GlassFocus 2016 Plant-wide automation and digitalization – the path to your company’s success

siemens.com/glass Contents

Focus on digitalization 02–27

Plant operators 28–33

Equipment suppliers 34–47

Focus on digitalization All photos: Siemens AG All photos: All photos: Siemens AG plied. plied. ap be can that scenarios different many are There lifecycle. plant’s the throughout efficiency and productivity increase steadily to possible it makes twin digital The step. planning first very the with starting built –is as a“digital twin” –known plant tion produc glass entire the or section plant the of representation virtual a plant,” “digital a Ideally, toachieve equipment. sensor additional using it expand intelligently, and it combine data, all available to assess tial is essen it plant, your tooptimize order In wasted. been has information of this much now, Until data. digital collecting and ating is gener supplier equipment and plant glass every of automation, level of the Regardless step strategic next The lifecycle. of the end to the clear and operation, during commissioning, and inconstruction planning, in systems – of sources range avast from data digital utilize and analyze, togenerate, able be to important more tobe isgoing it market, world inthe tothrive going are glassmakers If direction. inbusiness change major next its isfacing industry the Now cycle. life- entire equipment’s the over success sustainable promises plant production glass a automating extensively experience, own their from know operators plant many As for the glass isopeningupopportunities Digitalization industry Networked meansready to work - - - - used. and applied be will technologies new the how decide will who organizers core the and people, the on stay always should focus integrator. The supplier, systems or as an investor, glassmaker, equipment whether it, from profit can company Every manufacturing. inglass step next essential isthe Digitalization is certain: thing One automation. founded onahighlevelIt’s of next step inglass manufacturing. isthe essentialDigitalization

Electrification Automation Digitalization 00111001011 00111001011 01001101101 00111001011 10010111001 01001101101 Focus |GlassFocus ondigitalization 2016 ew business models models business ew • services lifecycle roduct • from effects earning • low-cost simple, afe, • • suppliers: equipment For • • • for expenses ower • range product roader • • production focused ore • • at changes product aster • surplus of oidance operationalfunction-free • commissioning irtual • planning eliable • planning omprehensive • reater transparency • • to thanks efficiency, efficiency, and energy cost productivity, higher profitability, Sustainable For plant operators: ­digitalization of advantages The

N P L S Simulation L B M F Av M V R C G eore optimization Resource flexibility Greater Asset (performance) (performance) Asset operation Optimized rejects Fewer guarantees on performance based services and update/upgrade like modernization services and lifecycle extended maintenance remote management training the optimal time andcapacity bottlenecks requirements requirements quality customers’ fit to field data

3 GlassFocus 2016 | Focus on digitalization

“Digitalization can only go Spotlight on ­digitalization as far as people will go Digitalization means imaging the real world with digital along with it.” data to mine the benefits. It calls for a comprehensive Oliver Krapp, approach that includes all head of the glass business at Siemens processes from the entire value chain. Digitalization can help the glass industry make its value-added processes faster and more flexible – in

other words, it shortens time Siemens AG All photos: to market, increases flexibility and efficiency, and cuts energy consumption. At the same time, it safeguards or A vision of digitalized glass production This digital approach extends throughout the Glass plants also have a large number of even enhances product The production plant’s lifecycle can be entire lifecycle. First, the system – or even different systems from plant section manu- quality. The talk these days is subdivided into the following phases: parts of it – can be “commissioned” in a facturers with their own individual solutions about the new stage in the ­product design, process and plant design, simulated environment. That makes it pos- for automation, drives, instrumentation, evolution of production, what is known as Industrie 4.0: production system engineering and con- sible to remedy defects in the virtual system switching equipment, and more. Digital the networked company. struction, operation, and services. At a that would have involved unnecessary costs production can’t work with these “island” Industrie 4.0 is driven by the digital company, these phases are no longer to correct in the physical system. After solutions. One of the biggest challenges is digitalization of products, treated as a chronologically arranged chain start-up, it protects the plant operator from digitally combining the product design, the production, processes, and of processes, but instead as a value-added unpleasant surprises, and essentially rules associated production systems and process- services. It’s based on net- process that delivers many forms of feedback out the risk of delayed commercial operation. es, plant design, and the actual glass produc- working and communication as well as plant-wide automa- to all phases. Data is gathered, transmitted, tion process itself. tion. So the necessary data and analyzed at every phase – and that In addition to commissioning, the operations can be generated, gathered, includes the relationships between the can be simulated digitally, and Asset Perfor- Following the slogan “Ingenuity for life – ­centrally, and used. different phases. mance Management can help glassmakers Driving the Digital Enterprise,” Siemens is derive real-time transparency about produc- investing heavily in integrating hardware At a digital company, all production steps tion processes. That can extend the service and software that will enable glassmakers and units are planned, tested, and modified life of the system components in a plant to digitalize their value chain and merge real with computer assistance. Long before the (assets), enhance the safety and availability processes with digital ones. The “Digital first glass melt, project designers develop a of the plant as a whole, and help plan for Enterprise” solution can combine the plan- virtual reproduction of the plant. This digital necessary maintenance. ning and operations world to enable com- twin enables them to determine in virtual prehensive plant management throughout tests whether the production system will How does it look in practice today? a glass plant’s lifecycle. meet the necessary requirements. The goal Today many software solutions are not yet is to relieve the plant operator from going mutually compatible. It is not uncommon for Siemens offers a portfolio of components. through the run-in phase for new equipment data sheets to be printed out and input Its foundation is an integrated range of or product changes, so the plant can begin manually into a different system – a compli- hardware, software, and services that make producing salable glass right from the start. cated process that tends to be prone to error. it possible to gather the vast quantities of

4 Focus on digitalization | GlassFocus 2016

ledge. The Comos planning tool provides the Mass of data Enhanced data foundation throughout the equipment’s operator A “flying start” benefits lifecycle and feeds data to the digital twin. thanks to a Analyzing the operating data in conjunction Digital description of knowledge lead with data from commissioning and the individual plant Plant optimization design phase of the plant sections makes it sections x possible to organize glass production more efficiently.

x Data gathering Take maintenance as an example. Histori- cally, motors would undergo maintenance according to a fixed schedule. Now, signifi- Glass plant cant wear factors like frequency ranges and operation ambient temperature can be recorded and 0 Installation Operation 15 time Commissioning years updated continuously by means of the plant’s digital twin. This means that glass- makers can apply advanced data analysis Digital data can be used to simulate commissioning – which makes it possible for the actual production system to get procedures to predict when a component off to a “flying start.” During operation, the gathered data is continuously analyzed in order to optimize production. will fail. The glassmaker can service or change out the part at the optimum time and prevent damage and production down- data that the ­manufacturing process gener- the course of product and systems design. time as part of a formal preventive mainte- ates and put it to intelligent use – which This data has been retained by the machine nance program. Many OEMs are already makes it possible to digitalize the entire and plant manufacturer. The plant operator offering this to customers as a service. plant with an Integrated Engineering ap- usually begins with no previous data gener- proach. All data is available centrally and ated prior to production start, but a digital in real time. That means users can use the data transfer – taking all ­relevant security identical virtual image of a system that was issues into account (see box on page 9) – generated in the engineering process to is conceivable: When plant operators buy simulate commissioning, operation, and the plant section, they can also buy the maintenance, and to optimize them in real data and use it for the production phase. time. In other words, to make the transition This “flying start” could significantly shorten from Integrated Engineering to Integrated time to market. Operations. Other elements that support a plant’s successful transformation into a Planning tools generate large volumes of Digital Enterprise are industrial communica- data that image the plant while the entire tions networks, industrial security solutions, plant is still in the planning phase. The plant and data-based services. is simulated and tested virtually, for exam- ple, using Simit software. These findings can Actual implementation again be fully incorporated into the actual All equipment supplier work with computer commissioning, enabling the plant operators assistance, and they develop valuable data in to constantly expand their digital know­ Simit makes it possible, for example, to simulate the control process for furnace firing.

5 GlassFocus 2016 | Focus on digitalization

Siemens’ Data-Driven Services Data analysis and processing are what turns big data into smart data – which is exactly what Data-Driven Services from Siemens achieves. The goal is to support business decisions and optimize services on the basis of transparent production and business ­processes.

“Energy Analytics” involve focused data gathering and meaningful analyses that can lead to substantial energy savings.

Another emphasis is “Condition Monitoring,” which monitors systems while they’re in operation. This process particularly supports the availability of machines and systems. Detecting and analyzing the right data makes it possible to respond early to material wear and other disrupting factors as part of planned preventive maintenance.

A third area is comprehensive security solutions that reliably protect the full array of information and communication technology at industrial plants against cyberattacks from outside and disruptions from inside.

Another data-based service is “Control Performance Analytics.” It gathers process and condition data from control loops in the Simatic PCS 7 process control system. Siemens experts analyze the data and derive recommendations for action. This provides companies with transparency about their control loops and enables them to take appropriate steps to enhance efficiency, quality, and throughput.

Software Plant Simulation from the Tecnomatix portfolio enables the simula- tion of the production process in the

All photos: Siemens AG All photos: entire glass line.

Step by step tional process information to a controller. but also provide more efficient use of en- As sensible and useful as digitalization is, it Even if the additional temperature or pres- ergy and resource. Operations in a virtually is difficult to fully implement it in an exist- sure data is not crucial for the plant’s opera- tested plant run smoothly, preventive main- ing system overnight. It is more effective to tion initially, it may help save energy or tenance averts downtime, and rejection take small steps that promise success in the improve glass quality by maintaining con- rates drop. The possibilities are significant. short term. It is conceivable that operators stant temperature and pressure in the might choose one part of a system first, like furnace. A small intervention or investment Analyzing digital data can also help plant the melting furnace. In a first step, they can yield tangible success, and that is how operators adapt quickly to market require- could use the digital data that the furnace the plant can be gradually digitalized. ments, and make the right strategic busi- sensors are already generating. In a second ness decisions. Product changes can be step, they could record and analyze an These scenarios make it clear that the intel- initiated at the right time, and be imple- additional temperature or a pressure, and in ligent factory of the future will not only mented quickly. For instance, a glassmaker a third step, they could connect this addi- enable greater flexibility and productivity, can use Plant Simulation to simulate how

6 Focus on digitalization | GlassFocus 2016

Digital services Digitalization also includes all services for customers, and therefore changes how equipment suppliers define themselves. Now OEMs can support plant operators better than ever in delivering the perfect glass for their customers – just in time, and at the lowest possible cost. These possibilities are creating new business models and customer relation- ships, as in preventive maintenance. With Lifecycle Analytics, Siemens offers an analyti- cal software solution for remote preventive maintenance. It also makes it possible to define the operating data that can give manu- Why do they call it Industrie 4.0? facturers useful tips on how to improve their The fourth industrial revolution was preceded by three other industrial revolutions products and their production. Siemens founded on the invention of the steam engine, the electric production line, and the supports equipment suppliers, and everyone introduction of the computer. Friedrich von Siemens started the industrial revolution in the glass industry exactly 160 years ago by inventing the regenerative furnace in 1856. involved in the glassmaking process can work together closely. Digitalization offers a signifi- cant benefit to all involved parties.

