to-market. ney. For example, we have more than 100
factures and markets utility robots in our Chakan plant. Currently, even
and light commercial vehicles, “First time right” will lead to a brighter the slightest change in a robot program
including auto rickshaws future requires us to contact the line builder and
(three-wheelers). It is the lead- “The benefits of the Tecnomatix digital ask for modifications. I believe we can
er in utility vehicles in India manufacturing tools for Mahindra are develop skills by using the Tecnomatix
and currently accounts for already invaluable,” Nidamaluri says. “This robotics off-line programming tools to
about half of the country’s toolset deployment strengthens the ‘first conduct some of this work ourselves. This
utility vehicle market. The time right’ mindset we have in Mahindra, will bring multiple benefits, including
Mahindra Group’s Automotive as it enables us to conduct different ‘what- higher flexibility due to greater engineer-
Sector is part of the globally if’ analyses of production scenarios. Still, ing capability, shortening the
recognized Mahindra Group, we are looking forward to make more modifications lead time and reducing
which is among the top 10 cost.”
industrial companies in India.
www.mahindra.com
Customer location
Chakan, Pune,
Maharashtra District
India
Partner
Tesis PLMware GmbH
www.tesis.de/plmware
Europe +44 (0) 1276 702000 registered trademarks of Siemens AG. D-Cubed, FactoryCAD, FactoryFLOW, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX,
Asia-Pacific +852 2230 3333 Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens
Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. Jack is a
trademark or registered trademark of The Trustees of The University of Pennsylvania. AutoCAD a registered trademark of
Autodesk, Inc. SAP is a trademark or registered trademark of SAP Aktiengesellschaft. Excel is a registered trademark of
Microsoft Corporation. All other logos, trademarks, registered trademarks or service marks used herein are the property of
www.siemens.com/plm their respective holders. Z19 30584 8/12 B
Tecnomatix
Paulaner
Use of Tecnomatix enables premier brewer to efficiently expand business
Industry Plant Simulation provides

Food and beverage Paulaner with key planning tool
for new brewery
Business challenges
Finding the right balance
Determine the right dimen- There are a number of factors that have to
sions of components for the be taken into an account when engineer-
brewery ing a brewery, including seasonal demand,
Invest in the right equipment product turnover, the flexibility to produce
Develop feasible and robust new products and multi-variety packs,
production plans and quality and freshness. It takes highly
automated and sophisticated technologies
and expensive equipment to effectively
Keys to success manage these factors, so it is particularly
Secure product quality with important to ensure that processes can
a stable and harmonized meet current and future requirements.
production flow
To meet this goal, simulation is the tool
Compare alternative of choice to implement fully validated
maintenance strategies processes that are “right the first time.”
Identify and fix bottlenecks By using simulation, the brewer can deter-
mine the most cost-effective and future-
proof planning solutions. Alternate
Results planning scenarios can be compared to
Developed optimal strategies select the best balance between perfor-
to fulfill customer demand mance, flexibility and cost. By using simu-
Understood the consequences lation, it is easy to identify bottlenecks
of different sequencing and plan the best strategy for profitably
strategies meeting customer demand.
Realized limits of the planned Optimizing systems and processes
brewery for future products
The first official mention of Paulaner
and demands
Brewery on 24 February 1634 is the brew-
Secured product quality ery’s foundation date, and since then
Paulaner Brewery has been a permanent
part of the culture, tradition and history of
Munich. The popularity of the Paulaner
beer has always went well beyond the bor-
ders of Munich. This is especially true of Evaluating performance
Paulaner Hefeweißbier, which today is one The input data of the simulation model is
of the most popular beers in the world. defined in a spreadsheet program.
More than two million hectolitres leave Structured into different registers, there
the brewery every year for more than 70 are inputs for customer demand and prop-
countries. erties of the process steps (brewery, fer-
mentation, filter, BBT, filling, warehouse).
Unfortunately, there is no room to expand Using additional registers, it is possible to
at the current Paulaner production site, define the tank capacities (number, size),
and even if there were, the nearby trans- availability of filling lines and shift calen-
portation connections are inadequate to dars for several process steps.
accommodate an increased volume of
product. To enable the company to grow, Paulaner can use this application without
Paulaner started planning a new brewery the detailed knowledge of how to create a
on the outskirts of Munich. simulation model; it is only required to
define the input data in the spreadsheets.
To facilitate the building of a state-of-the- After import into Plant Simulation, the
art brewery, iSILOG, a leading simulation components of the model are generated
service provider, provided a solution for and configured automatically according to
the beverage industry using the Plant the input data. This makes the solution
Simulation solution in the Tecnomatix® easy to use and creates the opportunity to
portfolio from Siemens PLM Software. The effectively investigate many different sce-
solution includes brewery-specific objects, narios in a short time period. The solution
such as the brew house, fermentation provides many different key performance
tanks, filters, bright beer tanks (BBT), fill- indicators to evaluate the performance of
ing lines and storage. Using these objects the brewery.
makes it easy to investigate the production
process and to evaluate different planning Using this solution, Paulaner is able to
strategies and scenarios. evaluate the influence of stochastic pro-
cess behavior (consumer demand, break-
downs, etc.) and to confirm that they are
making the right investment in tanks and
equipment.
Solutions/Services
Tecnomatix

The Paulaner Brewery was
founded in 1634 in Munich,
Germany. Today, Paulaner
produces about 2.4 million
barrels or almost 74 million
gallons of beer annually. It is
one of six breweries that pro-
vide beer for Oktoberfest, the
German beer festival dating
back to 1810.
www.paulaner.com
Meeting key challenges expected future products and demands;
Paulaner’s objectives for the project were establishing the best approach for harmo-
Customer location to continue to improve key performance nizing customer demand, incoming goods,
Munich indicators, including heat requirements, batch sizes and packaging lines; and
Germany power consumption, water consumption understanding the performance of differ-
and extract loss; implement environmen- ent sequencing strategies as a function of
tally-friendly energy concepts; and ensure product mix and quantity.
Partner that processes, workflows and capacities
iSILOG GmbH are balanced and optimized. In complex systems with large interdepen-
Rheinstraße 219 dencies such as in beer production plants,
D-76532 Baden-Baden Using Plant Simulation, Paulaner was able it is nearly impossible to manually estimate
www.isilog.de to get a grasp on a number of key issues. how the system will perform. The use of
These included determining existing bot- Plant Simulation technology makes the
tlenecks; developing best strategies, such effective management of such interdepen-
as cleaning, changeovers, batch sizes, pro- dencies a reality. Having proven its value,
duction planning and control, to fulfill cus- Paulaner considers Plant Simulation to be
tomer demand; understanding the limits an essential planning tool for its current
of the new planned brewery regarding and future success.
Using Plant Simulation, Paulaner

was able to get a grasp on a
number of key issues.
Americas +1 314 264 8499 © 2013 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of
Europe +44 (0) 1276 413200 Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and
Asia-Pacific +852 2230 3308 Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its
subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks
used herein are the property of their respective holders.
Tecnomatix
Siemens Energy Power Transmission

