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Siemens Mobility Case Study

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Siemens Mobility Case Study 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 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 is based on a stan- uring Process Planner solution in the dard Teamcenter Gateway for SAP, devel- Teamcenter portfolio as its foundation oped by Tesis, and supports updating an technology – to be a key element in our existing BOM with a new version. ability to deliver trains to customers on time and according to quality The process works as follows. The manu- requirements.” facturing engineers define the manufac- turing bill of materials (M-BOM) out of the Bridging the gap between the product E-BOM. Dedicated functionality allows the design and manufacturing engineering engineers to easily change the hierarchy, processes as the M-BOM is structured the way the “One of the big benefits of Manufacturing product will be manufactured, as opposed Process Planner is that it helps to remove to the E-BOM, which is structured accord- the typical barriers we have between the ing to product design considerations. In product designers and manufacturing addition, the manufacturing engineers add engineers,” says Semsek. “Manufacturing a number of manufacturing features to the M-BOM, such as lubricants, which are not “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 part of the E-BOM. Teamcenter is also used trains, similar to the Desiro, will be manu- to remove the typical barri- to obtain other information from SAP, factured entirely at the Siemens Rail ers we had between the including tooling data that is designed Systems plant in Krefeld. These trains are product designers and with Pro/Engineer® software and managed capable of top speeds of up to 160 kilome- manufacturing engineers. using the Windchill PDMLink® software ters per hour and are expected to enter Manufacturing engineers environment. service in the autumn of 2013. are now exposed to product data during product devel- At an appropriate time, the M-BOM is The Sochi project demonstrated to the opment, and can immedi- exported back to SAP to feed the shop Krefeld crew the tremendous advantages ately start to plan the floor systems. Martin Olbrich, who is of using Manufacturing Process Planner. needed production process. responsible for assembly manufacturing In this project, manufacturing engineers This clearly shortens engineering at the Krefeld Plant, notes, defined both the assembly and the weld- product development time.” “We were impressed with the openness of ing process using Manufacturing Process Siemens PLM Software’s manufacturing Planner by preparing the manufacturing Ulrich Semsek engineering solution. It enabled us to operations, linking the train parts to Krefeld Plant Manager create seamless integrations between the operations, and defining the tools Siemens Rail Systems Manufacturing Process Planner and other that were required for each shop floor commercial and legacy systems that we operation. The duration of each have in our engineering IT (information manufacturing operation was accurately technology) landscape.” calculated through an interface between Manufacturing Process Planner and a dedi- Digital manufacturing supports the cated time analysis system, which is used Winter Olympics by Manufacturing Engineering. The work- Construction work for Russia’s 2014 Winter flow is based on a high level of automa- Olympics around Sochi, near the Black Sea, tion that saves notable time for the is well underway. Environmentally friendly manufacturing engineers, as well as rail links are planned to carry athletes and extensive consistency checks that ensure spectators to and from the airport, the that no single part is left untreated. Sochi Olympic Park and the various sports Eventually, the complete work packages venues. To support the Olympics infra- are exported to SAP and consequently structure, Siemens has received an order other systems are updated as well. Olbrich from Russian Railways (RZD) to supply a points out, “One of the clear benefits we total of 54 regional trains. The first 38 have realized though the deployment of this train project is the ease and speed “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 A Sochi car in the production line. Krefeld Plant Siemens Rail Systems with which changes can be handled. Bernd Niesel, who manages welding across A train is a complex product, with a high the manufacturing engineering environ- level of customization per customer. ment at the Krefeld Plant, describes Our group, Manufacturing Engineering, another benefit of implementing typically encounters extensive product Manufacturing Process Planner: “When changes throughout
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