New business models for OEMs In specific terms, digitalization can mean that when plant operators buy from their equip- ment suppliers, they are not just buying the equipment but they are acquiring the associ- Model Predictive Control (MPC) in a process control ated planning and design data. Customers manufacturer (also see information about system. Optimized control of furnace heating enhances may not buy individual process operations, MindSphere in the box on page 9). energy efficiency and reduces wear. but rather production performance. They run the machines or process units, but they don’t Working in collaboration with the operator, own them. The use of leasing models is manufacturers would gain deep insight into different products can be produced most prevalent in many industries. What’s new is how plants operate. They can identify weak efficiently, or determine if there is value in the potential for digitalization, which opens points and advise their customers accord- manufacturing a new product in the exist- up new business models in the glass industry. ingly. Intellectual property and expertise can ing plant. Producers can respond appropri- be protected. New business models will ately depending on market demand. Thanks In the future the story wouldn’t end with emerge if the equipment supplier has digital to digital production systems and produc- simply developing, making, and selling a data available. For equipment suppliers, it’s tion data, it is possible to implement cus- furnace or cutter. Instead, the product would an excellent opportunity to continually tomer change requests on short notice, only be the beginning of the business model, ­service and enhance their customers. Plant under control, in a reproducible manner, because the equipment supplier would equip operators will also appreciate and benefit with documentation of systems technology the product with sensors that would continu- from the digital value added and be willing at the right place and time in the process. ously record data and transmit it back to the to pay for it.

7 GlassFocus 2016 | Focus on digitalization

“Digitalization starts when the first person in the chain works with a computer.”

Oliver Krapp, head of the glass business at Siemens

Just to clarify further, here is an example of preventive maintenance from another industry: The Siemens Mobility Data Service Center in the Munich suburb of Munich- Allach monitors hundreds of trains world- wide and also gathers data. The Siemens experts can predict malfunctions on the basis of changes in temperature, rotational speed, or vibration in the axle bearings and order maintenance on the trains before they get stranded en route. This help from Munich keeps high-speed trains like the Siemens AG Velaro E between Madrid and Barcelona on time 99.9 percent of the time.

Looking outside the box In this last instance, the smelter manufac- Using data strategically Pioneering companies have already discov- turer would guarantee that the plant If you want to stay ahead of the competi- ered these “disruptive” business models for ­operator gets the required smelting power tion, you need to make entrepreneurial themselves in other industries. Rolls-Royce at the agreed quality. It can promise this decisions at the right time – and digitaliza- is selling propulsion, instead of turbines, to because it can be certain from digital data tion is providing new and compelling oppor- airlines and calls the concept “Power by the and virtual tests that the furnace can be tunities to support them. You have to get hour.” Machine builder Kaeser is offering operated at optimal efficiency. It is also the right data from various sources continu- compressed air instead of compressors: It conceivable that the furnace supplier might ously, in real time, and analyze them. For bills only for the cubic meters that the offer customers efficiency-enhancing up- that you need intelligent sensor systems, customer actually consumes. grades. It can develop them because remote standardized communication among the monitoring enables it to analyze data from various systems, and central archiving in a Transferred to the glass industry, scenarios the furnaces in operation, and see where database – all of which are components of like these could be conceivable: billing for there is potential for optimization. An the concept of plant-wide automation. This batch output instead of the batch-making ­additional service might be to offer end is the foundation of all the scenarios de- equipment. Kilometers cut instead of the customers remote control of the smelting scribed here, as well as for the vision of cutter. Smelting power instead of smelters. process. Industrie 4.0.

8 Focus on digitalization | GlassFocus 2016

Most of the IT solutions needed for this vision are already available today. Yet a lot Security a top priority of interfaces still need to be defined and Many equipment suppliers and plant operators greatest possible transparency about the secu- have understandable concerns about the secu- rity of their industrial system, and therefore standardized. Siemens provides support rity of digitalizing processes and releasing data optimal protection for their investments at all from its portfolio in every area, so that to partner companies. Even in a networked times. “MindSphere – Siemens Cloud for plant operators and providers can master online world, business and product secrets must Industry” provides an open cloud platform. Data the transition to Industrie 4.0. Comos makes be securely protected. Many strategic ideas for is hosted on servers at SAP computer centers in it possible not only to plan the entire plant the future won’t be implemented without Germany, where all customers are covered by in terms of process engineering, but also to cybersecurity. Siemens offers its customers the same rigorous security and data protection comprehensive security solutions and a secure standards. An on-premises solution is envisioned set up and manage the database for the infrastructure for Internet-based communica- for the future, when data will remain at the digital twin – a database that will also have tion. “Plant Security Services” help minimize customer’s site and be processed via MindSphere a wide variety of other uses later on. For risk. This holistic approach is based on the latest remotely. In addition to these technical features, example, Simit and Comos Walkinside are technologies and on applicable security regula- it’s very important for MindSphere users – useful for virtual commissioning and plant tions and standards. Threats and malware are whether they are plant operators or equipment simulation, including training the operating detected quickly, weak points are analyzed in suppliers – that whoever produces the data still detail, and appropriate and comprehensive owns the data. Only the owner can decide what personnel. The Simatic PCS 7 process con- security measures are initiated. Continuous data will be transferred to MindSphere and who trol system has engineering interfaces that monitoring provides plant operators with the can access it. constantly gather and expand the digital data from these and other tools. Simatic PCS 7, in turn, is the interface to the higher- level systems like manufacturing execution NX CAD tool. During the actual production Digitalization: a necessity systems (MES), management information phase, the automation tools based on Digitalization is the most effective strategy systems (MIS), or enterprise resource plan- Totally Integrated Automation (TIA) enter for improving your competitiveness. It will ning (ERP). the picture. soon be a necessity in many industries including in the glass industry. Digitalization When it’s not a matter of designing a com- Another tool’s strengths come into play enables companies to make decisions plete plant but planning and designing when digital information from the entire ­quickly and knowledgeably, with an un- plant sections and products, the Digital plant is going to be processed for various heard-of level of quality based on facts. Enterprise Software Suite offers a compre- target groups during operation: XHQ Opera- This taps new opportunities for optimizing hensive portfolio of consistent software tions Intelligence filters and processes a the cost of operations throughout a plant’s tools. The heart of the software suite is vast range of technical and business data lifecycle. There’s an important message Teamcenter, Siemens’ platform for collabo- from a plant or a company’s production that needs to be heard in all discussions of ration. It provides the foundation for all the chain. Operating staff and managers can digitalization and Industrie 4.0: Digital data mutually compatible programs and tools watch the plant’s performance in real-time will be used only as far as people want it from the Siemens Digital Enterprise Soft- and compare it against business targets. to be used. On the path to creating the ware Suite throughout the plant sections’ That enables users to make informed deci- Digital Enterprise, it is crucial to have every lifecycle. In the development phase, this sions about plant performance and neces- employee on board – because they are the includes software programs from the Prod- sary measures regarding plant availability. ones who have to work with the new tools uct Lifecycle Management (PLM) portfolio, The close integration of Comos Plant and systems. So it is always advisable to ask which can be used to develop and optimize Lifecycle Management solutions and the for ideas from within your own company new products virtually. They include the ­Simatic PCS 7 process control system means and thereby encourage your own team to Tecnomatix development program and the that real-time information is jointly shared. accept change.

9 GlassFocus 2016 | Focus on digitalization

“A source of ideas and solutions, and a trendsetter” All photos: Zippe All photos:

Dr. Bernd-Holger Zippe, Chairman of the VDMA Glass Technology Forum, a Dr. Bernd-Holger Zippe, Dr. Zippe, how important is digitalization own control philosophy. So it’s important to ­department within the VDMA to the Glass Technology Forum? find appropriate, practical approaches in this Construction Equipment and ­Chairman of the VDMA Glass Dr. Bernd-Holger Zippe: We are deeply area. Approaches that will provide an end- Building Material Machinery Technology Forum, thinks the involved in this area. All of the control to-end control solution and an end-to-end Industry Association (VDMA- systems used by all our member companies flow of information. Fachverband Bau- und German mechanical engi- operate on a digital basis. And for the glass Baustoffmaschinen). neering industry is well industry, networking individual production Where do you see digitalization providing equipped for the digital age. sequences within a glass foundry will be- the greatest added value for mechanical come more and more important. Of course, engineers in the glass industry? this isn’t completely straightforward when it Dr. Zippe: I think the greatest added value comes to the suppliers to the glass industry, for our customers will lie in the fact that since almost every supplier company has its networking will enable different areas of the own control department and thus also its plant to communicate with each other. Our

10 Focus on digitalization | GlassFocus 2016

member companies, Zippe Industrieanlagen point. Likewise, customers can be offered an share data and to have visual access to other for example, have already implemented this evaluation of the recorded data. Following a areas within the glass works. approach by putting in place the plant-wide detailed analysis, process parameters can be automation concept. With this system, data improved to help increase quality, while What would you like Siemens to provide can be exchanged between different busi- saving both time and power. Networking, in the future? ness areas to optimize processes, save for example, also makes it possible for our Dr. Zippe: I would like Siemens to take its energy, or improve product quality. member companies to provide support for range of products and services further and customers by connecting to the control continue developing innovative engineering Can you offer some examples? system using remote access (VPN). tools. Our member companies are always Dr. Zippe: Targeted monitoring can reveal if interested in using solutions that will help one particular machine is using more power. What are the main challenges that still them implement glass industry projects with The cause could be a worn bearing, which have to be overcome? a high level of efficiency. From a sales will cause power consumption to increase. Dr. Zippe: I see the digital transformation as aspect, there needs to be a greater aware- The appropriate countermeasures or preven- extending from more efficient engineering ness of the need for innovative solutions tive maintenance can help deal with prob- to plant manufacture, not just in imple- among our end customers. Integral solu- lems like this. Or to take another example, menting projects for our customers. As I tions and the networking of individual plant targeted information from the batch house understand it, digitalization and Industrie areas have not yet developed into a compre- and preheating can flow into the control 4.0 also relate to the different divisions hensive standard. This is where I would like system at the melting end. The data of inter- in-house. Mechanical and electrical engi- Siemens to provide support. est here are the batch and cullet ratio and neering of glass industry systems, for ex- the batch temperature at the inlet. Staying ample. In these areas, the engineering tools Dr. Zippe, thank you for the interview. with the batch houses for a moment, the are growing closer and closer together. proportioning time is always an important More efficient interfaces ensure that data aspect. Monitoring the proportioning as- and information are available across divi- semblies makes it possible to recognize and sional boundaries. End-to-end consistency

All photos: Zippe All photos: rectify any negative trends at an early stage, of engineering data prevents extra work and such as lengthy proportioning times or increases efficiency. And digitalization and problems with raw materials. Interpreting simulation can enable the initial results to all this data properly lets us always be sure be viewed right at the development stage, VDMA member companies are we have set the best plant run times and or will let you take early corrective action at already using software tools for parameters for proportioning. the engineering end. project development. Without these tools it would be much harder to Do you think digitalization may even lead What role do you see for Siemens in achieve plant-wide automation. to new business models? ­digitalization? Dr. Zippe: I’m absolutely certain of it. With Dr. Zippe: I look at Siemens as a supplier, a regard to the plant-wide automation con- source of ideas and solutions, and as a cept, for example, service providers function trendsetter. Our member companies are as system integrators. Interfaces will have to already using software tools for project be defined here, to make it possible to development. Without these tools it would combine projects by the various OEMs to be much harder to achieve plant-wide form a multi-project. There is a greater need automation, for example. Standardized for a qualified solution provider at this interfaces for different OEMs make it easy to

11 GlassFocus 2016 | Focus on digitalization

Glass Futures – the name says it all Glass Futures Glass

Alistair Wallace, WilkinsonEyre All photos: CEO of Glass Futures.

The ambitiously conceived Mr. Wallace, as CEO of Glass Futures you be for production, and the fourth for virtual are literally designing the future of the ­simulation and augmented reality. “Center for Vitreous glass industry. What exactly is your plan? Materials” in northern Alistair Wallace: Over the coming five Mr. Dalton, as CEO of British Glass you England will seek to virtually years we will be building a campus in are presumably enthusiastic about these ­northern England following the theme of plans? simulate the entire glass “Glass Futures.” On 4.5 hectares of land, Dave Dalton: Definitely! Some €130 million manufacturing processes – four Centers of Excellence will be estab- will be invested over the coming years that lished that will be managed by Glass will generate benefits for the entire glass creating a blueprint for other ­Futures and operated with the help of community worldwide. What’s more, about industries as well. selected industrial partners. One will be 150 jobs for highly qualified workers will be British Glass British dedicated to research and development, created, which is important for Britain’s Dave Dalton, ­ another to education and training, one will domestic glass industry. We’re eagerly CEO of British Glass.