A new production plant is fully optimized before construction
Industry Complex material flow

Energy and utilities simulations identified areas of
inefficiency during the planning
Business challenges
process, reduced both capital
and operating costs
An optimized manufacturing
process for a new conduit Dynamic player in a dynamic market
plant
The Siemens AG Energy Sector (Siemens
Expanded conduit product Energy) is the world’s leading supplier of
portfolio products, solutions and services for power
generation, transmission and distribution,
as well as for the production, conversion
Keys to success
and transport of oil and gas. Delivering
Digital material flow simula- innovations in fossil and renewable tech-
tion using Plant Simulation nologies, Siemens Energy is steadily
Analyses of what-if scenarios expanding its leading position in the
dynamic energy market.
Many interacting variables
evaluated in a single simula-
Siemens Energy’s High Voltage Products
tion model
business unit, part of the Power
Transmission division, manufactures
Results conduits for circuit breakers that are con- 400-kV outdoor high-voltage switching station.
Lower capital and operational sidered the centerpiece of all switching
costs for the tempering stations. These conduits are made of fiber-
furnace reinforced polymers created by hardening manufacturing capacity by building an
a mixture of epoxy and fiber optics, or entirely new conduit manufacturing
Bottlenecks eliminated and aramid, which is typically used for bullet- plant. The purpose of this plant was
optimal material flows defined proof vests. ambitious: to manufacture conduits that
Baseline established for fur- are significantly longer and have greater
ther process optimizations Innovation to deliver an ambitious diameters than the previous versions. To
pilot project accommodate the new dimensions, a new,
Excess capacity avoided
To improve its position in the global automated thread winding process would
energy market, Siemens Energy Power be needed to replace the old manually
Transmission decided to increase its organized vacuum method. The new
“Plant Simulation helped us
avoid significant capital in-
vestments and operational
costs.”
Yasin Vardar
Manufacturing Planner
Siemens Energy
Test of a high-voltage circuit breaker.
facility and machinery would allow the Yasin Vardar, a manufacturing planner
company to manufacture conduit more with Siemens Energy and the main Plant
cost-efficiently and also improve quality. Simulation software user on this project.
“Without Plant Simulation, we would have
In the course of building the new plant, never been capable of determining produc-
manufacturing planners at the Siemens tion quantities.” The software solution was
Energy offices in Berlin took advantage of critical to the success of the new facility.
the Plant Simulation solution in the
Tecnomatix® portfolio from Siemens PLM Siemens PLM Software partner, SimPlan
Software. This software makes it possible AG, helped create the simulation models.
to simulate and optimize material flows Having already optimized many material
and resource utilization. It also enables flows using the Plant Simulation solution in
offline analyses of production system com- the Tecnomatix portfolio, SimPlan brought
ponents as well as evaluations of different a wealth of experience to the project. Arne
what-if scenarios. Frenkel, project manager at SimPlan,
implemented the simulation model on-site
The new conduit production method was a while at the same time training Vardar in
pilot project, which meant that manufac- the use of the software. “We assist our cus-
turing planners had to design a complex, tomers from initial purchase considerations
highly interlinked production process and to routine application of simulation during
ensure that annual target quantities would operations,” says Frenkel. “The use of Plant
be met, without any comparable experi- Simulation helps make certain that the
ence to guide them. “Surely, we would manufacturing planners will achieve their
have been able to plan the plant layout ambitious goals.”
with conventional methods,” explains
“Plant Simulation was a key
to the success of the entire
project. It’s hard to imagine
how we planned previously.”
Yasin Vardar
Manufacturing Planner
Siemens Energy
Aramid-isolated selector rod for power transmission.
Simulation and optimization of complex modify the order accordingly. “In this situ-
material flow ation, Plant Simulation helped us avoid
To create the simulation model, all auto- significant capital investments and opera-
mated portions of the proposed plant tional costs,” explains Vardar.
were modeled digitally. This included the
mandrels (the tools on which conduits are
made), the winding machine (whose
spools wind plastic threads onto the man-
drels), the pre-hardening furnace, and the
conduit removal machine, as well as the
tempering furnace in which the conduits
are hardened.
To define material flow, the planners had

to consider several parameters: number of
tools, availability of machines, speed of
transportation systems, cycle times, man-
power requirements, control of the
furnaces, and so on. In addition, three
The new thread winding method optimizes production of
types of conduits requiring different mate-
conduits made of fiber-reinforced polymers.
rials with different hardening times were
going to be manufactured. “With Plant Another optimization involved the control
Simulation, we were able to incorporate a of the start of the tempering furnace.
variety of interacting variables in a single Simulations of the planned start times led
model,” says Vardar. to a strategy that showed that it is more
efficient to turn the furnace on when it is
Delivering clear business value fully filled with conduits rather than at the
Plant Simulation made a clear and signifi- end of each shift. This small change would
cant difference in terms of added business lower energy costs. In addition, simulation
value. One simulation showed that one of helped planners identify the optimum
the three initial chambers of the temper- number of mandrels. And by evaluating in
ing furnace could be eliminated through detail the cooling phase of the tools, simu-
the use of an intelligent buffer concept for lations were able to make significantly
pre- and post-transportation tracks. The more precise predictions than previous cal-
furnace had not been purchased when the culation methods. As a result, unnecessary
simulation was run, so it was possible to overcapacity was avoided.
Solutions/Services
Plant Simulation
(Tecnomatix portfolio)
www.siemens.com/
tecnomatix

The Siemens AG Energy
Sector (Power Transmission
division) provides efficient
power transmission, reliable
switchgear, high-performance
Fiber optic conduit.
transformers and advanced
power transmission systems.
www.energy.siemens.com The digital model also revealed that the Even now that the new plant is opera-
original cycles of the pre-hardening tional, manufacturing planners at Siemens
furnace led to congestion at the winding Energy still benefit by using Plant
Customer location machine. A cycle change eliminated that Simulation. As a “living virtual model,” the
Berlin blockage and ensured a continuous software helps determine the right man-
Germany mandrel supply. The planners also saw power requirements for different quantity
that the speed of the transportation scenarios, and also helps in organizing
system was too slow throughout the entire shift work. The company is now consider-
Partner material flow. “Using Plant Simulation was ing the use of Tecnomatix for digitally
SimPlan AG a key to the success of the entire project. modeling and optimizing manufacturing
www.simplan.de It’s hard to imagine how we planned previ- processes at other, older plants.
ously,” says Vardar.
www.siemens.com/tecnomatix Z7 25933 10/11 A
Tecnomatix
Procter & Gamble

Designing and optimizing efficiency in consumer packaged goods manufacturing
Industry Tecnomatix supports

Consumer products efficient design
and delivers cost
Business challenges savings by boosting
productivity at new
Faster design of more efficient
factories and existing plants
Faster design of more

