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: Focus on digitalization | GlassFocus 2016 The advantages of Networked means ready to work digitalization For plant operators: Digitalization is opening up opportunities for the glass industry Sustainable profitability, higher productivity, cost efficiency, and energy efficiency, thanks to As many plant operators know from their One thing is certain: Digitalization is the • Greater transparency own experience, extensively automating a essential next step in glass manufacturing. • Comprehensive planning glass production plant promises sustainable Every company can profit from it, whether • Reliable planning as an investor, glassmaker, equipment • Virtual commissioning success over the equipment’s entire life- • Malfunction-free operation cycle. Now the industry is facing its next supplier, or systems integrator. The focus • Avoidance of surplus major change in business direction. If should always stay on the people, and the capacity and bottlenecks glassmakers are going to thrive in the world core organizers who will decide how the • Faster product changes at market, it is going to be more important to new technologies will be applied and used. the optimal time be able to generate, analyze, and utilize • Greater flexibility • More focused production digital data from a vast range of sources – to fit customers’ quality in systems planning, in construction and requirements commissioning, during operation, and clear • Broader product range to the end of the lifecycle. • Fewer rejects • Lower expenses for The next strategic step training • Optimized operation Regardless of the level of automation, every • Asset (performance) glass plant and equipment supplier is gener- management Digitalization is the essential ating and collecting digital data. Until now, 01001101101 • Resource optimization next step in glass manufacturing. 10010111001 much of this information has been wasted. 00111001011 It’s founded on a high level of 01001101101 In order to optimize your plant, it is essen- 00111001011 For equipment suppliers: automation. 00111001011 tial to assess all available data, combine it Digitalization • Simulation • Safe, simple, low-cost intelligently, and expand it using additional remote maintenance sensor equipment. Ideally, to achieve a • Learning effects from “digital plant,” a virtual representation of field data the plant section or the entire glass produc- • Product lifecycle services tion plant – known as a “digital twin” – is Automation and extended lifecycle built starting with the very first planning services like modernization and update/upgrade step. The digital twin makes it possible to services steadily increase productivity and efficiency • New business models throughout the plant’s lifecycle. There are Electrification based on performance many different scenarios that can be ap- guarantees plied. 3 All photos: Siemens AG All photos: 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