Solutions for Powertrain. On the road to success with Siemens in the automotive industry. siemens.com/automotive

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1 Solutions for Powertrain On the road to success with Siemens in the automotive industry siemens.com/automotive

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3 On the road to success with Siemens There is tough competition in the automotive industry the increasing globalization is creating pricing pressure, which is forcing car builders and suppliers to continually optimize their production processes. Only those companies that become more productive, more efficient and flexible will be successful. The intelligent automation concepts that allow a high degree of flexibility are key here. This applies especially to the production of Powertrain components. A wide range of car models and shorter production cycles mean that various types have to be produced on one line. At the same time, the total cost of ownership must be minimized. Our customized concepts Solutions for Powertrain and TRANSLINE are based on a completely modular design. They have a direct and positive impact on productivity, availability and system utilization when it comes to producing Powertrain components in the automotive industry. In the CNC production domain, with SINUMERIK, Siemens has already been actively using simulation, virtual machines as well as integration in the factory IT landscape for many years now. Pushing forward with this horizontal and vertical integration also paves the way to Industrie 4.0 also in the machine tool environment. Siemens Machine Tool Systems stand for seamless and integrated solutions that extend from the machine tool up to a company's enterprise level and are an element in the domain of a digital factory. Contents Siemens reliable partner for the automotive industry 4 The key to success Solutions for Powertrain and TRANSLINE 5 Solutions for Powertrain support across all project phases 6 TRANSLINE making more out of standards 7 TRANSLINE intelligent standard components down the line 8 TRANSLINE standardized applications 10 TRANSLINE standardized operation and diagnostics 12 Integrating plants and machines into the IT landscape 13 Success factor energy efficiency 14 Siemens as global service partner 15 3

4 Siemens reliable partner for the automotive industry For many years now, the automotive industry and its suppliers have set standards in automotive production. And they give significant impetus to develop innovative technologies and excellent production processes, as they are permanently confronted by significant challenges. These include shorter time-to-market, higher product quality and number of models, reduced total cost of ownership and the highest plant availability, with increasing energy costs and in the context of global competition. As a global partner to the automotive industry, Siemens has enjoyed a leadership position for quite some time when it comes to increasing productivity, technological competence and efficient processes. Taking into account the structural changes in automobile manufacturing regarding global competition, we have strongly aligned ourselves to addressing these central challenges. 4

5 The key to success Solutions for Powertrain and TRANSLINE Solutions for Powertrain is the comprehensive concept from Siemens for planning and implementing production plants in the Powertrain area, including project support, consulting and a wide range of services. As a leading automation and technology partner, we accompany the automotive industry as well as equipment manufacturer worldwide and over the complete lifecycle of their production systems. In conjunction with our TRANSLINE technical solution a standardized modular system based on our powerful product families we have created an innovative approach that has been established worldwide. The objective is to standardize and minimize the total cost of ownership for your Powertrain production plants and systems, but at the same time boost availability and productivity. 5

6 Solutions for Powertrain Planning First commissioning (machine manufacturer) Second commissioning (end user) Production ramp-up Series production Component list Project manual Specific software Coordination of machine manufacturers Project DVD Training machine manufacturers Commissioning support Hotline TRANSLINE support Training operators/ maintenance technicians Training racks Packages of spare parts Start-up support Warranty extension On-site service & support Solutions for Powertrain support across all project phases With our Solutions for Powertrain concept, we accompany and support you in all phases of your project from planning, through commissioning and production ramp up to smooth series production. Already starting in the planning phase, we define the project goals together with you, based on the established TRANSLINE standard. After the planning phase has been completed, we support you and the equipment manufacturers involved while implementing these project goals. For example, by providing the project DVD, so that standard software versions are used. Siemens provides professional project coordination for all project phases and that, around the globe. As your partner, we are the interface between the equipment manufacturers (OEMs) and your project team. Here, we place a lot of emphasis on open communication and harmonious collaboration. You can depend on us as experienced partner who is present around the globe. Further, with the extranet, we provide a communication platform for Solutions for Powertrain projects. All information for all of the companies involved is provided through this platform. The TRANSLINE standard manual and the individual project manual represent the core elements of this information. Minimizing total cost of ownership Our experience from numerous automation projects shows: The first investment is only a fraction of the overall costs for production plants and systems. The follow-on costs, for example for spare parts, maintenance and training, are far higher. Our solution: Reducing overall costs with overall solutions. This includes establishing the know-how of planning, maintenance and operating personnel at an early phase and providing them with detailed knowledge about their plant through our service professionals. It is also important to select spare parts tailored to your specific requirements, which guarantees maximum availability together with minimum costs. TRANSLINE standard manual Automobile manufacturers and suppliers Siemens Project book Offer Equipment manufacturers 6