Keys to success efficient factories
3D factory layouts everyone The Procter & Gamble
can understand Company (P&G) has one of
the strongest portfolios of
Fast, easy-to-prepare logistics
trusted brands, including
simulations
the following trademarked
In-house reliability algorithms products: Pampers, Tide,
integrated with plant Ariel, Always, Whisper,
simulation Pantene, Mach3, Bounty,
Standards-based, lightweight Dawn, Gain, Pringles,
CAD (JT) files Charmin, Downy, Lenor,
Iams, Crest, Oral-B, Actonel, Duracell,
Olay, Head & Shoulders, Wella, Gillette,
Results Braun and Fusion. The P&G community
Millions of dollars in global includes approximately 138,000
cost savings employees working in more than 80
countries worldwide.
33 percent increase in utiliza-
tion of factory space and
P&G is taking advantage of the
material handling resources
Tecnomatix® plant design and
20-25 percent savings in optimization solution from Siemens PLM
costs of moving materials Software in its efforts to minimize
Greater confidence in new production losses, and improve the
facility designs efficiency of manufacturing operations.
Engineers use the Tecnomatix FactoryCAD, “We have used these tools to improve
Optimized material handling,
FactoryFLOW and Plant Simulation different aspects of our manufacturing
logistics and indirect labor
applications to improve manufacturing operations throughout P&G,” says Brad
across the organization
processes at both new and existing Whitmore, technology section head in P&G
Increased planning accuracy facilities. Global Computer Aided Engineering.
and efficiency
“Tecnomatix lets us apply the
concepts used in equipment
design to optimize factories
and facilities.”
Brad Whitmore
Technology Section
Head Global Computer
Aided Engineering
Procter & Gamble
“The Tecnomatix applications work CAD model. JT files can be 10 to 20 percent

well together and let you visualize smaller than the CAD files and engineers
proposed factory layouts and determine no longer need CAD software to view the
quantitatively how they will perform.” files. JT files also help in the layout of
manufacturing equipment in FactoryCAD.
Efficient from scratch Objects such as walls, windows, doors
Prior to building new facilities, Whitmore and building supports can be modeled
and his colleagues use Tecnomatix in FactoryCAD, but 3D models of
FactoryCAD to create optimized layouts. manufacturing equipment designed in
“FactoryCAD allows us to design and other CAD systems can be imported as JT
visualize different concepts for a proposed files into the FactoryCAD layout.
facility,” says Whitmore. “The difference
with FactoryCAD is concepts are now The result of using FactoryCAD to help
presented in 3D – a huge improvement develop a new facility or revise an existing
over conveying ideas on drawings.” one is greater confidence in the design.
“We have a better idea what the final plan
“Seeing a layout in 3D brings it to life, will look like because we have already seen
especially for people who have trouble it and flown through it in the computer,”
interpreting 2D drawings,” Whitmore says. Whitmore notes. “Our teams have a lot
“We now get input from people who might more confidence in what will be built,
not have given their input in the past.” what it will look like, and how it will
He estimates that as many as 20 design operate before we’ve broken ground.
review meetings can be held to fine-tune a That’s a real success story.
plant layout. This doesn’t slow the project
schedule because it is easy to update the The use of FactoryCAD supports P&G’s
FactoryCAD layout with people’s input organizational performance goals for new
before we’ve started project execution. facilities in a number of ways. One aspect
Whitmore estimates review cycles happen involves making the construction of the
much faster compared to earlier projects facility more efficient by doing things
where FactoryCAD wasn’t used. right the first time and avoiding scrap and
rework. Building the plant virtually and
The FactoryCAD layouts are converted into working out problems in the computer
lightweight JT™ files that people can is proving to be helpful in achieving
review at their desks. The use of JT files this goal.
brings a number of advantages, including
a smaller size compared to the original
Solutions/Services Improving logistics
Tecnomatix P&G uses other Tecnomatix solutions,
www.siemens.com/ such as FactoryFLOW and Plant Simulation
tecnomatix as well. “We use Tecnomatix FactoryFLOW
to directly compare plant and equipment
layouts, to understand how our people,
Customer’s primary business fork trucks, and materials flow to and
Procter & Gamble Company is from manufacturing lines,” he explains.
one of the world’s largest “Without software such as this, the teams better understanding of productivity,”
consumer products compa- can talk through different layouts, but Whitmore notes. For further information
nies, with approximately 300 FactoryFLOW lets us match them up about P&G’s capabilities in computer
brands in more than 160 quantitatively.” experimentation, contact Mary Ralles
countries around the world. (ralles.ml@pg.com) in P&G External
www.pg.com Whitmore explains that P&G uses Relations.
FactoryFLOW as a screening tool to
identify and select layouts that have the Whitmore estimates the use of Tecnomatix
Customer location greatest potential before performing a software has resulted in millions of dollars
Cincinnati, Ohio detailed analysis with Plant Simulation. in cost savings across the global
United States “FactoryFLOW provides a good first pass organization. He also reports one project
because it doesn’t require a lot of effort saw a 33-percent increase in the utilization
or data to evaluate proposed layouts,” of factory space and 20 to 25-percent
“Tecnomatix applications he adds.
work together well to let savings in the cost of moving materials.
you visualize different Overall for P&G, Tecnomatix means faster
P&G uses Tecnomatix Plant Simulation design of more efficient factories with
factory layouts and deter- to optimize material flow, resource
mine quantitatively how optimized logistics and productivity in
utilization and logistics. Users create their manufacturing organization. With
they will perform.” computer models of production systems, Tecnomatix, P&G has powerful tools for
“We got a lot more confi- then run experiments and what-if focusing the company’s engineering and
dence in what the real scenarios to optimize them – quickly and manufacturing talents effectively.
plant will look like [using without disturbing ongoing operations.
Tecnomatix], because we “Plant Simulation is very fast in how it
had already seen it and does the calculations,” says Whitmore.
flown around it virtually.” “There are a lot of benefits in how easy it
is to implement and how models can be
Brad Whitmore built and re-used.”
Technology Section
Head Global Computer Aided P&G has coupled Plant Simulation
Engineering with its own expertise in computer
Procter & Gamble experimentation, a comprehensive
approach that identifies the factors most
likely to cause losses through simulation
of manufacturing operations. The
openness of the Tecnomatix software
supports this kind of computer
experimentation, which “adds another
layer to the simulation, so we have a
Teamcenter • Tecnomatix
Siemens Rail Systems

Digital manufacturing tools strengthen rapid organic growth
Industry or product Train manufacturer uses

