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Industrial machinery and equipment

Siemens I DT MC-CON
Award-winning Siemens plant adopts Teamcenter and NX as engineering backbone

Products NX, Teamcenter Business challenges Improve competitiveness and quality of factory in a global sector Convert data from legacy systems Operate two systems in parallel during conversion

Keys to success PLM toolset integration Phased implementation Comprehensive training and collateral Instant support from key users Results Completed migration of the data from the legacy computer-aided data integration system into Teamcenter Data is trusted, accurate and reliable, eliminating any chance of ambiguity No longer need to re-design, re-test and re-approve

PLM charter drives design anywhere, make anywhere strategy


Design anywhere, make anywhere The Siemens Industry Sector Drive Technologies Division Motion Control Group (Siemens I DT MC-CON) plant in Congleton, United Kingdom, is striving to become a world-class facility by 2015. The plant will be measured against such top manufacturers as Toyota, Bosch, BAE Systems, Jaguar Land Rover and Coca-Cola. The plant has already won numerous awards, including the Number One Drive Technology Assessment Plant and the Siemens UK Think Customer Silver Award.

The plant produces 1,100,000 electronic devices per year, including 500,000 inverters, 150,000 control units, 400,000 operator panels and various other ancillary equipment for AC motor control up to 18.5 kilowatts. Each of these devices saves approximately 900 grams of carbon dioxide each year. This is the equivalent of removing a million passenger cars from the roads. To improve the efficiency, productivity, cost base, and thus the competitiveness of the business, the decision was made at the Siemens Industry Sector level to bring all these plants together under the same umbrella, says Ian Donald, head of research and development, Siemens I DT MC-CON. Subsequently the decision was

www.siemens.com/plm

There is no need to re-design, re-test and re-approve.


made to make Teamcenter and NX our backbone for engineering through the Siemens Industry Sector PLM Charter. Our challenge was to make this a reality here in Congleton. The Big Bang The PLM Charter mandates the capabilities of all future solutions, including standardization across processes, through the Integrate Enable Collaborate (IEC) project. IEC is a Siemens Industry Sector level integration of toolsets to deliver the full product lifecycle management (PLM) landscape across the business through the implementation of Teamcenter software, with additional capability provided by the Siemens PLM Software IEC team in Nuremburg. We had been using a computer-aided data integration solution for many years, but it didnt meet the needs of the new structure, says Donald. In addition, each plant kept its own data on local discs, which meant that sharing data was problematic. The project here was two years in planning and preparation. The first phase of implementation involved commercially purchased parts, which meant running Teamcenter and computer-aided data integration management (Cadim) in-parallel for 12 months. The second phase brought in NX software, a comprehensive and integrated computer-aided design, manufacturing and analysis (CAD/CAM/CAE) system, which meant that all the new mechanical parts were generated using Teamcenter and copied to the legacy system. Three years after the first implementation we achieved what we term the Big Bang, or the complete migration of the data from the legacy Cadim system into Teamcenter, says Donald. Generate engineering information once and share it We are using Teamcenter to generate engineering information once and then share it around the business, supporting the exchange of information throughout the whole process, including schematic capture, PCB (printed circuit board) layout, mechanical design and simulation, says Jon Gokhale, tools and support engineer, Siemens I DT MC-CON. In the future, we will also include MES (manufacturing execution system). No matter where you are located, all users are aligned on the same processes. A part designed anywhere can be made anywhere. There is no need to re-design, re-test and re-approve.

We are seeing big benefits coming now that something designed here can be made anywhere in the world and anything designed anywhere in the world can be made here. Ian Donald Head of Research and Development Siemens I DT MC-CON NX for simulation has been really useful. We analyzed the performance of the motor housing and how the motor was fastened to make sure it was strong enough to withstand a 25 gravitational force shock load. We also solved a PCB resonance problem. Simon Charlson Mechanical Design Team Leader Siemens I DT MC-CON

The engineers who enter commercially purchased parts into the system, such as electronic components, fastenings, connectors and so on, used to do that only for their own sites. Now, they are all part of one worldwide group. By using Teamcenter, much of the responsibility for data quality has reverted to the owners who generate data in the first place. This means that they pass on only trusted, high-quality and reliable data, virtually eliminating any chance of ambiguity. All data is held in the system in a secure central location. There is no local storage, so there are no issues over different versions in different places and there are no synchronization issues. There is just one authorized version of everything. Increasing efficiency while saving time Has Teamcenter made us more efficient? Gokhale asks. The answer is yes. In a large organization such as ours, where we have also changed CAD systems, it can take quite a while to see real improvements. As expected, we were less efficient initially, but there are definitely benefits as we moved forward. With the Cadim system, parts were only referenced alphanumerically. Using Teamcenter, if you are searching for a part, you can see the JT preview and immediately recognize if the part is the right one or not, ensuring accuracy and saving time.