7 TRANSLINE Components Applications Machine operation Diagnostics Software structures TRANSLINE making more out of standards With TRANSLINE, Siemens offers a complete, technical solution and a standard modular system. This simplifies the configuration, while still allowing you to individually adapt all of the hardware and software components to your particular application. The modular system includes components from our product families, for instance SIMATIC, SINUMERIK, SINAMICS and PROFINET. They demonstrate their productive interaction in production environments around the world on a daily basis. As a consequence, you can leverage all of the strengths of Totally Integrated Automation for your Powertrain production plant or system. TRANSLINE's recipe for success: standardization, simplicity, seamless integration. The key elements: The use of standard components, always the same structure and topology for typical applications, consistent user interface, always identical tools for engineering, programming, commissioning and diagnostics. The result: Wide-ranging synergistic effects from engineering up to service. In the manuals, component lists and individual project DVDs, we provide all of the information for all of the relevant electrical hardware and software products. This means that equipment manufacturers can ensure that the production equipment they build is precisely tailored to address the requirements of end users. Furthermore, a hotline is available throughout the complete planning phase. These employees are specialized in automobile projects with the appropriate expertise that is required when planning a production environment. Your advantages with Solutions for Powertrain and TRANSLINE Higher availability and productivity through standardization and professional project coordination An experienced partner for all automation tasks Straightforward, standardized automation concepts Standard machine operation Shorter commissioning times Lower training costs Simpler maintenance and shorter machine downtimes Less spare parts to stock Efficient professional service globally, daily and around the clock Minimized total cost of ownership 7

8 TRANSLINE intelligent standard components down the line From controls through drive systems, operator panel fronts and interfaces to peripheral devices and sensors: Intelligent automation solutions set themselves apart due to the fact that they are standard and integrated. Precisely like our TRANSLINE modular system, which gives you Totally Integrated Automation for your Powertrain production. Communication IT and software solutions SINUMERIK 840D sl: a CNC fit for every task SINUMERIK 840D sl is our drive-based control system with scaled performance and integrated with SIMATIC S7-300 the epitome of PLC controls. It can handle simple positioning tasks as well as complex machining operations involving up to 31 NC axes and 10 channels. Its versatility makes this CNC the ideal solution for Powertrain applications in the automotive industry. With its compact, modular design, it fits into each and every configuration. With "Safety Integrated" functionality, it provides safety-relevant protection for people and machines without requiring any additional monitoring devices. Further, in addition to the PLC and the NCK, it also integrates the drive control and HMI. CNC controls and drive systems SINAMICS S120 brings your production up to speed Scalability in the drive power, number of axes and performance these are the key parameters of the modular, compact SINAMICS S120 drive system for demanding single-axis and multi-axis applications. It allows distributed topologies to be configured over considerable distances. It is simple to commission using smart software tools with operator-prompted screen forms and automatic control optimization as well as automatic identification of electronic motor rating plates. Operating components and user interfaces SINUMERIK operator panel fronts: everything at a glance 8 Whether PLC or CNC-based machine with the stationary and mobile SINUMERIK operator panels, we can offer you devices that can be optimally used in your application thanks to their scalability from 7.5" up to 15". The combination with the powerful PCU50 guarantees full flexibility and performance. The combination of operator panels with a thin client application is a favorably-priced solution with low installation dimensions and maintenance-free components. Thin clients are ideal for multi-station operation. The range of operator panel fronts is rounded-off by SINUMERIK pushbutton panels and machine control panels.