Automotive and transportation Manufacturing Process Planner
and Process Simulate to ensure
Business challenges its products are manufactured
at the highest quality standards
Deliver trains to customers on
time and per quality require- against continuously shorter
ments delivery times
Plan the production process
All tracks lead to the Krefeld-
for a highly complex product
Uerdingen plant
against significant time
Every regional and high-speed train built
pressure
by Siemens in Germany passes through
Support the production of the doors of its Siemens Rail Systems plant
products for different custom- in Krefeld (Uerdingen district). Krefeld is
The Siemens Rail Systems plant in Krefeld.
ers, with high levels of strategically placed between the two
variation major cities of Düsseldorf and Dortmund. Krefeld, with some of them put through
Reduce shop floor production Siemens has taken advantage of this loca- their paces at the company’s own test
errors and scrap tion by making its Krefeld facility one of center. The high-speed Velaro train is
the most important centers of competence already operating successfully in Spain,
for the railway industry. Every year, more China and Russia. The latest generation of
Keys to success than 450 car bodies are delivered by the the train is also due to run in its home
Remove barriers between plant, where approximately 2,000 people country – Germany.
Product Design and Manufac- work on the development and production
turing Engineering groups of rolling stock, electrical systems and
through Manufacturing Pro- components.
cess Planner
Define the M-BOM out of At the Siemens Rail Systems plant, the
the E-BOM aluminum components for the body shells
are fitted together, welded and painted.
Plan a production process, in- Individual parts are then put together,
cluding operations sequence, and the car bodies take on the form and
needed tools and handled shape that passengers will later see and
parts use. Only when every seat and door has
Integrate Manufacturing been correctly installed is the train rolled
Process Planner with existing out the doors and ready for service.
engineering IT systems Regional trains like the Desiro and high-
speed trains like the Velaro, both used in
the United Kingdom (UK), are built in The Siemens high-speed Velaro train.
www.siemens.com/plm
Results
Project delivery time is
reduced
Product changes are system-
atically handled by manufac-
turing engineering through a
controlled change process
Visualized and self-
explanatory shop floor
work instructions
Dynamic 3D simulations of
complex assembly scenarios
Planning a train assembly process with Manufacturing Process Planner.
Planning the production of complex engineers are now exposed to product

products requires dedicated tools data during product development, and
Ulrich Semsek, who manages the Krefeld can immediately start to plan the needed
Plant, describes the organization’s business production process. This clearly shortens
challenges, “We are now facing a huge product development time.” Siemens Rail
pressure to deliver trains, due to our ever- Systems’ digital manufacturing capability
increasing order book. The commercial includes a tight, bi-directional interface
trend we are experiencing is that the time between its enterprise resource planning
from order to delivery becomes shorter, (ERP) system, SAP® software, and its
and the complexity of projects becomes manufacturing engineering backbone,
higher. A typical train is a very complex Teamcenter® software. The engineering
product and includes 400,000 parts. The bill of materials (E-BOM) is imported into
level of commonality among trains manu- Teamcenter from SAP, and includes the
factured for different countries is some- structure (hierarchical information),
Train assembly is a complex process.
times as low as only 10 percent – so they relevant attributes (such as materials),
are very different from each other. The transformational matrices and the associ-
bottom line is that we need a tool to man- ated geometric data (JT™ data format,
age this complexity. Therefore, we per- which is used also within the ERP
ceive the digital manufacturing project environment). The seamless integration
deployment – which uses the Manufact- of Teamcenter and SAP supports updating
uring Process Planner solution in the an existing BOM with a new version.
Teamcenter portfolio as its foundation
technology – to be a key element in our The process works as follows. The manu-
ability to deliver trains to customers on facturing engineers define the manufac-
time and according to quality turing bill of materials (M-BOM) out of the
requirements.” E-BOM. Dedicated functionality allows the
engineers to easily change the hierarchy,
Bridging the gap between the product as the M-BOM is structured the way the
design and manufacturing engineering product will be manufactured, as opposed
processes to the E-BOM, which is structured accord-
“One of the big benefits of Manufacturing ing to product design considerations. In
Process Planner is that it helps to remove addition, the manufacturing engineers add
the typical barriers we have between the a number of manufacturing features to the
product designers and manufacturing M-BOM, such as lubricants, which are not
engineers,” says Semsek. “Manufacturing
“ We perceive the digital
manufacturing project
deployment – which uses
the Manufacturing Process
Planner solution in the
Teamcenter portfolio as
its foundation technology –
to be a key element in our
ability to deliver trains to
customers on time and
according to quality
requirements.”
“ One of the big benefits
Analysis of the cabin rear part using Manufacturing Process Planner. of Manufacturing Process
Planner is that it helps
to remove the typical barri-
part of the E-BOM. Teamcenter is also used capable of top speeds of up to 160 kilome-
ers we had between the
to obtain other information from SAP, ters per hour and are expected to enter
product designers and
including tooling data that is designed service in the autumn of 2013.
manufacturing engineers.
with Pro/Engineer® software and managed
Manufacturing engineers
using the Windchill PDMLink® software The Sochi project demonstrated to the
are now exposed to product
environment. Krefeld crew the tremendous advantages
data during product devel-
of using Manufacturing Process Planner.
opment, and can immedi-
At an appropriate time, the M-BOM is In this project, manufacturing engineers
ately start to plan the
exported back to SAP to feed the shop defined both the assembly and the weld-
needed production process.
floor systems. Martin Olbrich, who is ing process using Manufacturing Process
This clearly shortens
responsible for assembly manufacturing Planner by preparing the manufacturing
product development time.”
engineering at the Krefeld Plant, notes, operations, linking the train parts to
“We were impressed with the openness of the operations, and defining the tools Ulrich Semsek
Siemens PLM Software’s manufacturing that were required for each shop floor Krefeld Plant Manager
engineering solution. It enabled us to operation. The duration of each Siemens Rail Systems
create seamless integrations between manufacturing operation was accurately
Manufacturing Process Planner and other calculated through an interface between
commercial and legacy systems that we Manufacturing Process Planner and a dedi-
have in our engineering IT (information cated time analysis system, which is used
technology) landscape.” by Manufacturing Engineering. The work-
flow is based on a high level of automa-
Digital manufacturing supports tion that saves notable time for the
transportation network improvement manufacturing engineers, as well as
The transportation network in and around extensive consistency checks that ensure
the city of Sochi in Russia, near the Black that no single part is left untreated.
Sea, will go through a major improvement. Eventually, the complete work packages
To support this, Siemens has received an are exported to SAP and consequently
order from Russian Railways (RZD) to sup- other systems are updated as well. Olbrich
ply a total of 54 regional trains. The first points out, “One of the clear benefits we
38 trains, similar to the Desiro, will be have realized though the deployment of
manufactured entirely at the Siemens Rail this train project is the ease and speed
Systems plant in Krefeld. These trains are with which changes can be handled.
A train is a complex product, with a high
“ We were impressed with the
openness of Siemens PLM
Software’s manufacturing
engineering solution. It
enabled us to create seam-
less integrations between
Manufacturing Process
Planner and other commer-
cial and legacy systems that
we have in our engineering
IT landscape.”
Martin Olbrich
Manufacturing Engineering
Assembly Manager
Krefeld Plant A Sochi car in the production line.
level of customization per customer. Bernd Niesel, who manages welding across
Our group, Manufacturing Engineering, the manufacturing engineering environ-
typically encounters extensive product ment at the Krefeld Plant, describes
changes throughout a project. With another benefit of implementing
Manufacturing Process Planner, we have a Manufacturing Process Planner: “When
clear methodology that readily identifies we first started the deployment, we
the changes, analyzes their impact, and planned to employ the software mainly in
carries them out in the process plan.” the assembly area, but as the benefits
became more evident, it was clear to us
Strategic deployment demonstrates that we would deploy the tools in the
value across disciplines welding area as well. There are 1,500 to
“We don’t calculate the benefits of the digi- 2,000 parts in the chassis, and the major-
tal manufacturing project in the sense of ity of the welding operations are manual.
saving manpower, as we treat this project Therefore, using Manufacturing Process
as a much more strategic initiative,” says Planner, we experience a big benefit in
Semsek. “In Siemens Rail Systems, our cul- analyzing and defining the right welding
ture is to invest in innovative solutions, sequence upfront, taking into account the
Aluminum ribs that form the car and push for real values.” Semsek notes physical constraints of the materials; for
chassis on the production line.
that this typically means taking some example, weld on one side, then balance
chances, pushing for practical benefits with a weld on another side.”
and, in many cases, exceeding expecta-
tions. He explains, “We now see more and
more value in the digital manufacturing
project – more structured methodologies
and work procedures from engineering on
the top floor down to production on the
shop floor. What is interesting is that we
now experience some benefits that we did
not foresee in the first place; for example,
in the Krefeld Plant, the perfect fit of the
digital manufacturing tools to our lean
assembly initiative.”
Using Manufacturing Process Planner to define the

