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Siemens Rail Systems Digital Manufacturing Tools Strengthen Rapid Organic Growth

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Siemens Rail Systems Digital Manufacturing Tools Strengthen Rapid Organic Growth Automotive and transportation Siemens Rail Systems Digital manufacturing tools strengthen rapid organic growth Products Teamcenter, Tecnomatix Train manufacturer uses Business challenges Manufacturing Process Planner Deliver trains to customers and Process Simulate to ensure on time and per quality its products are manufactured requirements at the highest quality standards Plan the production process against continuously shorter for a highly complex product delivery times against significant time pressure All tracks lead to the Krefeld- Support the production of Uerdingen plant products for different custom- Every regional and high-speed train built ers, with high levels of by Siemens in Germany passes through variation the doors of its Siemens Rail Systems plant in Krefeld (Uerdingen district). Krefeld is Reduce shop floor production The Siemens Rail Systems plant in Krefeld. strategically placed between the two errors and scrap major cities of Düsseldorf and Dortmund. Krefeld, with some of them put through Siemens has taken advantage of this loca- their paces at the company’s own test Keys to success 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, Remove barriers between for the railway industry. Every year, more China and Russia. The latest generation of Product Design and than 450 car bodies are delivered by the the train is also due to run in its home Manufacturing Engineering plant, where approximately 2,000 people country – Germany. groups through work on the development and production Manufacturing Process of rolling stock, electrical systems and Planner components. Define the M-BOM out of the E-BOM At the Siemens Rail Systems plant, the Plan a production process, aluminum components for the body shells including operations are fitted together, welded and painted. sequence, needed tools and Individual parts are then put together, handled parts and the car bodies take on the form and shape that passengers will later see and Integrate Manufacturing use. Only when every seat and door has Process Planner with existing been correctly installed is the train rolled engineering IT systems out the doors and ready for service. 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 Train assembly is a complex process. factured for different countries is some- structure (hierarchical information), 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 Ulrich Semsek “We were impressed with the openness of the operations, and defining the tools Krefeld Plant Manager Siemens PLM Software’s manufacturing that were required for each shop floor Siemens Rail Systems engineering solution. It enabled us to operation. The duration of each 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. Siemens Rail Systems 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
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