9 PROFINET and more: optimum communication Especially in distributed concepts, communication has a tremendous significance when it comes to process efficiency. With PROFINET, TRANSLINE offers all of the options for optimum networking and facilitates: TCP/ IP communication between the controls and the operator panels, programming devices and the master computer Real-time communication between the machine controls connected to the plant or system network and to peripherals Optimum match: the versatile family of SCALANCE products SCALANCE has a wide range of switches, thus providing a high degree of freedom when configuring Industrial Ethernet networks and using PROFINET. Rugged connection systems, user-friendly diagnostics and security functions support fast commissioning and reliable operation. Safety components Motors and spindles PLC systems I/O SIMATIC ET 200pro: more intelligent local control State-of-the-art automation concepts are based on distributed peripherals and I/O: installation time, cabling and therefore costs as a whole can be noticeably reduced. The compact, modular distributed SIMATIC ET 200pro I/O can be connected to PROFINET and PROFIBUS DP, and is admirably suited for use with Safety Integrated. With an IP67 degree of protection, it can be used at the machine and offers the optimum module for every application from motor starters through RF identification systems up to integrated PLC functions. SIMATIC S7-300 and SIMATIC S7-1500: PLC par excellence With various central processors, scalable performance and an extensive instruction set, SIMATIC S7-300 can tackle even the most complex control applications. Realtime communication via PROFINET and the well proven PROFIBUS DP open up various options for optimum data exchange in the process. Handling is made easier using automatic parameterization, expanded diagnostic functions, password and installation friendliness. SIMATIC S is the recommended PLC to address more complex applications: It combines power and efficiency and fulfills high demands when it comes to communication capability, flexibility and the technological functions it can implement. 9

10 TRANSLINE standardized applications SCALANCE S602 SCALANCE X Server Ethernet Factory network Ethernet 1 Ethernet 1 Ethernet 1 SINUMERIK OP PCU SINUMERIK OP TCU SINUMERIK OP PCU SINUMERIK HT8 Ethernet 2 SINUMERIK Ethernet 2 SINUMERIK Ethernet 2 X150 HT8 X150 HT8 X150 X130 X120 X130 X120 X130 X120 SINUMERIK 840D sl SINAMICS S120 SINUMERIK 840D sl SINAMICS S120 SINUMERIK 840D sl SINAMICS S120 ET 200 ET 200 ET 200 SIMOTICS SIMOTICS SIMOTICS CNC head station CNC machine 1 CNC machine n Application example: Flexible production line When manufacturing Powertrain components, such as cylinder heads, crankcases and gearbox casings, the trend toward flexible production lines is uninterrupted just as before. The gantry loader of the production line coordinates the part flow. Flexible production lines, which were automated according to the TRANSLINE concept, are based on standard hardware and permit the use of a standard software concept. Data is exchanged via the Ethernet network. Real-time data is exchanged using the PROFINET protocol. 10

11 SCALANCE X Factory network Cellbased system SCALANCE S602 Server System network SIMATIC Comfort Panel SIMATIC Comfort Panel SIMATIC Comfort Panel SIMATIC S7-300 PN SIMATIC S7-300 PN SIMATIC S7-300 PN Nut runner system ET 200 SINAMICS Motor starter ET 200 ET 200 SIMOTICS SIMATIC Ident SIMATIC Ident SIMOTICS Automatic station Transport section Manual work station Application example: Assembly line An extensive range of components is used on the assembly line for Powertrain components. Frequently, extensive data communication is required, e.g. for part tracking or for an assembly order supervisory control system. TRANSLINE is precisely aligned to address these tasks. Cell computer and server are integrated. The network concept allows individual controls and components to be connected, such as nutrunners and identification systems. Data is exchanged via the Ethernet network. Real-time data is exchanged using the PROFINET protocol. TRANSLINE a seamlessly integrated control architecture and a standard concept for your Powertrain production systems, for example: Flexible lines Transfer lines Assembly lines Machining centers/grinding machines Loaders/gantries Winders 11

12 TRANSLINE standardized operation and diagnostics In your Powertrain production plant or system you combine systems and machines from a wide range of manufacturers. To facilitate standard operation and diagnostics, TRANSLINE provides operators and maintenance technicians with standardized, cross-manufacturer user interfaces HMI PRO und HMI Lite. Additional process-specific content can be seamlessly integrated into these user interfaces. TRANSLINE user interfaces facilitate standard operation, irrespective of whether your machine is controlled from a SINUMERIK or SIMATIC control this is true both in mechanical assembly as well as in the Powertrain domain. 12