welding sequence is straightforward and effective.
Manufacturing Process Planner helps “Another big advantage of using
avoid shop floor mistakes Manufacturing Process Planner is the
Highly visual, self-explanatory work ability to easily update documents. For
instructions represent a key resource for example, if there is an engineering change
avoiding assembly mistakes, which often to one of the parts, the use of Teamcenter
result in costly rework and scrap. The makes it easy to make that change and
Krefeld Plant’s Manufacturing Engineering it’s automatically reflected in any related
department was experiencing a number imagery in the work instructions. As part
of obvious problems on the shop floor of our previous process, we used to invest
that were related to work instructions. a lot of effort in order to generate 2D
Specifically, the work instructions were assembly drawings for the shop floor
often difficult to understand and insuffi- personnel. This is no longer needed, due
ciently visual. In addition, it wasn’t always to our highly effective, new work instruc-
clear that the instructions were up-to-date. tions solution.”
Ultimately, the shop floor workers’ use of
the instructions was inconsistent and less
than optimal.
To address the problems associated with

the work instructions, Siemens Rail
Systems Krefeld engaged the 3D portable
data format (PDF) Work Instruction appli-
cation of Manufacturing Process Planner.
Olbrich explains, “While looking for a solu-
tion that would support the reduction of
shop floor scrap and rework, we became
excited about the ability to create highly
visual work instructions for our shop floor
personnel. So we created a PDF template
and used it to start generating work
instructions in a format that could be eas-
ily loaded on any workstation throughout
the shop floor. Each work instruction,
An example of a crash box assembly 3D PDF work instruction.
delivered in PDF format, includes a list of
sequenced production or assembly steps,
the necessary tools to address each step,
specific production values (for example,
fastening torque), relevant security warn-
ings such as needed protective equipment,
and generic information like requisite
worker qualifications and associated imag-
ery. With such clarity of work instruction
content, especially through the use of
visualized processes, we have decided to
optimize communication by purchasing
23-inch monitors and positioning them
throughout the shop floor.
Coupling assembly after crash box –
a Process Simulate analysis.
Coupling assembly – a Process Simulate analysis. Crash box assembly (with the needed tools) –
a Process Simulate analysis.
“ Another important aspect Dynamic 3D simulation of complex “Another important aspect of using
of using Process Simulate assembly scenarios Process Simulate is that Manufacturing
is that Manufacturing Siemens Rail Systems uses the Process Engineering now has a tool to carry out
Engineering now has a tool Simulate solution in the Tecnomatix® assembly analysis whereas, with our prior
to carry out assembly analy- portfolio to analyze any planned assembly approach, this task had to be performed by
sis, whereas with our prior operation that requires virtual validation. Product Design. As we are dealing with a
approach, this task had to This analysis occurs in an entirely 3D complex assembly process, the simulation
be performed by Product environment. Process Simulate is inte- (including animations and images acquired
Design. As we are dealing grated with Manufacturing Process during this analysis) represents a valuable
with a complex assembly Planner. Simulations typically include the resource in training our shop floor
process, the simulation product being assembled and the tools personnel.”
(including animations and that are used for the assembly, fixtures
images acquired during this and logistic jigs. The future – capacity planning
analysis) represents a valu- and disassembly
able resource in training our Olbrich explains, “When putting all this Siemens Rail Systems has realized signifi-
shop floor personnel.” data into the context of an assembly, we cant benefits from the deployment of
can validate upfront whether a planned Siemens PLM Software’s digital manufac-
Martin Olbrich
process is feasible for execution on the turing tools. The organization is now eval-
Manufacturing Engineering
shop floor. For example, consider the uating additional digital manufacturing
Assembly Manager
assembly of the coupling and the crash applications that are well-suited to deliver
Krefeld Plant
box modules at the front-end of a train. significant process advantages, including
This is a tricky assembly scenario, because Plant Simulation in the Tecnomatix portfo-
whatever module you assemble first makes lio. “We already did an evaluation of the
assembling the second module difficult. In Plant Simulation tool,” says Olbrich. “We
the past, the assembly sequence for such built a discrete-event simulation model for
modules was determined by the product one of the pre-assembly lines in order to
designers. Now, manufacturing engineers support resource capacity planning. The
use Process Simulate to analyze the opti- manufacturing process and resources are
mal assembly sequence of the train mod- defined using Teamcenter and populated
ules. Using Process Simulate, we combined to Plant Simulation. This is a big benefit.
product data with tools and fixtures, and The planned scheduling is imported from
we found that the coupling had to be Excel. The initial outcome shows the
assembled after the crash box to avoid potential for notable productivity advan-
additional assembly steps and unnecessary tages, so the deployment of Plant
shop floor complexity. Simulation appears imminent.”
Solutions/Services
Teamcenter
www.siemens.com/teamcenter
Tecnomatix