12 Focus on digitalization | GlassFocus 2016

A closer look at digitalization The people responsible for the “Glass Futures” project would like to be the first industry in the UK to virtually simulate entire production processes. Siemens technol- ogy will provide the basis for exploring every possibility that virtual and augmented reality can offer.

looking forward to applying the concepts of UK. We thought about a “Glass Academy.” technology, and expertise can be used to

Industrie 4.0 to the glass manufacturing At that time we also sought advice from reduce CO2 emissions in future production industry here in the UK. Siemens, and at meetings it quickly became processes. apparent that we could actually go for Dalton: The support Siemens is providing What will be the future centerpiece of something bigger – and that’s how the idea has been invaluable to us. We’ve managed the campus? for “Glass Futures” came about, a Center of to save about nine months of valuable Wallace: The centerpiece will be a fully Excellence for glass manufacturers and time just through their consulting, support, functional, industrial-size furnace that their customers that would simultaneously and many insights. We also find their anyone can rent for research purposes. On be attractive to scientists and academia. ­corporate culture very refreshing because a smaller scale, we will also be constructing Wallace: Siemens really inspired us with our contact people there are always sharing production buildings for special glass, their vision for the glass industry. Because their v­ isionary ideas with us and giving us fiberglass, hollow glass, and float glass. ultimately, the technological horizon is not ­ongoing encouragement. Ideally, research outcomes will quickly yet in sight – we can still make a lot hap- produce prototypes that, in turn, will pen, both for and within the sector. What will the Center for Virtual Simula- Glass will also play a leading role in promptly turn into mature, market-ready tion and Augmented Reality be all about? the buildings’ architecture in terms products. How is Siemens involved in your project, Wallace: That is our most ambitious sub- of design, functionality, and ­sustainability. Dalton: While we’re aware that some manu- specifically? project. We want to be the first industrial facturers have their own research facilities, Wallace: Siemens is our technology part- sector in the UK to virtually simulate entire the needs-based provision of this kind of ner, and therefore acts as a door opener for production processes. Based on Siemens opportunity is something unique that others. It’s helpful for us when we can technology, we’re banking very heavily on promises to be very much in demand. More- proudly declare to potential partners that the possibilities of virtual and augmented over, it’s the holistic approach of the cam- Siemens has also promised us financial reality. pus that will promote and advance the support. industry: We’ll be sharing and disseminating And when will construction of the Dalton: Right now we’re discussing what Partners for production, technology, and management ­campus begin? concrete things Siemens can do to lend us “Glass Futures” expertise. Dalton: Optimally, we hope to start this more support – for example, with automa- As of today, the following year. But even if construction of the build- tion and drive technology and in the fields business enterprises and How did you actually come up with the ings is not completed, we’ll begin work in of building services technology and traffic organizations have already idea for “Glass Futures”? 2016. pledged their support: management, and also with training. Dalton: It was at the end of 2012 that we Siemens, Guardian Indus- originally started giving some thought to Wallace: For example, we’re working with Mr. Wallace, Mr. Dalton, thank you very tries, the University of Leeds, and British Glass. Others will how specialized training programs for the Siemens UK to perform “audits” that will much for speaking with us! follow soon. glass industry could be established in the help us find out how Siemens equipment,

13 GlassFocus 2016 | Focus on digitalization

Premieres and prizes with the Panther project

System integrator A&E Engineering and Siemens ­pro­vided plant-wide automation for the most advanced glass veil line at Owens Corning (US) and introduced Simit for ­simulation and training purposes. Siemens was given the Value Creation Award for its work on the project.

When the subject of the Panther project a range of international OEMs and define comes up, everyone involved goes into programming standards. Other milestones raptures. There’s a lot to celebrate: The included the completion of Factory Accep- construction of the most advanced glass tance Tests (FAT) in June 2015 followed by veil line at Owens Corning involved numer- the manufacture of the first veil materials ous premieres and prizes. The new facility by Owens Corning in February 2016. “The in Gastonia, North Carolina, also serves as most important element was the close a center of excellence for Owens Corning’s professional collaboration across national glass-reinforced nonwoven materials busi- and local boundaries,” says Chip Brown, ness in North America. The plant produces Senior Project ­Manager at A&E Engineering, a thin sheet of glass-reinforced material, looking back at the project. called veil, which is used in cushioned Owens Corning built its vinyl flooring, suspended ceilings, gypsum Efficient simulation and training ultramodern glass veil wallboards, and carpet tiles. The company with Simit production system in is based in Toledo, Ohio, and specializes in At an earlier stage of the project, Owens Gastonia, North Carolina, and equipped it plant- insulation, roofing, and fiberglass compos- Corning had opted for a Siemens solution wide with hardware and ites. based on Simatic S7-400F PLCs and the software from Siemens. Simatic WinCC/Siemens Industry Library for System integration on a global scale the graphic representation component. An As system integrator, A&E Engineering was overarching Profinet network was designed All photos: Owens Corning Owens All photos: first engaged in August 2014 to coordinate and implemented using Scalance switches.

14 Focus on digitalization | GlassFocus 2016

Owens Corning is based in Toledo, Value Creation Award for Siemens Ohio, and specializes in insulation, Owens Corning honored Siemens with the roofing, and fiberglass composites. Value Creation Award, which is given only to suppliers that provide measurable added value with their products and services. This project involved plant-wide automation, the To facilitate the precommissioning tests for use of Simit, coordination between OEMs, the programming and graphic representa- and “the impressive services from Siemens” – tion, a test system was set up at A&E in conjunction with Siemens Solution Partner ­Engineering with four Simatic S7-400 PLCs A&E Engineering. with a fail-safe CPU 416F. These were inter- connected with each other and the OS server using a Profinet network. The OS server was also connected to a number of operator stations to display and test the user interface. The Simit simulation frame- work was used for basic I/O simulation with “narratives” were developed and pro- “ Simit proved to be a highly efficient process custom charts for easy manipulation of the grammed in Simit. The goal was to have ­variables as required. a user sit at a computer viewing the same simulation tool for precommissioning, graphics used in the real environment and factory acceptance testing, and training, A&E has learned from other customer interacting with identical versions of the projects that Simit is invaluable for discov- real PLC programs. The user would be able and therefore is a success factor for us. We ering and rectifying problems in addressing, to go through the same start-up procedures will be sure to use Simit for all projects like programming flaws, graphics malfunctions, and witness the realistic dynamics of the and basic configuration errors – all in a glass veil process. The operator also asked this in the future.” relatively safe environment where correc- for additional specially designed user tions can be easily made. “Furthermore, screens for training purposes. Users can Wim Weeres, when used in conjunction with client-­ select any one of 10 unknown process Technical Director for the nonwoven business at Owens Corning observed Factory Acceptance Testing, “disturbances” that are introduced into conflicts and errors in the basic functional the system via Simit, and they are then requirements can be discovered early and required to identify the nature of the The manufacturer uses the Simit fixed quickly,” says Brown, who headed the ­“disturbance” and take the necessary simulation framework for process ­Panther project for A&E Engineering. “That corrective action. simulations. It allows them to identify errors in addressing, would all take four to five times as long programming, graphics, and basic during the actual commissioning process in To accomplish this, A&E provided a Simit configuration at an early stage, and the field.” solution in conjunction with the new it also provides intensive training for Virtual Controller (VC 3.0). This enables a users. Simit also plays a very important role in PC to be used instead of actual PLC hard- user training. Owens Corning wanted a ware, with the real PLC program being training system that was self-contained loaded onto the VC. Simit is directly con- and capable of mimicking dynamic process nected to the VC and makes the necessary conditions as closely as possible. Simulation I/O functions available.

15 GlassFocus 2016 | Focus on digitalization

Full speed in the digital transformation All photos: Fuyao All photos:

How the largest Chinese Mr. Geisinger, the Fuyao Group is rapidly tion of vehicle windshields in a highly increasing the pace of its global expan- automated process. It will also perform automotive glass sion. Can you list the most important overmolding of side windows with TP/PVC manufacturer, Fuyao, is milestones over the past three years? and encapsulation of glass sunroofs with accelerating its global growth Norbert Geisinger: That’s right: In 2013 we polyurethane foam. If everything goes opened the first factory for completing according to plan, we’ll be able to put the with highly automated and automotive glass production outside China, plant into operation in October 2017. Our networked systems. An in Kaluga in Russia, and then another in production and storage area will then total Dayton in the US in 2015. This year we’ve approximately 40,000 square meters. interview with European CEO acquired an 85,000-square-meter site near Norbert Geisinger. Heilbronn. How important is this major expansion of the German location for Fuyao? Norbert Geisinger, Can you reveal any more details at this Geisinger: Germany is definitely the most CEO of Fuyao Europe GmbH. stage? important market for Fuyao in Europe, Geisinger: Starting in October we’ll be which is why we set up Fuyao Europe in building a new plant there for the comple- Heilbronn back in 2007. Right now we’re

16 Focus on digitalization | GlassFocus 2016

Milestones and plans at the Fuyao Group

First factory for the Construction of a new completion of plant near Heilbronn for automotive glass the highly automated outside China completion of vehicle opened in Russia windshields and many other processes

2007 2015 Plans

2013 2016

Establishment Second factory for the Construction of of Fuyao Europe completion of automo- another site in in Heilbronn tive glass outside China Mexico and in opened in the US the medium-term future a full processing automo- tive glass plant in Europe Digitalization under the microscope The Fuyao Group will implement everything that’s currently feasible and practical in alignment with Industrie 4.0 at the greenfield plant near utilizing a total area of about 15,000 square What about digitalization? How can Siemens partner you along Heilbronn. Siemens will meters for the manual completion of Geisinger: In the new building we will this path? partner with the company ­vehicle windshields; the planned enlarge- implement everything that is currently Geisinger: In Siemens we see a highly in factory planning and ment of the site is therefore substantial. feasible and practical in alignment with competent partner that is extremely experi- networking. However, I must be clear that our market Industrie 4.0. enced in virtually all areas. That’s why share in Europe is still very low, but we Siemens will partner with us in the areas of aim to reach 20 percent in the medium What expectations do you have? factory planning and networking. The issue term. Geisinger: A lot: Thanks to digitalization we of plant-wide automation is of great impor- will be able, for example, to trace our prod- tance to us. As a Chinese company in high-tech ucts. Our production processes will also be ­Germany, you will certainly attract significantly optimized. Basically, in the Mr. Geisinger, thank you very much for ­attention … future we’ll be able to interconnect and speaking with us! Geisinger: Yes, in the positive sense. Our control our process with the appropriate German customers in particular will very tools. We’ll be able to access all essential much welcome this step. And for us it’s a factory data from anywhere, and planning very important strategic project. reliability at Fuyao will increase significantly.