With the Zuken CR5000 PCB design software integration that is part of the IEC version of Teamcenter, rather than setting up all the parts individually, you press a button and the parts are created for you automatically in a way that is similar to using NX. Overall, the more new data that is going in, such as CAD drawings, change release processes, test results and approvals, the more we are seeing the benefits.

We are using Teamcenter to generate engineering information once and then share it around the business, supporting the exchange of information throughout the whole process, including schematic capture, PCB layout, mechanical design and simulation. Jon Gokhale Tools Support Engineer Siemens I DT MC-CON

NX the timing was right We were the second facility to start using NX. Prior to that we were using Pro/Engineer, says Simon Charlson, By using Teamcenter, much mechanical design team leader. We chose of the responsibility for data probably the most complicated project quality has reverted to the of the last ten years to do first. It was an owners who generated the all-new product, so there were no legacy data in the first place. This issues. The timing was right, too. If we means that they pass on hadnt done it when we did, we would not only trusted, high-quality have acquired the expertise and skill we and reliable data, eliminatnow have. ing virtually any chance of ambiguity. NX for simulation has been really useful. Jon Gokhale We analyzed the performance of the Tools Support Engineer motor housing and how the motor was Siemens I DT MC-CON fastened to make sure it was strong enough to withstand a 25 gravitational force shock load. We also solved a PCB resonance problem. During vibration testing, we discovered the reason for an intermittent contact. We simulated the vibration testing using NX, identified how things were bending and stiffened the casting to eliminate the problem. It was a massive process in the past to create 3D CAD data and then have to create 2D drawings simply to be able to measure dimensions for quality measurement of incoming parts. We now pull the

If you ask some of my guys who have been using Pro/Engineer for 13 years or more theyll say they prefer NX.

Solutions/Services NX www.siemens.com/nx Teamcenter www.siemens.com/teamcenter Customers primary business Siemens Industry Sector Drive Technologies Division Motion Control Group designs and manufactures electronic inverters and drive products for AC motor control up to 18.5 kilowatts. www.automation.siemens.com/ mcms/mc/en/motion-control/ Pages/motioncontrol.aspx Customer location Congleton United Kingdom

CAD data into the inspection machine and compare it with the actual part, which saves time and reduces the risk of errors and re-ordering. Ensuring good data quality We have a lot of designs that were built using Pro/Engineer, says Charlson. In the past, some agency engineers were better than others at keeping the Pro/ Engineer model up to standards. There were, for example, numerous frozen and suppressed features that really should have been edited out but were included in the released part. With NX, if a part hasnt passed the checking system, you cant release it, which forces people to ensure the data quality is good. Now, if you ask some of my guys who have been using Pro/Engineer for 13 years or more, theyll say they prefer NX. We have worked very hard to make sure we had widespread acceptance of Teamcenter, promoting it and selling it at every opportunity, notes Gokhale. Ive given training courses for each of our 150 users in this plant. Ive also created online guides and created videos. Ive run departmental question-and-answer sessions and I also provide telephone support. Our support network of key users was vital to the successful implementation of Teamcenter. If you have someone close by in your office who knows how to use the software, then you can just call them over and resolve your issue more-or-less

straightaway. The key user in the mechanical team certainly helped me a lot. Perhaps we should have had more of them who had knowledge of how their own departments run. We are now fine-tuning our processes to work effectively using Teamcenter to eliminate duplication of effort. The next step is to integrate Teamcenter with a yet-to-be chosen MES (manufacturing execution system) and that is a Siemens Industry Sector decision. We are also looking to increase adoption even further by enhancing our network connection to Germany. This is a huge undertaking, says Donald. Across Siemens Drive Technology, there were 1,244 users of Cadim, our legacy data management system. Now there are 16,166 registered Teamcenter users. Its a major effort and even though we are a Siemens plant, we still have to justify and pay for the software. Its clear, though, that we are seeing big benefits coming now that something designed here can be made anywhere in the world and anything designed anywhere in the world can be made here.

Something designed here can be made anywhere in the world and anything designed anywhere in the world can be made here.
Siemens Industry Software Americas +1 314 264 8499 Europe +44 (0) 1276 413200 Asia-Pacific +852 2230 3308 www.siemens.com/plm
2014 Siemens Product Lifecycle Management Software Inc. Siemens and the Siemens logo are registered trademarks of Siemens AG. D-Cubed, Femap, Geolus, GO PLM, I-deas, Insight, JT, NX, Parasolid, Solid Edge, Teamcenter, Tecnomatix and Velocity Series are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc. or its subsidiaries in the United States and in other countries. Pro/ENGINEER is a trademark or registered trademarks of PTC Inc. or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders. Z6 39262 1/14 F

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