Siemens Rail Systems com-
bines comprehensive urban,
interurban and logistics
mobility expertise to
deliver integrated mobility
solutions – precisely tailored
intermodal technologies for
rail, road, and air traffic –
that enable its customers to
transport people and goods
more efficiently.
www.mobility.siemens.com Intercity trains production hall.
Customer location Another promising area is engineering we must be technology leaders, and an
disassembly analysis, which is needed advanced digital manufacturing deploy-
Krefeld
for maintenance and service tasks. ment is another reflection of our leader-
Germany
“Maintenance and service are part of the ship. Additional plants in our division are
overall solution we provide to our custom- already looking to learn from our plant,
“We now experience some ers,” says Olbrich. “It is clear that with the and adopt the digital manufacturing tools
benefits that we did not Process Simulate tool, which is integrated and methodology we have developed
foresee in first place; for within the Teamcenter environment, we using the tools of Siemens PLM Software.
example, in the Krefeld can simulate disassembly activities in Luckily for our other plants, they will get
Plant, the perfect fit of the order to define the best disassembly meth- the system production-ready to support
digital manufacturing tools odology and effectively train maintenance their unique needs.”
to our lean assembly personnel.”
initiative.”
Semsek concludes, “Our train manufactur-
Ulrich Semsek ing business is doing extremely well. We
Krefeld Plant Manager recently received an order from Deutsche
Siemens Rail Systems Bahn (German Rail) for the ICx train –
the biggest single order in the history of
our company. To support such growth,
Americas +1 800 498 5351 © 2012 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered
Europe +44 (0) 1276 702000 trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter,
Asia-Pacific +852 2230 3333 Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software
Inc. or its subsidiaries in the United States and in other countries. Excel is a registered trademark of Microsoft Corporation.
SAP is a trademark or registered trademark of SAP Aktiengesellschaft. Pro/Engineer and Windchill PDMLink are trademarks or
registered trademarks of Parametric Technology Corporation or its subsidiaries in the United States and in other countries.
All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.
www.siemens.com/plm Z18 27246 7/12 C
Plant Simulation for shipyards
Simulation, visualization and optimization of shipbuilding processes
Benefits Summary
• Optimized space and Tecnomatix® software’s Plant Simulation enables the simulation and
crane utilization optimization of complex shipyard production systems and processes. Using
• Advanced assembly Plant Simulation, you can optimize material flow, resource and space
sequence scheduling utilization as well as the logistics for all levels of the shipyard from scheduling
• Increased planning safety individual welding activities up to the complete ship assembly.
and accuracy
• Higher service reliability
• Improved logistics and
material management with
clarity of complex processes
• Safer investment decisions
• Ability to better decide upon
make versus buy issues
• Ability to more accurately
predict delivery times
• Ability to reduce the risk of
product failure or delay The challenges of
today’s shipyard
User case industry are
• Decreased throughput complicated by
time from 60 to 52 days having to deliver
(-14 percent) increasingly
• Decreased direct labor on the complex products in
panel line from 8,280 to a highly competitive
6,600 hours (-20 percent) marketplace.
Shipyards now face
Features the need to build
• Simulation of complex more ships in a
production systems and shorter time and to
control strategies offer services at competitive prices and with short delivery times. Plant
• Object-oriented, hierarchical Simulation is an event-driven simulation tool that helps shipyards handle
models of shipyards, these needs more easily, providing computer-supported answers to major
encompassing business, questions such as when and where to develop what products and with
logistic and production resources limited by availability and restricted materials.
processes
Plant Simulation is a simulation-based and modular toolset with proven
benefits for optimizing production and logistics in the shipbuilding industry,
allowing the graphical representation of parts and resources and interfacing
TECNOMATIX
TECNOMATIX
Tecnomatix Plant Simulation for shipyards
Features continued to database systems. This toolset enables cannot be accounted for when traditional
• Graphs and charts for you to model the employment of available planning tools are used. In addition,
analyzing throughput, shift calendars with customer-specific the visualization does not offer 3D
resources and bottlenecks user-interfaces and interactive model animation capabilities.
• Comprehensive analysis manipulation. Plant Simulation is used to
tools, including automatic optimize the building of cruise liners, Result
bottleneck checking car and passenger ferries, container Plant Simulation facilitates the simulation
• Sankey diagrams and Gantt vessels and gas tankers, aircraft carriers, of the highly complex shipyard
charts submarines and naval ships. Plant environment. It offers a good basis for
• 3D online visualization and Simulation supports strategic corporate deciding the outsourcing and production
animation projects by enabling project managers to strategies, while facilitating cross-project
• Integrated neural networks identify the best shipyard at which to build resource planning, increasing planning
and experiment handling new ships. Plant Simulation also can be safety and improving the utilization of
• Automated optimization of used to manage internal production and major resources such as employees, cranes
system parameters outsourcing strategies, as well as the and square footage.
• Open system architecture operational work sequences and schedules
supporting multiple that are used to distribute the daily Where Plant Simulation applies
interfaces and integration workload. • Predicting schedule problems
capacities (ActiveX, C, CAD, • Predicting workplace-efficiency
MS Excel, Oracle SQL, ODBC, All processes follow easy-to-understand • Finding concept changes for expanding
XML, Socket, OPC, etc.) interactive and iterative functions. Users shipyards
start the scheduling, look at results and, if • Sequence-control of assembly lines
needed, make changes (for example • Optimizing warehouse and transport
excluding a special sub-block). Users capacities
restart the scheduling to verify that the • Steel planning
changes were correct. Plant Simulation is • Optimizing availability of needed
able to predict utilization in each project manpower
area, depending on the number and kind
of blocks being assembled every day, week References
and month. • Aker Yards, Germany
• Center Of Maritime Technologies,
Why traditional planning tools do Germany
not work • Flensburger Schiffbau-Gesellschaft,
Static planning tools, such as spreadsheets Germany
or flow-charting software, are unable to • Meyer Werft Papenburg, Germany
generate results that account for variability • ThyssenKrupp Marine Systems:
and changing conditions over time. Blohm + Voss, Germany
Relevant interdependencies between Nordseewerke Emden, Germany
system components and technological Kockums, Sweden
constraints are not usually taken into • Volkswerft Stralsund, Germany
consideration. Complex rules that control
the flow of information and material often

X10 8852 9/11 B
Shipbuilding
Digital planning boosts shipyards’ efficiency

Tecnomatix production planning software helps shipbuilder optimize production across multiple facilities, reducing
development costs and ensuring on-schedule deliveries
FINCANTIERI
Business initiatives Ambitious targets

Commonization and re-use Fincantieri is one of the biggest
shipbuilding companies in the
Production efficiency
world, with particular expertise
Business challenges in the production of cargo and
cruise ships. In 200 years of its
Ensure high quality
history, the company has
Limit costs launched more than 7,000 ships
Meet delivery times and is the leader in supplying
hulls, surfaces and submarines at
Keys to success a global level. Divided into six
Scientific approach to business areas (cruise ships,
production planning cargo ships, military ships, mega
Ability to simulate production yachts, ship repairs and
alternatives remodels, ship systems and
Common library for components), the company
production data employs 9,200 people, with at
least twice as many working for
Standardized production
documentation its supplier companies.
Production takes place at nine facilities across Italy.
Results Fincantieri invests five percent of its turnover into research and development to ensure its
Closer cooperation between leadership position into the future. Along with goals for increasing in both size and market
shipyards share, the company is working to reduce costs through the adoption of digital manufacturing.
Optimized production capacity
at each shipyard Planning revolution
Reduced development costs Fincantieri has implemented the Tecnomatix™ digital manufacturing solution from Siemens PLM
Better ability to meet Software to enhance production planning, to integrate production systems so that the entire
delivery dates organization functions as one shipyard, and to transform strategic goals into operational
activities. All of this is aimed at providing the highest quality services, at lower costs and
meeting delivery times.
The adoption of Tecnomatix created a revolution in the production planning process, starting
with production engineering and extending through shop floor operations. The starting point
was a new way of breaking down a hull to best exploit the capabilities of the various plants
Shipbuilding
Solutions/Services without exceeding their limits. This begins as a