17 GlassFocus 2016 | Focus on digitalization

Solid reasons for ­digitalization All photos: Lathi Precision Lathi All photos:

Jarmo Näppi, Vice President of Glass Technology How Jarmo Näppi is getting Mr. Näppi, the glass industry has a rather zation. That’s why we want trailblazers that at Lahti Precision. conservative reputation. How are you others will follow. the Finnish batch-house approaching the issue of digitalization? ­specialists at Lahti Precision Jarmo Näppi: You’re right: Like other tradi- It feels like the right moment has come. in shape for Industrie 4.0. tional industries, the glass industry takes a Would you agree? bit longer to pick up on and embrace new Näppi: Definitely: because even individual technologies. But if we can demonstrate that components are being designed as smart operating costs can be significantly reduced devices. No longer are process control plat- over the lifecycle of a manufacturing facility, forms the only systems that are able to then there will be no getting around digitali- communicate their status; networked s­ ensors

18 Focus on digitalization | GlassFocus 2016

and actuators can do this as well. Entirely in and coverage. What’s more, the Finnish art platforms and components for demand- keeping with the Internet of Things, our Siemens team provides us with excellent ing automation projects. It’s therefore my customers will soon be able to access our support in a spirit of partnership. wish that Siemens continues to invest in R&D, scales data from a cloud service. as they’ve been doing all along, while leaving What would you like to see in your future room in the market for customer-oriented How will this change your business? collaborative efforts? niche solution providers like Lahti Precision. Näppi: As a fairly small company, we are Näppi: The best thing Siemens could do agile and can quickly assimilate new tech- would be to continue offering state-of-the- Thank you very much, Mr. Näppi. nologies and transfer them to our core business. And we’re in the thick of an ongo- Lahti Precision is a Finnish company ing transformation that will undoubtedly specializing in bulk materials change our business. It’s possible that every- handling that employs a workforce of 150. The firm’s core competencies thing in the future will shift more toward include materials dosing, weighing, service provision. and mixing as well as handling and services. Lahti’s customers originate How would that look? not only in the glass industry: The Näppi: For example, our customers could gypsum, cement, and other process view important performance parameters industries also s­ trongly value Lahti as one of the world’s leading online, regardless of location or time of day vendors of house-batch, gypsum, – even from mobile devices, if secure data and cement handling systems. transfer is ensured.

How is Siemens supporting your efforts? Näppi: As a Solution Partner of Siemens, we’re of course always keeping pace with the newest trends, and we greatly appreciate sharing ideas and information with Siemens and its other Solution Partners. Even more important for us, however, are the training courses and product presentations by sales. Reference customer Park Cam Since the early 1990s it’s been a pleasure to As a newcomer to the glass industry, the Ciner Group in Turkey be able to count on Siemens to help us meet founded the company Park Cam and established a complete our glass customers’ needs, relying very production line equipped with two furnaces for making glass bottles. Lahti was contracted to supply a batch-house processing frequently on automation and control sys- system and cullet return system. The highly productive glass tems as well as drives, converters, and field factory is the most modern of its kind in Turkey, benefiting from a devices from Siemens. comprehensive, end-to-end automation and drive solution as well as radar-level measurement methods based on Siemens What is it, generally, that makes you opt technology. The factory management and owner can access all for Siemens? performance parameters via a cloud service at any time and from any location. The facility is considered to be an exemplary model Näppi: When you invest in Siemens technol- of a networked factory. ogy, you’re investing sustainably. For me personally, I value the availability, reliability,

19 GlassFocus 2016 | Focus on digitalization

For the first time, the US company Gallo Glass chose the plant-wide ­ Successfully enter- automation concept from Siemens for the conversion of its plants.

ing new territory meant one interface less and a seamless solution, the demand on the operators is automation concept.” significantly reduced because the new system, including the control system, is fully Gallo Glass implements solution for plant- redundant: weighing, mixing, and transport wide automation for the first time with to the tanks. The result is a tremendous Siemens increase in flexibility and operating reliability With the now completed upgrade of the at Gallo Glass. batch plant at the glass production facilities located in Modesto, California, EME was Virtual commissioning with Simit able to go one step further on behalf of its In addition to its first-time use of Simatic customer and implement an end-to-end, PCS 7, EME also successfully premiered Simit. cross-supplier automation system based on “The Gallo Glass plant is so complex that All photos: Rumans Photography Rumans All photos: the Simatic PCS 7 process control system. Simit was essential for us for conducting “The switch to Siemens was new territory tests and evaluations. It optimized our engi- for Gallo Glass,” says Knüttel, stressing the neering and substantially shortened the Gallo Glass was The total package tipped the balance: To importance of the project. It was a complex commissioning time,” says Knüttel. “We’re modernize its plant during operation, the US task, especially since there are several positively astounded by the simulation the first place that glass manufacturer, Gallo Glass commis- hundred different combinations and trans- platform.” the Sorg Group sioned EME Maschinenfabrik Clasen GmbH portation routes that the batch can follow implemented a to plan and upgrade the batch plant and within the batch plant and on its way to the Praise from all sides parts of the cullet return system at its glass melting tanks. With the Siemens Siwarex U Gallo Glass’s converted plant has now been solution for plant- bottle production facilities. Because these and Siwarex FTC weighing modules, it was in operation since August of 2015, and the wide automation projects are always accompanied by an also possible to integrate weighing applica- company has been impressed by EME’s automation system, Siemens also partici- tions directly into the automation system. consulting, project planning, and implemen- based on Simatic pated as a longtime supplier for the Sorg tation services. The excellent support PCS 7, and their Group. “What was probably decisive was Redundancy for greater flexibility and throughout all project phases was especially initial experiences that, with the batch plant from EME and the operating reliability important to the plant operators, a compli- melting tanks from its sister company Niko- Originally, the four melting tanks in opera- ment that EME gladly passes on to Siemens: with Simit were laus Sorg, we were able to supply core tion were supplied by two batch plants, with “Siemens’ products and especially its support excellent. technology from a single source,” explains the tanks assigned to a specific plant. This are exemplary; there isn’t a competitor that Roger Knüttel, Manager of the Control meant a relatively high deployment of staff comes anywhere close,” says Knüttel. Engineering Department at EME. “This to operate the two plants. With the new

20 Focus on digitalization | GlassFocus 2016

Digitalization up close “High level of trust” Thanks to Siemens’ modern development and project- planning environments, EME Roger Knüttel from EME Maschinenfabrik Clasen GmbH, on plants can be planned and the benefits of digitalization – based on the example of Simit. tested in about one-third of the time compared to just 15 years ago.

Mr. Knüttel, when was your first encoun- third of the time. Just 15 years ago it took us ter with digitalization at EME? three times as long. Roger Knüttel: In 1994 the Sorg Group – and therefore we at EME – became the first What else impressed you about Simit? EME specializes in the networking of batch plants to recognize the possibilities and implement Knüttel: In addition to faster commission- and melting tanks. the philosophy of plant-wide automation in ing, it was the obviously higher engineering the glass industry. We’re still committed to quality, lower costs, reduced risks, and the this philosophy today, and we operate fact that we could use Simit to train accordingly. I would say that plant automa- ­customer personnel. tion based on this principle is one of EME’s distinctive characteristics. Do you see even more potential for platform and making it your standard re- ­plant-wide automation? quires a high level of trust and a mutual What are the areas where you think the Knüttel: Our main focus is on the plant- partnership. principle of digitalization especially pays wide automation of batch plants and melt- off? ing tanks – but we’re also interested in What would you like to see from Siemens Knüttel: In virtual commissioning and plant integrating other parts of the glass factory in the future? simulation with Simit. But we also benefit at the customer’s request. Knüttel: As a Group and world leader in from the template-supported automated automation solutions, Siemens should planning of plants using modern control That must be difficult sometimes, isn’t it? respond even more vigorously to market systems like Simatic PCS 7 and Simatic S7 Knüttel: Ultimately, it all depends on eco- demands and convert them into new prod- with Simatic WinCC AS-OS transfer. nomic factors as well. We have to find the ucts – entirely in line with Industrie 4.0. areas that make economic sense and offer I think it’s important that Siemens under- Can you quantify the added value? the user added value. stands the demands that the batch process Knüttel: With Simit, we’re able to test our places on automation, which the experts at All photos: EME All photos: plants and put them into virtual service How can Siemens best support you in EME are extremely familiar with, and work beforehand, with no mechanical or electri- this? with EME to further optimize the specific Roger Knüttel, Manager of the cal hardware involved. Faults are detected Knüttel: With good consulting and support solutions. Control Engineering Department, and corrected and the actual commissioning services and intelligent, networkable prod- has been with EME since 1992 and established the Control time at the building site is significantly ucts. And by continuing the intensive, Mr. Knüttel, thank you for speaking Engineering Department there. reduced. Thanks to Siemens’ modern devel- productive collaboration with our automa- with us. opment and project-planning environments, tion experts. Siemens is definitely a key we can plan and test plants in about one- supplier for EME. Choosing an automation

21 GlassFocus 2016 | Focus on digitalization

More ­transparency on the scales

Requirements for a modern weighing solution in the age of digitalization. All photos: Siemens AG All photos:

The answer to increasingly networked production: the new Siwarex WP521 ST electronic weighing module from Siemens.

Weighing and metering technology plays an antee high operating reliability and simple crucial in the choice of an appropriate solu- important role in batching plants, from the operation. These functions are usually ad- tion architecture. vehicle weigh bridge through static weight dressed by autonomous systems that are measurements of silos, and metering the connected to the process controller via many Automation with integrated weighing batch in the mixer to recording and control- different interfaces. However, in the age of and metering technology ling delivery volumes on conveyor belts. digitalization, factors like the consistency of As a specialist in automation technology, In addition to the usual requirements for hardware and software, standardization of Siemens views the weighing process as an measuring technology and reproducibility components and tools, and flexibility play a integral component of the control system specific to scales, it’s also necessary to guar- central role. As a result, they are increasingly and offers a comprehensive range of

22 Focus on digitalization | GlassFocus 2016

With its Siwarex portfolio, Siemens meets all the requirements of a modern weighing Seamless integration in the Simatic PCS 7 control solution in the age of digitalization. system with the Siwarex functional modules.

­hardware and software: the Siwarex product sible by existing, multilingual standard Siwarex complete portfolio for weighing family. It is fully compatible with the Simatic modules. This shows how the conceptual and conveyor technology automation system, and the advantages are integration of weighing technology in Siemens has marketed components and self-evident. Direct incorporation in the modern automation systems plays a strong solutions for weighing systems for more system for end-to-end communication role in boosting the company’s success on than 50 years and has built a comprehensive makes additional interfaces unnecessary an ongoing basis. portfolio: load cells and built-in units form and allows simple scalability and expand- the basis of every weighing device. The ability of the weighing system: for example, Transparency anywhere at any time broad spectrum of Siwarex weighing elec- for the implementation of additional control In addition to the Simatic bus, the RS485 tronics meets virtually every requirement, functions on the scales. The use of standard and Ethernet interfaces offer more options either integrated in Simatic S7 or PCS 7 or as modules as well as standard software guar- for visualizing multiple weighing modules a stand-alone weighing terminal, in a com- antees an open-concept, standardized on a touch panel, or even independent of pact or higher-performance version. Belt operation and straightforward handling. location via the new Sm@rtServer concept. scales, weigh feeders, and solids flow me- Construction, function, and cross-series This enables mobile, location-independent ters cover the full range of continuous compatibility follow the Simatic philosophy monitoring and operation of all parameters weighing processes. and provide high plant availability. Tailored, and functions stored on the panel via the low-cost system integration is made pos- Sm@rtClient app on a smartphone or tablet.

23 GlassFocus 2016 | Focus on digitalization

Busbar cutting and terminal strip-place- ment machine made by W. Althaus AG.

