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 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 Siemens Rail Systems 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 www.siemens.com/tecnomatix

Customer’s primary business 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,

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