top-down process that divides the ship into
Tecnomatix
areas, sections, blocks, sub blocks, panels and so
on. Then the process reverses, that is it
Client’s primary business
becomes bottom-up, to plan the production of
Fincantieri is the world’s leading every single object, including constraints
supplier of cruise ships and
large ferries, and among the (material availability, type, weight, sizes and
leading companies in the field of delivery date) and optimize the work of the
hull supplies. individual shops.
www.fincantieri.com
The use of the Tecnomatix suite allowed
Client location Fincantieri to achieve a dramatic reduction in
planning time for the hull construction and
Trieste and Genova
Italy provided the ability to investigate more process and planning alternatives as well as analyze each
project on the basis of the shipyards’ production capacity – simulating the same process on the
various yards.
“The use of Tecnomatix has
opened the way to closer Innovative approach
collaboration between the The Tecnomatix implementation, which was performed by Fincantieri along with representatives from
various shipyards.” Siemens PLM Software, introduced an innovation into the company’s way of working. “The most
Alessandro Nevierov interesting result is a more scientific approach to production planning through all of our plants,” adds
Methods and Technology Alessandro Nevierov, methods and technology development manager at Fincantieri. “Also,
Development Manager Tecnomatix led to the adoption of a common method as well as the creation of a reference library
Fincantieri that makes it possible to share production analysis data with the various plants. It has also enabled us
to standardize our planning documentation.”
The use of Tecnomatix has reduced development costs as well as the risks associated with missing
delivery dates. The most significant results of the new approach have been time and cost savings
resulting from the increased quality of the planning.
Simulation optimizes production

In the production of a hull, the use of the Tecnomatix Plant Simulation enables production engineers
to analyze multiple production strategies in relation to the machinery and labor constraints of the
distinct workshops or Homogeneous Technological Areas (HTAs). This type of analysis makes it
possible to optimize each shipyard’s throughput and more easily balance the allocation of materials
and capacity across multiple sites.
The introduction of Tecnomatix has allowed Fincantieri to centralize the initial planning process
while improving decision making. It also fosters the re-use of data, thus shortening the development
time for detailed production plans.
“The use of Tecnomatix has also opened the way to closer collaboration between the various
shipyards by allowing the exchange of the data,” says Nevierov. “Transfer times for construction
documentation from one plant to another have been reduced to the minimum, to days instead of
months.” Moreover, the automatic production of product planning reports and summary documents
has eliminated a significant amount of time-consuming compilatory work.
Contact
Americas 800 498 5351
Europe 44 (0) 1276 702000
www.siemens.com/plm
Teamcenter, NX, Solid Edge, Tecnomatix, Parasolid, Femap, I-deas, Velocity Series and Geolus are trademarks or registered trademarks of Siemens Product
Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or
service marks used herein are the property of their respective holders. 9/08
Tecnomatix
Plant Design and Optimization solution helps protect centuries-old

market leadership
Issues: MEYER WERFT

Process excellence
Tecnomatix Plant Design and Optimization proves to be a most effective solution for the
Approach: demands placed on a modern shipyard.
Apply Tecnomatix® Plant
Simulation software to optimize Meyer Werft – Jos. L. Meyer
production and speed new GmbH was founded in 1795
production planning and can look back on a very
successful track record,
Results:
especially in the building of
Improved overall production special-purpose ships. The
process, including planning
worldwide demand for
Improved storage and readiness luxury liners with a capacity
of semi-finished products of 2,000 passengers and
Reduced development time above is growing, as is
Lower shipbuilding costs confirmed by the full order
books of Meyer Werft. To
Construction sequence
cater to the need of building more ships in less time, shipyards have to make their production
demonstration for customers
during the offer phase processes more efficient. Improving efficiency can also help Meyer Werft counter heavy
competition from the Far East.
Throughout its long company history, Meyer Werft set goals to use innovative tools, take new
directions and turn visions into reality. The growing demand gave rise to the vision of a “digital
shipyard” and in Siemens Tecnomatix, Meyer Werft found the ideal partner for turning this
particular vision into reality. The Tecnomatix Plant Simulation application within the Plant
Design and Optimization solution has now been in use since 1998. Tecnomatix is used for the
planning, simulation and optimization of production systems and processes. Using Tecnomatix,
Meyer Werft can optimize its existing production systems and develop planning alternatives
more easily. Future manufacturing processes in the shipyard can thus be developed more
quickly and optimized from the start. At the same time, the software cuts shipbuilding
development times and costs significantly by simulating and improving the work process,
accounting for various factors and resources (for example workers, equipment and transport
infrastructure). Because the shipyard has only limited space available for large, heavy ship
components means storage of the semi-finished products is a major production challenge.
However, this problem has likewise been overcome thanks to simulations using Tecnomatix.
Tecnomatix
Solutions/Services Following extensive product benchmarks, Plant Simulation proved to be the tool most suitable to
cope with the demands placed on a modern shipyard, due to its modular architecture and seemingly
endless scope of functionality.
Client’s primary business According to Dr. Frank Roland, Manager of Research & Development, Meyer Werft is “…now able
Shipbuilding to plan and simulate different production processes via Tecnomatix, such as the use of personnel by
www.euroyards.com/ worker skill level and by project priority.” Furthermore, the software “optimizes the use of transport
ey_companies_jos.html equipment, such as cranes.”
or www.meyerwerft.de
Dr. Roland adds that Tecnomatix is “eminently suitable for visualizing and optimizing production
Client location activities, and that users are particularly enthusiastic about its 3D graphics capabilities. This is very
Papenburg helpful in making production-related decisions,” explains Dr. Roland, adding that “unnecessary risks
Germany are avoided and the entire productivity increased as all processes can be simulated and tested
before implementation.”
Meyer Werft is one of the first shipyards to use Plant Simulation on a large scale. Chantier
d´Atlantique, Fincantiari and Flensburger Schiffsbaugesellschaft also recently decided to use Tecnomatix
in this manner. This confirms that a constantly growing demand for digital manufacturing also exists
in this market, joining the heavy industries, consumer electronics and automotive industries.
On the whole, nothing but benefits