Core component All photos: W. Althaus W. All photos:

First wiring robot worldwide at switchgear cabinet W. Althaus AG. creating the first wiring robot in the world, Althaus has been breaking new ground in the automation of switchgear cabinet con- struction. Examples of applications include “Smart manufactur- Siemens Solution Partner Althaus in Switzerland has float glass plants (modernization measures ing offers us and all made a name for itself as an automation specialis­ t in and new plants) and glass processing plants.

other small and the glass industry. A Siemens Solution Partner – with ­medium-sized auto- ­conviction mation specialists a Many years of experience in the glass W. Althaus AG is a family business in Swit- viding our customers with expert and initial- industry using Siemens products and solu- great ­opportunity to zerland that was established in Aarwangen ly system-neutral consulting, analyzing the tions – including the automation system ­become a smart in the Canton of Bern in 1968 and now has requirements in detail, planning the project Simatic S7, the visualization system Simatic value-added ­partner more than 100 employees. Its core expertise carefully, and setting high quality standards WinCC, and the motion control system is in the development and manufacture of for products, processes, and materials. We Simotion – motivated Althaus to become instead of a contract products ranging from straightforward elec- also aim to achieve a visually appealing, a Siemens Solution Partner. Althaus de- ­manufacturer that trical controls to complex automation solu- compact, yet easily accessible switchgear scribes it in a nutshell: “From our view- tions – including for the glass industry. As a cabinet solution,” states Managing Partner point, Siemens’ product range, consistency, can be substituted full-service company, Althaus offers a wide Walter Althaus. and support add up.” He continues, “Our and replaced.” range of services comprising consulting, customers report that what they appreciate engineering, system delivery, switchgear Fully automated processes about Siemens in particular is the consis- Walter Althaus, cabinet construction, installation support, For its flexible and customized switchgear tency of the solution, from the drive to the Managing Partner of commissioning, and training. cabinet production operation, Althaus relies visualization.” Ultimately, the people who W. Althaus AG on fully automated processes with optimally are profiting from this interaction between Switchgear cabinet as core component adapted depth of production. “The high Siemens solutions and the in-depth plan- “A switchgear cabinet is the core of a sys- degree of automation enables us to achieve ning and engineering expertise of Althaus tem, a machine, or a building. That’s why very high and consistent quality under in the glass industry are exactly the right we attach considerable importance to pro- competitive conditions,” says Althaus. By ones – namely, the customers.

24 Focus on digitalization | GlassFocus 2016

“Smart manufacturing ­offers a huge opportunity”

Walter Althaus on the potential of ­digitalization from the point of view of an SME and system integrator.

Mr. Althaus, if smart manufacturing is all players can now network more effec- create documentation systematically at the the recipe, what ingredients are needed? tively so that we can implement larger, right places and at the right time – with no Siemens products and Walter Althaus: To begin with, digitaliza- more efficient, and higher-quality solutions. loss of quality whatsoever. solutions in service tion of data and information is a basic Althaus is firmly committed requirement. However, digitalizing data And the actual value added from this? In what specific ways can Siemens to system neutrality. Based on consistently over the entire vertical and Althaus: We become more competitive ­support you in this transformation? its great experiences over many years, Althaus is happy horizontal process chain is also crucial. across all important parameters: costs, Althaus: With its innovative product range! to use the following products efficiency, flexibility, and finally, quality. To me, this includes technology, design, and solutions from Siemens: Wishful thinking or reality? and the availability of digital data and Althaus: From what I observe, this finding Can you offer any concrete examples? information – because this is the only way Automation system is gaining increasing acceptance among Althaus: Digitalization makes our engineer- that products can be optimally automated. Simatic S7 glass producers, plant equipment suppliers, ing faster – and also, for example, our And finally, our success is critically depen- Visualization system and also system developers. This shared switchgear cabinet production – so that our dent on qualified contact partners with Simatic WinCC understanding increases the possibilities customers can in turn use this extra time to which we continually exchange ideas. Motion control system and accelerates the trend. order from us at shorter notice or even Simotion request just-in-time deliveries. Mr. Althaus, thank you very much. Industrial switchgear What possibilities do you mean? technology Althaus: Smart manufacturing offers us What else could be possible? Sirius and Sentron and all other small and medium-sized Althaus: Think of digital manufacturing Frequency converters automation specialists a great opportunity documentation and production data. Sinamics to become a smart value-added partner Thanks to this data, we can also process Power supply instead of a contract manufacturer that can last-minute change requests from custom- Sitop be substituted and replaced. That’s because ers in a controlled and transparent way, and

25 GlassFocus 2016 | Focus on digitalization

The engineers at Grenzebach have come up with the idea of a mobile and flexible branch line and Production are eagerly awaiting market feedback. on demand

The high-tech company plans, manufactures, and delivers com- plete plants for the production and processing of flat glass with ­industrial-grade automation ­equipment for process monitoring and quality inspection.

26 Focus on digitalization | GlassFocus 2016

“Our mobile and flexible branch lines are, figuratively speaking, a promising direct line to the future.”

Roland Jenning, head of Research and Development at Grenzebach

Grenzebach relies on plant simulation from the Siemens Tecnomatix family, an object-oriented 3D software program for discrete result simulation, which can be used to create digital models of logistics systems. Roland Jenning, head of Research and Development at Grenzebach.

Industry is undergoing a period of transi- installed at the so-called cold end of the Grenzebach is now developing a concept tion, and Grenzebach has traditionally glass production line. With these analytical for a mobile and flexible branch line. “Mo- played a very active role in furthering new tools it is possible, for instance, to identify bile and flexible means that it easily fits in a trends. The high-tech company plans, bottlenecks and analyze different produc- container and can be attached and disman- manufactures, and delivers complete plants tion scenarios and optimize them directly. tled again without difficulty,” says Jenning, for the production and processing of flat describing the concept. One of the technical glass with industrial-grade automation Innovative idea of a mobile and flexible requirements for this is plug-and-play auto- equipment for process monitoring and branch line mation. Once again, Siemens is involved quality inspection. The Bavarian company With their latest study for the glass indus- with Profinet, the market-leading Ethernet- was quick to take on board the mindset try, the enterprising plant equipment sup- based system. All modules, and therefore behind Industrie 4.0. For example, it has pliers are hoping to arouse the interest of the mobile and flexible plant components, been simulating its plants for many years customers at glasstec 2016 in a mobile and have a standard and intelligent interface Digitalization under and is a pioneer in the sector. Roland Jen- flexible branch line. “The requirements of and are mutually self-configuring. Automat- the microscope ning, head of research and development, flat glass manufacturers are changing in ic network configuration of the pre-prog­ As a solution provider, relies on plant simulation from the Siemens ever shorter cycles. For example, new cars rammed add-on plant section is effected Grenzebach has already Tecnomatix family, an object-oriented 3D are always coming on the market, and this through neighborhood detection in Profi- created the basis for net- software program for discrete result simula- calls for innovative car windows,” explains net. The master computer automatically worked and smart machines, tion, which he and his colleagues can use to Jenning. Because float lines now can oper- recognizes the new branch line and its including reliable, plant-wide

All photos: Grenzebach All photos: create digital models of logistics systems. ate 24 hours a day for more than 15 years, properties, and can output the new glass automation. The company’s These models can be used for running they can only produce glass panels in a formats as the objective. “Our mobile and recipe for success is its many years of process and control “what if” scenarios without affecting exist- limited range of sizes, which must be flexible branch lines are, figuratively speak- expertise in conjunction with ing production systems. These models are known at the time of construction of the ing, a promising direct line to the future,” the expertise of partners like already employed in planning at Grenze- plant. To enable glass manufacturers to says Jenning, and he is looking forward to Siemens. bach long before the actual systems are react spontaneously to new requirements, the market’s feedback.

27 Plant operators

Siemens AG Plant operators | GlassFocus 2016

Horn Glass Industries AG From a basic operation to a globally successful technol- ogy provider for glass melting processes: Melting units and special systems are now sent out to glass manufacturers worldwide from the com- pany’s base in Plössberg. With 300 employees and over 125 years of experience, Horn Glass is a preferred system solution partner for some 440 customers in 61 countries worldwide. The associated Horn Glass is responsible for all of the plant, with its fossil-based technology for this new factory in heating technology using Central Asia. The image shows the gas or oil, electrical control production building in Plössberg. systems, and customer-­ oriented services, round

All photos: Horn Glass All photos: out the overall package.

Record order from the Caspian Sea

Horn Glass has been engaged by general contractor Tepe to fully equip a huge float glass and container glass plant in Turkmenistan.

Glass production for an entire country: ­Turkish general contractor Tepe Türkmen construction to supply the entire country that’s what the largest order in the history İnşaat ve Ticaret to act as technology with float glass and container glass in the of Horn Glass amounts to. At the beginning supplier for the construction of Turkmeni- future. of this year, Horn Glass, based in Plössberg, stan’s first glass factory. Turkmenistan, on Germany, was awarded the contract by the Caspian Sea, is investing in the new >

Siemens AG 29 GlassFocus 2016 | Plant operators

Constructing control Siemens technology used in the project cabinets at Horn Glass • The shielding gas mixing station became host to a challenging for the Tepe project. application, in which Siemens Calomat devices are used to perform continuous measurement of hydrogen and inert gases. These are very reliable in operation and provide very good measurement values. • Siemens is also a dependable partner for field instrumentation when it comes to equipping the new factory. • Powerful Siemens industrial PCs used in all the business areas of the new factory form the basis for the Simatic PCS 7 process control system. • Switches with a diagnostic capability that cover the process level in combination with the latest Simatic S7 410H controllers will be used for communication via Profinet and Profibus. • To minimize assembly and wiring effort, the Simatic ET 200iSP decentralized peripheral system provides an economical solution for this explosion-risk zone. The fail-safe, modular periphery is particularly flexible in its engineering, requiring minimal input. • Switchgear from Siemens, redundant power supply units, and drive technology using Sinamics G120 and G150 frequency converters round out this all-encompassing application.

> Horn to supply all technology needs Zippe. Horn will also be responsible for annually. The clear and colored glass pro- Ekaterina Firsova, head of department for providing technical training for future duced by the factory will be used mainly float glass at Horn Glass and project contact employees in Turkmenistan. for architectural purposes. person for Turkmenistan, is as proud as the rest of her colleagues: “We are responsible Huge capacities cover country’s needs Plant-wide automation from Siemens for all of the technology for this new factory The container glass plant is expected to be As usual, Siemens is also on board on the in Central Asia. From the sand and raw in operation by September 2017, with a basis of a contract with Horn. Plant-wide material preparation systems to the batch planned annual output of 95 million bottles, automation from Siemens enables all the house, melting assemblies, and tin bath to which equates to a daily capacity of 50 different automation solutions in the project the glass processing units, in addition to metric tons. The lines are designed to ac- associated with the different machine and storage technology. And we’re also the commodate the needs of the pharmaceuti- plant units to be integrated into an overall preferred supplier when it comes to the cal and beverage industries. The float glass system covering the entire value chain. This power ­systems.” Anything that Horn is plant will be in service from the fall of 2017, complete, modular system brings together unable to design and build itself, it buys with a target daily output of 250 metric automation, drive, instrumentation, and from selected partners like Siemens or tons, or eight million square meters of glass power technology.

30 Plant operators | GlassFocus 2016

Stephan Meindl, CEO of Horn Glass Industries AG.

And how is the second pillar looking? Meindl: Because there are only a few com- panies around the world capable of making turnkey float glass plants available, we are very positive that we will also enjoy growth in this difficult segment. A further plus is that we develop and manufacture furnaces, tin baths, and automation solutions our- selves. These are the aces in our hand as we seek to win plate glass companies with a “Two stable pillars” global ambit as customers, and expand our global locations in the process, while con- tinuing to rely on strong partnerships.

What experience have you gathered Stephan Meindl, CEO of Horn Glass Industries during the relatively short time with the This is the first time that a glass Siemens portfolio so far? production facility is being built in AG, comments on market developments and Meindl: I have been familiar with Siemens Turkmenistan. The giant float glass and container glass plant will begin the company’s strategic response. products for a very long time now. From our operations in the fall of 2017. perspective, comprehensive, plant-wide automation has proven to be highly efficient Mr. Meindl, you have been in your Which developments underlie that and convenient. Coordinating and optimiz- ­current position since 2015. What are ­viewpoint? ing processes within a single, universal, your main concerns right now? Meindl: Take the foodstuffs industry, for proven system is naturally faster and easier Stephan Meindl: When I analyze the mar- example. Luxury and quality are high on the than with heterogeneous solutions with ket, I am convinced that, more than ever, priority list again, and so too is glass packag- components from a wide variety of manu- Horn Glass needs two stable pillars now: ing. That’s why we would like to consolidate facturers. container glass and float glass. our market share for glass furnaces in our existing markets while breaking into new ones. Mr. Meindl, thank you for the interview.

