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 . 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 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 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 a project. With we first started the deployment, we Manufacturing Process Planner, we have a planned to employ the software mainly in clear methodology that readily identifies the assembly area, but as the benefits the changes, analyzes their impact, and became more evident, it was clear to us carries them out in the process plan.” that we would deploy the tools in the welding area as well. There are 1,500 to Strategic deployment demonstrates 2,000 parts in the chassis, and the major- value across disciplines ity of the welding operations are manual. “We don’t calculate the benefits of the digi- Therefore, using Manufacturing Process tal manufacturing project in the sense of Planner, we experience a big benefit in saving manpower, as we treat this project analyzing and defining the right welding as a much more strategic initiative,” says sequence upfront, taking into account the Aluminum ribs that form the car Semsek. “In Siemens Rail Systems, our cul- physical constraints of the materials; for chassis on the production line. ture is to invest in innovative solutions, example, weld on one side, then balance and push for real values.” Semsek notes with a weld on another side.” that this typically means taking some chances, pushing for practical benefits 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.

Another promising area is engineering we must be technology leaders, and an Customer location 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, ers,” says Olbrich. “It is clear that with the and adopt the digital manufacturing tools “We now experience some Process Simulate tool, which is integrated and methodology we have developed benefits that we did not within the Teamcenter environment, we using the tools of Siemens PLM Software. foresee in first place; for can simulate disassembly activities in Luckily for our other plants, they will get example, in the Krefeld order to define the best disassembly meth- the system production-ready to support Plant, the perfect fit of the odology and effectively train maintenance their unique needs.” digital manufacturing tools personnel.” to our lean assembly 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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