Meyer Werft derives considerable benefits from the use of Plant Simulation as explained by
Dr. Roland: “Our planning engineers can already digitally demonstrate in the offer phase the
construction sequence of the new ship to the commissioning shipping line. We can also determine
quickly whether or not a specific ship can indeed be built, and if so, how.”
As the shipbuilders in Papenburg were already well versed in the use of simulation, it comes as no
surprise that a development partnership formed between Meyer Werft and Siemens. This resulted in
the creation of an enhanced tool for space allocation that has already been integrated in Plant
Simulation, as well as numerous other developments, including a library of shipyard-specific objects.
The overall Tecnomatix offering from Siemens has proven an effective solution for the optimization
of planning and production at shipyards.
Contact
Americas 800 498 5351
Europe 44 (0) 1276 702000
www.siemens.com/plm
Teamcenter, NX, Solid Edge, Tecnomatix, Parasolid, Femap, I-deas, JT, Velocity Series, Geolus and the Signs of Innovation trade dress are trademarks or
registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. All other logos,
trademarks, registered trademarks or service marks used herein are the property of their respective holders. 3/08
Student download
Plant Simulation discrete-event simulation modeling – helping prepare
students to meet the manufacturing challenges of the future
Benefits Summary
• Free annual license to Tecnomatix® Plant Simulation software from Siemens PLM Software enables
production software used in the simulation and optimization of production systems and processes. Using
industry Plant Simulation, you can optimize material flow, resource utilization and
• Early job market preparation logistics for all levels of operations planning from global production facilities
by learning industry-leading through local plants to specific lines and processes. In times of increasing
production simulation cost and time pressures in production, along with ongoing globalization,
technology logistics has become a key factor in the success of a company. The need to
• Networking opportunities deliver JIT/JIS (just-in-time/just-in-sequence), introduce Kanban, plan and
through access to a global build new production lines and manage global production networks requires
forum of users objective decision criteria to help management evaluate and compare
alternative approaches.
Features
• Simulation of complex
production systems and
control strategies
• Object-oriented, hierarchical
models encompassing
business, logistic and
production processes
• Dedicated application object
libraries for fast and efficient
modeling of typical scenarios
• Graphs and charts for
analysis of throughput,
• Comprehensive analysis
tools, including automatic
bottleneck detection, Sankey
diagrams and Gantt charts
• 3D online visualization and
animation Plant Simulation helps create digital models of logistic systems (e.g.,
• Integrated experiment production) to explore the systems’ characteristics and to optimize their
handling performance. The digital model enables you to run experiments and “what-if”
• Automated optimization of scenarios without disturbing an existing production system or – when used
system parameters in the planning process – long before the real system is installed. Extensive
analysis tools, statistics and charts let you evaluate different manufacturing
scenarios and make fast, reliable decisions in the early stages of production
planning.
Tecnomatix
Tecnomatix
Tecnomatix Plant Simulation Student download
Features continued What is included

• Open system architecture The Plant Simulation Student download
supporting multiple contains the same core functionality used
interfaces and integration by leading engineers and leverages the
capacities (CAD, ODBC, software’s powerful object-oriented
XML, etc.) architecture and modeling capabilities that
• Interactive training materials enable you to create and maintain even
and social media access to highly complex systems, including
relevant content advanced control mechanisms. Plant
Simulation’s user interface follows
Microsoft Windows standards, making it By registering for the Plant Simulation
easy for you to quickly become productive. Student download you will become part of
Simulation models can be created quickly a global user community. Siemens hosts
by using components from application dedicated channels on YouTube,
object libraries dedicated to specific Slideshare, Facebook, Twitter and other
business processes. You can extend the public social sites that include tips, current
library with your own objects through a events and useful training materials.
powerful programming environment for
the furthering of simulation capabilities. Who it is for
Tools for automatic optimization, analysis The Plant Simulation Student download is
of simulation results and 3D visualization available to any active student of any age
of simulation models are also available. who is attending any academic institution
such as accredited universities, technical
Training and support colleges, trade and high schools. You can
There are a number of ways for you to create models up to 80 objects in size and
learn how to use Plant Simulation. utilize the Plant Simulation class libraries.
Included within the product are example The software is available only for the
models, demonstration videos, and an Windows platform. The duration of this
interactive tutorial that covers essential offering is valid for one year, but can easily
modeling and simulation, along with a be extended with re-registration. Usage of
Demonstration of the different behavior of an
step-by-step online help guide. These Plant Simulation Student download is
assembly line once with a Push-control and then
again with a Pull-control (Kanban) – Andreas
training tools are a perfect way for you to intended for academic course work, and
Eiband, October 2011 Student Plant Simulation learn how to use the discrete-event files created in the Student download
Contest Winner. simulation modeling techniques in Plant cannot be opened in commercial versions
Simulation, to increase your productivity of Plant Simulation.
and gain the skills required by some of the
world’s leading engineering and product
design companies.

X7 30544 6/12 C

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Benefits Summary existing production system or – when used

Features is achieved through powerful object-ori- production variations. Statistical analysis,

© 2013 Siemens Product Lifecycle Management

Tecnomatix Plant Simulation

what-if scenarios without disturbing an Tecnomatix Plant Simulation

Plant Simulation helps users:

Objectives and benefits

The aim is to optimize production

Standardized method based on generally

Predefined core objects: Value Stream Mapping Library in Plant

© 2012 Siemens Product Lifecycle Management Software

Renovating Russia’s largest airport – virtually

The first assignment for

Solutions/Services number and specifications of cargo handling transports,

© 2010 Siemens Product Lifecycle Management Software Inc.

Industry A leading provider of lithography

objects, e.g. an optimization

Plant Simulation result box plot: the time (in weeks)

Plant Simulation result chart: comparison of

Siemens Industry Software

Keys to Success positions worldwide in the fields of

A Bühler chocolate production line.

Bühler ship unloading solutions.

Mixing production equipment operation

Client’s primary business

Siemens Industry Software

Industry Comau (Shanghai) simulates

Expanding innovative automation

Customer’s primary business

Siemens Industry Software

Continental Automotive Group

Industry Tecnomatix Plant Simulation

resolved faster nearly 2,000 employees produce about

Electronic component on work-piece carrier. Customized laser marking of a manufactured

Siemens Industry Software

Customer’s primary business

populate real operational data into the Effectively managing change

Siemens Industry Software

Designing better factories, virtually

EICHER ENGINEERING SOLUTIONS

Siemens PLM Software www.siemens.com/plm

Business initiatives Consultants to the auto

Broad-based software solution

Industry Eisenmann shortens project using computer systems, which simulate

Eisenmann electrified monorail system.

The complexity factor

Siemens Industry Software

To manage these challenges, simulation is the tool to implement fully vali-

Tecnomatix Plant Simulation for the food and beverage industry

© 2012 Siemens Product Lifecycle Management Software

Source image: DB Schenker.

Plant Simulation for Warehousing and Logistics

Features continued applications support the analysis and re-

about equipment and flow of goods. Plant Redesigning operations At various

© 2011 Siemens Product Lifecycle Management Software

Manufacturing optimization with Tecnomatix Plant Simulation enables you to

© 2012 Siemens Product Lifecycle Management Software

KUKA Systems do Brasil

Innovative automation solutions KUKA Brazil was founded in 1998. Having

An automotive body-in-white production line delivered by KUKA Brazil.

“Due to the superiority of the

“Process Simulate Virtual