31 GlassFocus 2016 | Plant operators

The production of ultrathin glass is one of Schott’s future-oriented fields.

Building special-purpose

solutions from standard ET 200SP to build a function generator with a fast output rate of 35.7 microseconds. With the oversampling function, the analog components output module is able to transmit all calcu- lated measured values from the Simatic S7-1500 to the Profinet controller in chrono- logical order and to subsequently output them in the peripheral module clock-­ synchronously and at consistently equal intervals within a Profinet transmit cycle. The main advantage of oversampling is that a fast CPU cycle is not needed to output the Schott chronologically high-resolution measured values. Siemens also meets the company’s requirement for electromagnetic compatibil- Schott AG uses the Schott is a leading international technology all of which Schott prefers to achieve ity with Simatic ET 200SP. group that specializes in specialty glass and through the use of well-known automation Simatic S7-1500 con- glass-ceramics. With more than 130 years of technologies and standard solutions. And Smooth interplay between team and troller integrated experience in development, materials, and the systems must be able to tolerate a harsh technology into the TIA Portal, technology, the company offers an exten- environment, where electromagnetic com- “We have benefited enormously from Sie- sive portfolio of high-quality products and patibility is a must. mens’ innovative products and technological ­including the decen- intelligent solutions. Schott is therefore an expertise,” says Schott’s project manager, tralized Simatic innovative partner to many industries, Using standard components adding, “This holds true for the TIA Portal, including the household appliance, pharma- To meet Schott’s quality standards, the with its maximum engineering efficiency, ET 200SP peripheral, ceutical, electronics, optics, automotive, and measured data must be detected quickly the new Simatic S7-1500 controllers, and the for its cutting-edge aviation industries. and reliably. Measuring devices with a fast Simatic ET 200SP I/O system. Siemens’ manufacture of oscillation of up to 100 Hz are used for this product managers and regional consultants Requirements of ultrathin glass purpose. To meet this requirement, Siemens have given us such good advice that we ­ultrathin glass. One of Schott’s current fields of research uses the Simatic S7-1500 controller with the were able to meet our strict requirements and development is ultrathin glass. In AI 2xU/I 2-/4-wire HS analog input module with standard components while optimizing ­manufacturing this type of glass, everything and the AO 2xU/I HS analog output module costs – and we did this in the shortest depends on accuracy, reliability, and speed, as standard components of the new Simatic possible time.”

32 Plant operators | GlassFocus 2016

The Sitrans LR560 radar- level transmitter can reliably and continuously determine the filling level of the cullet silo over the entire silo height. All photos: Ardagh Group, Bad Münder Group, Ardagh All photos:

“ We’re very satisfied with the solution and will continue to rely on the good advice, Measurable successes ­rapid support, and reliable technology ­provided by Siemens in the future.”

Marcus Mai, Ardagh utilizes radar technology for optimized level responsible for technical maintenance of the supply area at Ardagh Glass GmbH measurement of the cullet silo.

Recycling raw materials is of great importance deployment conditions that are the result of materials like broken glass, and prevents The Ardagh Group in in the production of glass. The German the highly abrasive material and mechanical wear and tear caused by the glass fragments Germany subsidiary of the Ardagh Group at the Bad stressing. Because Ardagh had already had thanks to its contactless mode of operation. The Ardagh Group with Ardagh Münder location feeds more than 50 percent good experiences with Siemens measuring The scavenging air port, provided as stan- Glass GmbH operates a total of eight container-glass produc- scrap glass from its own production cycle and technology, the faulty point-level sensors dard, has also been used to prevent conden- tion plants in Germany. Huge recycled glass from consumers into the were replaced with a new filling-level technol- sation forming on the sensor. The continuous numbers of glass containers are production of new container glass. The cullet ogy operating at 78 gigahertz. Marcus Mai, filling-level signal is visualized on an on-site manufactured there day in and silo acts as an important buffer for the pro- who is responsible at Ardagh for the technical display, which is included in the delivery day out for the beer, sparkling duction of the mixture that is fed continu- maintenance of the supply area, easily in- scope and is integrated in the control system wine, wine, and food seg- ously to the glass melt. With a height of stalled the Siemens device himself and was of the cullet system. The ascertained bunker ments, among others. The Bad Münder location with 160 approximately 19 meters and a six-meter impressed by its plug-and-play functionality. volume can be used for controlled discharg- employees specializes in diameter, the silo has a large enough capacity ing, especially during maintenance work; this pharmaceutical, chemical, and to resupply the production plant for more Sitrans LR560 radar-level transmitter represents an enormous improvement in the specialty containers made of than two weeks. The Sitrans LR560 radar-level transmitter can process. Mai sums it up: “We’re very satisfied glass. Roughly 300 million glass now continuously determine the filling level with the solution and will continue to rely on containers are produced Faulty full and overfull sensors of the cullet silo over the entire silo’s height. the good advice, rapid support, and reliable annually on three production lines, which represents an The full and overfull sensors originally in- High-frequency microwave offers unique technology provided by Siemens in the annual capacity of 40,000 tons. stalled developed faults due to the harsh measuring properties, even with difficult future.”

33 Equipment suppliers Siemens AG Equipment suppliers | GlassFocus 2016 Masters of glass processing

Chinese glass processing specialist NorthGlass can produce very large-format bent glass in its tempering furnace – in world record-breaking dimensions.

­Sinamics series S120, G120, and G130, Simotics 1LE motors, and Sirius industrial switchgear.

New coater based on the Simatic PCS 7 NorthGlass not only specializes in tempering furnaces; it is also one of the world’s largest At the 2015 China Glass exhibition in manufacturers of coaters. There are more Beijing: In the background is the than 20 low-emissivity coating lines made electrical cabinet of a T-series furnace designed and manufactured by the Chinese manufacturer in service by Siemens. From left: He Yuankai, around the world. In this area, too, the Vice General Manager at Siemens The bent-glass panels that the Chinese in the world that provides both processing company relies on automation technology Limited of China; Gao Li, General company NorthGlass can produce in its glass machinery and glass products. Tempering from Siemens. For example, in the Chinese Manager of NorthGlass; and Li tempering plant, developed in 2013, boast systems for flat and bent glass are among its province of Hebei, a new coater is currently Deming, Senior Manager at Siemens impressive dimensions unmatched to date most important products. According to the being developed based on the Simatic PCS 7 Limited of China. anywhere in the world, with lengths of 18 company’s own information, NorthGlass process control system and Simatic S7-400 meters and a bending radius of 3.50 meters. enjoys the world’s highest sales volume of automation devices. Simatic WinCC and And that’s with a deviation of ±0.1 percent tempering furnaces. other SCADA technology from Siemens are on the straight edge and duplicated accu- also being used. racy on the arc edge of ±0.1 percent. On The high-tech company has worked in top of that, the company has managed to collaboration with Siemens ever since its Processing as well as production reduce its energy consumption by 50 per- beginnings. It uses the state-of-the-art NorthGlass has long been an established cent compared to previous solutions. These automation engineering framework TIA name in glass processing technology, but it large-format products are used for glass ­Portal with communication via Profinet has also been a manufacturer in its own facades, for example, at the headquarters technology in the newly developed device. right for some time. Siemens is following in the US of the world’s most famous These technologies allow NorthGlass, by its this development with great interest and All photos: NorthGlass All photos: ­electronic brand. own account, to achieve reliable quality and will continue to provide the company with improve its efficiency. “Siemens operates all advice and practical support for all its inno- Siemens involved since the company’s over the world, it has substantial capacities, vations, as it has been successfully doing all From left: ­Han Yonggang, Siemens foundation and it always finds great solutions for our along. It will help NorthGlass master all its Limited of China; Wu Qiang, NorthGlass has notched up total sales of industrial machines,” says NorthGlass challenges in the areas of automation, drive ­NorthGlass low-e coaters chief engineer; Heinz-Josef Lennartz, nearly 4,000 glass-tempering furnaces on General Manager Gao Li, explaining the and visualization systems, instrumentation, Siemens Deutschland; and Zhao Wu, the global market in its more than 20-year company’s choice. The Siemens products and industrial switching technology, includ- Siemens Limited of China, at the history. It manufactures at five locations in that NorthGlass buys most are Simatic ing corporate information systems. NorthGlass production site in China, China, which makes it the largest company S7-300 controllers, converters in the Luoyang City.

35 GlassFocus 2016 | Equipment suppliers

At the end of February 2016, the Chinese Ruiben Investment Group decided to work with numerous German specialists in the

First choice among Group Ruiben glass industry on four special float glass projects. ­thin-glass float plants

JSJ Jodeit and GFT have signed a collaboration agreement to position themselves as the first independent suppliers of float glass plants for thin glass.

Two German machinery manufacturers, JSJ Complete core technology in the the flat glass industry. “In the field of float Jodeit (JSJ) and German Floatglass Technol- melting area glass plants for thin glass, we’re the only ogy (GFT), have been combining their For both JSJ and GFT, their exclusive and companies in the free market that offer the expertise in a close collaboration for over close collaboration is far more than a conve- entire core technology in the melting and two years. As a result, they have been nient partnership. The companies are an forming area,” says Dennis Schattauer, operating successfully on the market as the excellent match both in terms of their managing partner of German Floatglass first independent suppliers of complete float orientation and their size. In addition, they Technology GmbH, as he describes the glass plants for thin glass. With years of share a common philosophy. Both are inno- unique selling point of the collaboration. application experience in the process auto- vative and collaborative players that offer Both companies see themselves in the roles mation of float glass plants, Siemens has their customers complete solutions and of coordinator, consortium leader, and even come on board as a preferred partner. services from a single source, especially in general contractor, depending on their

36 Equipment suppliers | GlassFocus 2016

customers’ requirements. Experience shows they provide tailored solutions for the thin “ We’re proud that we’ve been able to win that plant operators and investors prefer to glass field that JSJ and GFT can integrate in look for complete turnkey solutions, not their portfolio. “That’s just one side of the over so many leading German companies just individual disciplines. This is another coin, however. Siemens is more than just a for equipping our new production facilities argument in favor of the collaboration, component supplier. We and certainly the particularly because conventional general glass manufacturers value the solutions and in the Chinese glass sector. That represents contractors typically only provide planning systems expertise at Siemens,” explains a milestone in the industry.” services and not the actual value creation. Jodeit. Zhou Zhijian, Interfaces to Siemens First reference project with the Ruiben Chairman of Ruiben Group Depending on the scope of the project, JSJ Group and GFT bring other close partners like The collaboration has already delivered its Siemens on board. “Siemens in particular is first successes: At the end of February 2016, our first choice when it comes to projects the Chinese Ruiben Investment Group involving automation and drive technology, decided to work with JSJ and GFT. JSJ will that will be used in the new production electrification, instrumentation, and even handle the overall coordination for four facilities. With Umicore (platinum systems), Ruiben Group Ruiben the supply and auxiliary systems in the glass special float glass projects and will supply Pennekamp (lehrs), Grenzebach (cold end), factory,” says Dr. Harald Jodeit, managing the melting furnaces and batch plants (in and Siemens (plant-wide automation), the partner of JSJ Jodeit GmbH, speaking as a collaboration with Zippe). GFT was commis- Chinese investor is also relying on other representative for the collaboration. And sioned to provide the float bath technology German specialists in the glass industry. JSJ Jodeit

Ruiben Group Ruiben Dr. Harald Jodeit and the JSJ employees benefit from the company’s technical center for research and The ceremony to mark the project launch took place in mid-April. development at the headquarters in Jena.