13 Integrating plants and machines into the IT landscape Protecting your investment and keeping fit for the future A typical production environment has a useful life of several years or even decades. In this time, the IT infrastructure is undergoing continuous change, while the machines remain almost unchanged. At the same time, new requirements frequently arise, which can be satisfied by expanding the software functionality if at all possible without modifying the machine-related software itself. With SINUMERIK Integrate, resources can be networked and processes as well as production data centrally managed. Guaranteeing data security has top priority on one hand using encrypted data communication and on the other hand operating machines with firewalls. Link to the corporate level SINUMERIK Integrate allows machine tools to be simply networked in higher-level IT systems of the production environment. The software runs directly on the CNC, acquires all data from the CNC and PLC and provides this data to other systems. A central server provides various applications. If machines are connected with the server, then the new functions can be simply loaded into them. This is where the level of integration and seamlessness of the Siemens portfolio pays off, as PLM and MES systems can also be easily connected to improve productivity even more. This secures cost advantages both in the initial capital investment and subsequently in operation. Production managers, plant operators, programmers in production planning, maintenance technicians as well as plant and system builders are networked with one another so that they can communicate efficiently. One platform many advantages SINUMERIK Integrate is a central platform that can be used to increase the productivity of end users or increase the service efficiency of equipment manufacturers. Further, the automation level of the production environment can be expanded. Through optimized production, more parts can be produced, and also mistakes reduced for example, as a result of missing tools, incorrect CNC programs, high energy usage along with inventory levels of material and tools. 13

14 Success factor energy efficiency The more energy efficient production in the automotive industry, the more competitive it is. We can support you with our range of products, systems and solutions in order that all of the potential for increasing efficiency is fully utilized. This portfolio covers all phases of the product development and production processes. Energy-efficient solutions Already today, automotive production is characterized by the high degree of automation. However, there is also potential to make production even more energy-efficient. Here, the decisive factor is that all of the components optimally interact with one another. can be planned Efficient and productive plants and systems can already be planned at an early phase by simulating the complete production environment on the screen. Using digital models and analyses, motion sequences of your machines are optimized or load peak overlaps avoided, for example. In a real production environment, a significant amount of costs can be saved through innovative drive solutions. We are more than willing to support you in this area Product design Production planning Production engineering Production Service

15 Siemens as global service partner Long-term success is a sound basis for the best collaboration. The motivated and committed service personnel of Siemens develop individual solutions, perfectly tailored to a wide range of customers and industries. The focus is on absolute trust and in-depth know-how of the latest technology. It goes without saying that customers can also depend on this in the future. Industrial services Field Services Siemens Field Services guarantee that plants and systems are smoothly commissioned. This is then followed up by experts that service and maintain your plants and systems. Any faults that arise are quickly resolved. Comprehensive maintenance concepts and service agreements secure optimum availability of your plants and systems. Field Services at a glance: Global service infrastructure A wide range of products and technologies as well as state-of-the-art remote maintenance tools Comprehensive support during commissioning Siemens personnel ensure contact to the manufacturers of the components used Technical Support (Hotline) Siemens Technical Support supports its customers with a comprehensive portfolio tailored to address specific requirements. This starts with outstanding basic support and extends up to support contracts that are precisely tailored to address customer requirements. The following guarantee that an investment is kept secure, also over the long term: High planning reliability and optimized engineering costs Increasing plant and machine availability Technical Support: +49 (911) Spare parts and repair Spare part packages and services for optimum spare part stocking Repairs carried out with the high quality level of the manufacturer Transparency of the services provided and the parts used based on repair reports Global network of certified workshops Warranty is provided for the repairs carried out Motors and gearboxes from other manufacturers are also repaired Products that have already been discontinued are fully supported Training SITRAIN offers professional training courses for operation, programming, commissioning and maintenance of control systems around the globe. More than 280 certified trainers worldwide Training centers at over 170 locations in more than 60 countries More than 300 types of courses siemens.com/sitrain Our special services for machine tools Siemens provides support over the complete machine lifecycle. From the idea and conception up to operation and subsequent retrofit. The complete portfolio of innovative services offers enormous potential to optimize total cost of ownership. Manufacturing IT Process optimization by implementing the SINUMERIK Integrate product suite Extended machine contracts Customized service contracts Spares Plus Preventive spare parts management Productivity Improvement Shortening cycle times of existing machines Machine retrofit General overhaul of machine tools siemens.com/sinumerik/manufacturingexcellence 15

16 Everything about our solutions for the automotive industry: siemens.com/automotive You can learn more about our portfolio for the automotive industry. Subject to change without prior notice Article No.: E20001-A1480-P610-V Dispo D&M/74184 V1.MKAUTO.WES WS Printed in Germany Siemens AG 2015 The information provided in this brochure contains merely general descriptions or characteristics of performance 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. The required performance features are only binding if they have been expressly agreed upon in the form of a written contract. All product designations could be trademarks or product names of Siemens AG or other companies which, if used by third parties, could infringe the rights of their owners Siemens AG Digital Factory P.O. Box Erlangen GERMANY