37 GlassFocus 2016 | Equipment suppliers

Two partners, one goal

RoviSys is one of the leading system integrators for automation solutions in the glass industry in North America and ­beyond – thanks in part to its partnership with Siemens.

Despite wishing to grow independently, the in Singapore. RoviSys not only supplies the Solution Partner for nearly a decade American system integrator RoviSys still glass industry but is also active in markets Despite this independence, RoviSys has prioritizes its close cooperation with Sie- such as life sciences, chemicals, metals, fostered close and lasting relations with mens. As a Siemens Solution Partner, RoviSys packaging, and the food and beverage leading product and service suppliers, and supplies the glass industry with sophisticated industry, as well as in the energy sector. To with Siemens in particular. RoviSys has and innovative solutions for process automa- offer its customers the very best solution for cooperated with Siemens for over 20 years tion, all the way to plant-wide automation. them, RoviSys deliberately avoids committing and has been a Solution Partner since Together, the two companies bolster each to particular manufacturers, and instead 2006. “What won us over was the breadth other’s strong position in the market. works with a variety of technologies and of technology available, their scalability, platform specialists. “Our clients use our and flexibility, with the potential to provide Though just a small city, Aurora, Ohio, has solutions to monitor and control their core plant-wide automation. We recognize earned an enviable reputation in the North processes. That’s why it is essential that they Siemens as a world leader in the automa- American glass industry. And with good have the freedom to choose the best avail- tion industry. And not only are Siemens reason: Aurora is home to the headquarters able technologies and solutions with alterna- products and solutions available world- of RoviSys, one of the leading suppliers and tives for support and upgrades. In short, they wide, so too is the support,” says Keith service providers for process automation. want open systems. RoviSys was founded to Bagarus, Director of Global Glass Automa- Founded in 1989, the company employs fulfill those needs,” says John Hall, Director tion. some 450 staff members at four US sites and of Business Development at RoviSys.

38 Equipment suppliers | GlassFocus 2016

“Our close partnership has gone from strength to strength. Working together has enabled us to make a success of a number of projects and convince clients of the benefits of automation solutions based on Siemens’ portfolio.”

Keith Bagarus, Director of Global Glass Automation at RoviSys All photos: RoviSys All photos:

Controlling machines and plants location solutions including web clients. Keith Bagarus. Finally, RoviSys also uses In projects for clients in the glass industry, One of the special features of Simatic WinCC Simatic IT, an advanced manufacturing RoviSys therefore uses a wide variety of is its total openness. It can be readily used execution system with high scalability. This Siemens products, for example Simatic in combination with standard and user makes production particularly efficient and controllers from the Simatic S7 range for programs, creating HMI solutions that transparent, ensures quality, and accelerates controlling machines and plants. Simatic S7 precisely meet practical requirements. time to market. Precisely what the glass controllers are fully scalable, meaning industry needs to react rapidly to the chang- RoviSys can install them in individual Plant-wide automation with Simatic PCS 7 ing requirements of the market. ­machines and entire plants alike. The higher- The process control system Simatic PCS 7 performance controllers build on the func- has also become a first-choice solution in All-around product expertise tionality of less powerful controllers. Users ­RoviSys’s projects. Simatic PCS 7 controls Siemens not only provides Solution Partners benefit from uniform handling as well as a subprocesses as well as entire production like RoviSys with the products they need, it high degree of efficiency in engineering, processes, from batch processing all the way also contributes the necessary expertise to operation, maintenance and migration. With to the cold end. It even ensures connection utilize and market them. Each year, a num- As Director of Global Glass Automa- standardized interfaces, the controllers are of the supply systems. For the glass industry, ber of training sessions are organized to tion at RoviSys, Keith Bagarus is a compatible with products from other manu- plant availability is paramount. With its facilitate this. Siemens specialists regularly valued contact for Siemens in the glass industry. facturers – which allows the independence intelligent redundant concepts, Simatic PCS 7 bring engineers at RoviSys up to date on the RoviSys finds so important. enables uninterrupted operation. The system latest product developments so that RoviSys also shortens engineering and commission- can also obtain certification as a Solution Visualizing processes ing times considerably, and simply makes Partner for new solutions. Account Manger To monitor automated processes, RoviSys businesses more profitable. “We particularly Bob Ziemba visits RoviSys at least once a uses the process visualization system value the modular design and compatibility month to discuss ongoing projects. ­Simatic WinCC. It provides complete SCADA of solutions from Siemens. For example, functionality in Windows, and is also fully Simatic S7 controllers and the process control scalable – from single-user to multiple-user system Simatic PCS 7 utilize the same basic systems with redundant servers and cross- components, which simplifies servicing,” says

39 GlassFocus 2016 | Equipment suppliers

Tuned for high performance

Bottero’s newest gantry stacker can stack to both the air and tin sides of the glass, and is currently the most productive and flexible on With Siemens at its side, Bottero is continually the global market. upgrading the automation of its laminated glass lines, making them significantly more productive and flexible.

The Italian Bottero Group is one of the world’s Fully automated high-performance line a static relay, which also minimizes energy leading providers of complete solutions for the With Siemens’ help Bottero has fully auto- consumption. In a final stage, an automatic glass industry. Bottero recently implemented mated the line, which has resulted in ex- stacker unloads the autoclaves and creates one of the most productive and flexible lami- traordinarily high performance: “A sheet of packets optionally with or without spacers. All photos: Bottero All photos: nated glass lines on the market on behalf of a plate glass measuring six by three meters is well-known European manufacturer. The main processed in less than 40 seconds, which is The fully automated line is not only high- The latest generation of Bottero’s applications are structural glass, safety win- very fast. Normally that would take at least a performance, it can also be deployed very automation system uses state- dows and doors, and anti-intruder and bullet- full minute,” says Marco Guarguagli, auto­ flexibly for manufacturing different products of-the-art Siemens automation proof glass. The composite film used is made mation manager of Bottero’s Flat Glass in small batches, with practically no down- technology throughout. of polyvinyl butyral (PVB) with characteristics Engineering Business Unit. time for retooling. including varying levels of thickness, color, and acoustic insulation. This high productivity is the result of a In line with Siemens variety of mechanical improvements and a Bottero is truly working in line with Siemens fully automated, integrated overall process: on this order. The Italians now rely com- “A sheet of plate glass measuring six from charging various glass qualities through pletely on the engineering framework TIA washing at throughput speeds of up to 26 Portal and the latest-generation controllers by three meters is processed in less than m/min to joining different and even multiple and drives. A total of six Simatic 40 seconds, which is very fast. Normally PVB films. When trimming the films, the line S7-1500s communicating via Profinet and a adjusts automatically to the glass format and Simotion controller, as well as Sinamics that would take a full minute.” film type(s). A precisely operating infrared converters and Simogear geared motors, furnace and gentle nip rolls create optimal ensure fast, problem-free processes – and Marco Guarguagli, automation manager in conditions for the calandering process. Each optimal connections to upstream and down- Bottero’s Flat Glass Engineering Business Unit. heating element is controlled individually via stream sections of the plant.

40 Equipment suppliers | GlassFocus 2016

Cost-optimized edge grinding

Benteler relies on decentralization with the TIA Portal, making its Benteler glass edge-grinding lines more cost-efficient and fit for the future.

Industry insiders know that the globally and drive technology. This meant dividing “A key aspect of the new approach is the Among other products, Benteler operating Benteler Group has a German the previously central control cabinet, which convenient and, above all, consistent re- Maschinenbau GmbH produces fully subsidiary in Bielefeld that specializes in the was up to seven meters long, into smaller mote service for all components,” says automatic, modular production lines for loading, cutting, breaking, manufacture of glass processing machines, control cabinets and implementing a univer- Andreas Lüdtke, who heads the software grinding, and drilling both flat and among other products. For example, sal automation concept in the TIA Portal. engineering group for glass technology curved glass of practically any type. ­Benteler Maschinenbau GmbH produces In addition, the company switched to the e-design at Benteler in Bielefeld. The company has long relied on fully automatic, modular production lines latest generation of Simatic S7-1500 control- control and drive technology from for loading, cutting, breaking, grinding, lers, decentralized the Simatic E­ T 200SP This new approach was implemented using, Siemens. and drilling both flat and curved glass of peripheral modules, and cost-­optimized the among other devices, Profinet-capable practically any type. The company has long drives in the modular Sinamics G120 and Simatic TP1500 Comfort Panels with Touch relied on control and drive technology from S110 series for specific applications. This Display. It enables the production lines to be ­Siemens. includes installation on the up to 14 machin- operated and monitored – and therefore ing units for grinding, seaming, and polish- diagnosed – from Germany over a virtual Putting edge grinding to the cost test ing on the loose and stationary sides. private network (VPN), just as they would be To ensure that the company can keep pace on-site. “This allows us to localize and clear with the global competition, Benteler re- What all components now have in common faults quickly, which helps keep productivity cently put its edge-grinding lines to the test is universal communication via Profinet, high,” Lüdtke says. Using the latest compo- – both in their entirety and especially their including the upstream and downstream nents from Siemens gives users the requisite automation concept and components, machines. The decentralized field bus-based future and investment security, because thereby generating significant savings approach shortens cable lengths, simplifies spare parts will be available for many years potential. One of their key solutions was the and speeds up the installation, and mini- to come. consistent decentralization of the control mizes EMC-induced interference.

41 GlassFocus 2016 | Equipment suppliers

The Italian company Forvet is renowned for its machines used in flat glass processing.

in glass production than in other sectors due to the typically constricted space conditions. Second, horizontal processing also promotes All photos: Forvet All photos: higher quality and productivity compared Complete processing with vertical processing. Processing a sheet For many years Forvet has favored with maximum dimensions of 1,500 x 3,000 the use of Siemens automation tech- millimeters takes approximately three min- nology, and the company always utes. develops efficient, cost-optimized under one roof solutions with the help of Siemens as its equipment supplier. Complete automation from Siemens For many years Forvet has favored the use of Siemens automation technology, and the Forvet integrates a variety of processing steps under the company always develops efficient, cost- optimized solutions with the help of Sie- ­umbrella of Simotion, thus reducing their footprint while mens as its equipment supplier. In this ­increasing quality and yield. particular case, the straightforward CNC functionalities required are implemented throughout in the Simotion motion control In Forvet’s broadly diversified machine and in Volvera near Turin, has now combined all system, which coordinate the interaction of system portfolio for special applications in these steps in a single production line of Simotics S-1FK7 servomotors via Sinamics glass processing, innovation is always modular design known as Combiflex, and S120 series converters. In addition, Sinamics needed somewhere. Recently, the focus has put them all under the control of a V70 servo drives are used for the standard was once again on processing flat glass. Siemens Simotion D445. positioning functions. A robust Simatic Glass factories that manufacture flat glass industrial PC overlays the system. Thanks to usually consist of various machines for Greater efficiency on a smaller floor area end-to-end Profinet communication, the line loading, cutting, polishing, drilling, milling, First, this integration reduces the floor area can be readily expanded if necessary in the and washing. The company, which is based required, which is a more important factor future.

42 Equipment suppliers | GlassFocus 2016

Sharing a path to success for 10 years

The global success enjoyed by container glass machines from Sklostroj is based in part on 10 years of collaboration with

­Siemens. Sklostroj

The strategic decision by Sklostroj in 2006 Simotics S server motors. Fail-safe operation guarantee that all plant components work For 10 years Sklostroj has equipped to develop its own drive and timing con- (up to performance level PLd) is provided by together perfectly: fast and with a high all its glass container manufacturing trol system based on established, standard a decentralized Simatic F CPU, which is degree of repeat accuracy, ensuring maxi- machinery with automation technol- ogy from Siemens. ­Siemens automation components marked incorporated into the overall concept via mum productivity and quality. the beginning of the collaboration between Profinet with isochronous realtime (IRT), the two companies. To start with, Sklostroj – together with fail-safe Simatic ET200S For the first time, Sklostroj has also inte- a well-known Czech manufacturer of indi- peripherals on the individual sections. With grated the control system for the annealing vidual section (IS) machines and equipment this foundation, Sklostroj produces individu- lehr into the drive and control system at the for container glass manufacture – worked al automation concepts for highly produc- hot end, in order to combine as many pro- alongside a local Siemens Solution Partner. tive IS machines with four to 12 production cess parameters as possible in recipes and sections, or tandem machines with up to 24 manage them with the control system. That An innovative step toward the second-­ parallel sections. makes handling even more convenient and generation SDT-10 in 2010 was achieved job change even easier and safer, since through a direct collaboration between Fully coordinated automation more and more parameters can be automat- Sklostroj and Siemens. Since then, the drive Sklostroj’s most sophisticated comprehen- ically set and adjusted, minimizing human and timing control system has been used in sive solutions for the hot end include all error. all machines built by Sklostroj, and is also units needed for the forming process: servo sold as a stand-alone solution – both as a feeder (plunger, tube, shears) and servo IS Another good reason that Sklostroj prefers replacement for retrofitting work and in machine (gob distributor, section mecha- Siemens components is because spare parts new machines from other manufacturers. nisms, pushers, transfer units, cross convey- are readily and quickly available locally – in- The core components are the drive-based ors, and stackers). With a typical 12-section cluding for end users – anywhere in the motion control system Simotion D, the ISS machine in triple-gob operation, up to world. Sinamics S120 modular converter, and 13 Simotion systems via 120 Simotics servos

43 GlassFocus 2016 | Equipment suppliers

as well. The development of novel solutions and projects also forms part of the innovation- driven collaboration between the two compa- nies. One of the results is the compact system Timer&Drive, which was specifically devel- oped for comprehensive control and monitor- ing of IS machines. This is a definitive innova- tion for the container glass sector and is still unparalleled in its reliability, ergonomics, user-friendliness, and price. “The develop- ment of this control unit is in line with our requirement to offer machines with optimal Hardware and software and state-of-the-art hardware at the lowest possible price,” explains Themann. All photos: GPS All photos: Integrated or stand-alone solutions software from The innovative system can be integrated in all Synchronization of multiple servo IS machines, not just in those made by GPS. axes of an IS machine in the micro- “Our system is more of a module that can be and millisecond range. a single source integrated in existing machines according to specific requirements,” says Themann. “This means that it’s energy- and cost-efficient – and therefore absolutely in the interest of our customers.” The individual components of the new GPS controller, for example, the proven GPS and Siemens – innovation drivers for Siemens solutions Logo, Simatic S7, and Simotion, are also suitable for small control- GPS Glasproduktions- the container glass industry. lers, and are therefore a good choice. Service GmbH GPS designs state-of-the-art Glasproduktions-Service GmbH (GPS) can nology and software. With Siemens, GPS has IS machines for the container look back on over 90 years of corporate found the ideal partner for precisely this glass manufacturing industry history. Today, under the management of sector. For the past two years, GPS has been worldwide. The company, headquartered in Essen, works CEO Rolf Themann, GPS is an independent equipping its IS machines with control and with its clients and customers manufacturer of ultramodern IS machinery monitoring systems from the integrated to develop tailor-made for the container glass manufacturing indus- technology company. ­solutions. GPS has won over try. As a former subsidiary of Saint-Gobain prestigious customers in the Oberland AG, GPS has the expertise and Perfect interoperation of machine and container glass industry thanks experience to identify the needs and require- control system to its high quality, process reliability, efficiency, ments of the container glass sector and to Siemens supports GPS as its go-to partner for and environment-friendly develop customized solutions. In the age of technical issues and as a reliable supplier and ­machines. digitalization, a full-service offering always provider of training courses on many different IS machine for the production of bottles and jars in includes the corresponding computer tech- subjects – not just in Germany but worldwide all shapes and sizes.

44 Equipment suppliers | GlassFocus 2016

Flexibility in Heye International GmbH All photos: Heye All photos: With more than 50 years of IS machines experience, the Obernkirchen- based company Heye ­International GmbH is a world-­leading equipment supplier to the container glass industry. Over the past few Heye uses the Siemens Simotion motion control bottles – can be manufactured simultaneously years, Heye has continually on one machine. With the Heye solution, every strengthened its position on system for ­assortment operations in the narrow- last drop can be used so there is no glass the market through the systematic implementation of neck press and blow ­process. wastage. The time expenditure for the neces- a sustainable growth strategy. sary conversions is also significantly reduced. “This is an innovative solution for which there The production of small-batch quantities and tributed to the IS machine’s individual stations. is market demand. It shows that our engineers the changes of container type this entails has Some of the special features of the servo drive have the right feel for what will bring real always posed a problem for the hollow glass- controller are its reproducible motion profiles value added for the container glass industry,” ware sector because the IS (individual sec- and the easy integration of additional servo says Wilfried Seidensticker, Product Manager tion) machine has to be stopped completely axes. It can also be employed for all sizes and at Heye International. He adds: “Siemens has and reconfigured. In addition, the entire types of feeders and achieves production always been our partner when it comes to production run must be reorganized for the speeds of up to 250 cuts per minute. innovative control and drive technology.” type changeover, which considerably reduces efficiency and productivity. Heye Internation- Initial applications in NNPB lines al has developed a solution for this problem With the Heye solution for assortment opera- The Simotion-based Heye servo that it has now extended to the narrow-neck tion already in service in large numbers of drive controls a plunger (above), press and blow process as well. plants, the company has now also acquired its dual-motor shears (left), and other hot-end components quickly and first customers who are employing this solu- precisely. Flexibility for different bottle shapes tion in the narrow-neck press and blow pro- The core element of this recent innovation is duction process (NNPB). In the NNPB process, a the Heye servo drive control unit that is based specially shaped plunger is used, as the name on the Siemens Simotion motion control suggests, to enable bottles to be produced system. In conjunction with the servo plunger with a narrow-neck mouth. In a Heye customer and dual-motor shears from Heye, gobs of reference plant, for example, 280 g and 304 g different weight can be sheared off and dis- containers – or alternatively, 256 g and 280 g

45 GlassFocus 2016 | Equipment suppliers

Efficient solutions for glass produc- the speed, torque, and direction of rotation tion like this fully automatic carousel- of a servomotor, which uses energy only type press line represent Waltec’s core when needed for the press cylinder. There competency – all built around automation and drive technology are no loss-producing valves throughout the from Siemens. entire drive train, and the large oil tank has been replaced by a compact pressure accu- mulator. In practice, this provides energy savings of up to 80 percent compared to a traditional solution.

Powerful and accurate timing for the rotary table A high-torque segment motor minimizes The fully electric time delays while turning the rotary table. Waltec now has the option of installing standardized, gearless, backlash-free ­Simotics T direct drives from Siemens. path to the future Like the other motors, they’re also driven by a Siemens Sinamics converter.

On the road to the fully electric machine Simpler electric drives are sometimes used in Precision, compactness, low maintenance expenses, materials handling. Many auxiliary axes (for example, for opening press molds) have and outstanding energy efficiency are all the previously been pneumatically operated. ­encouragement Waltec needs to go fully electric Waltec intends to switch to an increased use by converting the last of its nonelectric drives. of compact electric cylinder units in the future in order to further reduce energy consumption and maintenance expenses. Waltec Maschinen GmbH is a leading maker ­dynamic and extremely low-wearing linear Combinations of Simotics S-1FK7 synchro- of complete production lines for glass manu- motors. Waltec builds carousel-type nous servomotors and SKF spindle units are All photos: Waltec All photos: facture, focusing on carousel-type machines ­machines with up to four press cylinders, ideal for this purpose, preferably in a space- for pressing, press-blow, blow-blow process- each supplied by its own plunger and an saving parallel arrangement. Another eco- Unlike conventional valve hydraulics, es, and centrifugation. Precise motion individual volume of glass. nomical option for a wide range of tasks is the servo pump directly transmits the control on fully automatic press lines starts the decentralized Sinamics G120D converter energy from the drive motor to the with metering the glass out with maximum Servo pump rather than valve hydraulics with a Profinet connection – which is stan- hydraulic press cylinder. In other words, the servomotors provide only accuracy. That’s why for many years Waltec For the actual press process, too, dynamics dard with Siemens components – with the energy that is needed for each has been relying on automation and drive and precision are essential to product quality integrated safety functions. With these phase of the press process. technology from Siemens for its feeders, and output. To ensure the maximum pos- innovations and Siemens at its side, Waltec which consist of plungers and cutters. sible energy efficiency, Waltec has been is well on the way to having a system in A special feature of these feeders is their using a servo pump solution from Siemens place that is almost entirely electrically plungers, which are driven by highly since 2012. It governs the hydraulics using driven.

46 EquipmentEquipment supplierssuppliers | GlassFocus 2016

Running even truer

A buffer capacitor from ­Siemens has helped Olivotto Thanks to buffer capacitors from improve the energy efficiency Siemens, Olivotto has reduced the and performance of its rotary- effective power consumption of its

All photos: Olivotto All photos: new rotary glass press machines to type glass press machines. only 14 kW.

Italian manufacturer Olivotto is an impor- oped a new concept that will reduce power use it during acceleration, thanks to a tant international partner to the hollow consumption still further. Siemens buffer capacitor connected to the glass industry that specialized at an early DC link (600 V). In this way, Olivotto can stage in rotary machines for glass blowing, The challenge: rotary glass press now choose a much smaller Active Line pressing, and spinning. Numerous acquisi- ­machines Module (55 kW instead of 250 kW), since tions have made Olivotto more than just The engineers always faced a challenge the machine now needs the mains power a machine supplier – it can now offer its when it came to rotary press machines. With primarily for the pressing process. “We have customers in the glass industry complete up to 1,800 kg, these machines carry a very cut our power costs by a lot, since the rated lines and turnkey systems. high load. During each cycle, the load has power consumption for the entire machine to be rotated by 30 degrees within 0.3 is now only 100 kW instead of 300 kW,” says Powerful and energy-efficient seconds, requiring precise acceleration and Stefano Triolo, Chief Automation Engineer Because Olivotto is constantly alert to ways deceleration. Olivotto previously dealt with at Olivotto. “The capacitor brings our effec- of making its machines both powerful and this requirement using a torque motor on a tive power consumption down to just 14 kW.” energy-efficient, it has chosen to work with Sinamics S120 system comprising an active Siemens as its project partner. When it line module (infeed) with power of 250 kW Because Olivotto is constantly alert comes to machine automation, the first and a 200 kW motor module as the power to ways of making its machines both choice is the Simotion motion control sys- unit. The active line module had to be so powerful and energy-efficient, it has chosen to work with Siemens as its tem with the Sinamics S120 drive system. Its large to be able to deliver the energy the preferred project partner. chief advantages are its extremely precise motor needed for acceleration. motion control and modular structure that can be perfectly adapted to the application Buffer capacitor provides desired effect in question – and the way it helps minimize The new concept enables the machine to power costs. To expand the range of oppor- temporarily store the energy generated tunities still further, Olivotto has now devel- during the decelerating process and then

47 Plant-wide automation and ­digitalization – the path to your ­company’s success

Find out more siemens.com/glass

Published by: Siemens AG Vertical Glass Siemensallee 84 76187 Karlsruhe, Germany For further information: siemens.com/glass Subject to change without prior notice Order No.: VRGS-M10009-00-7600 Dispo 41513 Printed in Germany © Siemens AG 2016

The information provided in this brochure contains merely general descriptions or performance characteristics, which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective characteristics shall only exist if expressly agreed in the terms of contract.

Availability and technical specifications are subject to change without notice.

All product designations may be trademarks or product names of Siemens AG or supplier companies whose use by third parties for their own purposes could violate the rights of the owners.