Machine Modernization: Retrofit Aging Equipment with Modern, Cutting-edge Products to Extend Life and Save Costs

Transcription

1 Machine Modernization: Retrofit Aging Equipment with Modern, Cutting-edge Products to Extend Life and Save Costs Presented by David Dupre Manufacturing in America March 14-15, 2018 Unrestricted Siemens 2018 usa.siemens.com/mia

2 Before we start A Penny for Your Thoughts At the end of the session, share your feedback via MiA App - and get a chance to win tickets to the Detroit Tigers baseball game!

3 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

4 We Can Handle Any Technology! Turning Gear Hobbing Milling Welding Combi center Plasma cutting Laser Grinding

5 A Small Sample of Machine Brands we have Modernized...

6 A Few of Our Many Clients Worldwide.

7 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

8 What is Machine Modernization? Taking you from here to there

9 Different Types of Machine Modernizations 1. Only Drives (Drive Retrofit) (Siemens/non Siemens to New Siemens drives) 2. Only Control (Siemens/ non Siemens tot New Siemens Controls) 3. Complete machine (With/without mechanical modifications) 4. Component Upgrade, Digitalization, or Automation Upgrade (Machine specific modifications) Sinumerik Integrate

10 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

11 Overall Benefits of Machine Modernization Machine availability Long failure times Event Spare parts Spare parts availability Machine lifetime Extended lifetime Reduction of various costs Costs Faults Years Years Unit costs Investment costs $ Operational costs Technology Operation Accuracy Functionality Operation Functionality Accuracy

12 Machine Modernization Realizing the Benefits Decide Improved Machine Performance for older machines and plants Function Expansion i.e. Digitalization / Industry 4.0, Safety, PC Operating System, etc. Renewal of the mechanical system Spare component availabilty Extension of the overall Machine Life Cycle Cost effective alternative to buying new machines Compatibility with new technology, digitalization platforms, etc.

13 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

14 Is Machine Modernization a Good Investment? 1 Compared to a New Machine What would a new machine with the same production quality and capacity cost today Original type of machine still available or being replaced by a more expensive type of machine 2 Machine Properties Machine is in a good mechanical state Machine has proven its stiffness Operators and Service staff knowledge 3 Implementation Logistical issues and speed, guaranteed production Implementation into Digital environment

15 Costs Consideration of the Benefits New investment approx. 1M 10M $ 0 5 New investment approx. $250k 750k Retrofit Mechanical and/or Electrical system Midrange machines Approx % compared to purchase of new machine Retrofit Mechanical and/or Electrical system High-end machines Approx % compared to purchase of new machine Complexity

16 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

17 Project Phase 1: Analysis / Concept Analysis Plan Implementation Acceptance Service Measures Assessment of the machine at the customer Determination of the scope of the retrofit ( upgrade, retrofit in stages, or complete retrofit ) Preparation of the entire project processing (schedule, identifying partners, determining responsibilities, etc.) Clarification of the problem areas for the retrofit (machine guidelines, device/product safety regulations, risk analysis, safety concept, CE certification, etc.) Customer benefits Joint discussion establishes trust Consideration of special wishes Problem-free project execution through: Exact timing Definition of the areas of responsibility Fixed price when order is placed

18 Analysis - Retrofit versus Upgrade Analysis Plan Implementation Acceptance Service Cost Age of Machine Technical Needs Lifecycle Needs Budget

19 Analysis - Determining the Scope of the Modernization Analysis Plan Implementation Acceptance Service UPGRADES Update control components within a controller family (840D Powerline to newer 840D Powerline) as needed to extend machine lifecycle and parts availability Upgrade to a newer PC/Operating System for network/software compatibility, improved HMI performance, i4.0. Do not significantly change the machine function/look and feel of the HMI interface. RETROFITS Upgrade to a newer version of Control System to extend machine lifecycle, add functionality, improve performance Upgrade drives/drive system and/or motors to extend machine lifecycle, or performance improvement A complete machine upgrade, including a completely new control system, machinery refurbish, new motors and drives and i/o and auxiliary automation systems Upgrade automation, auxiliary systems, ncu system software, digitalization, tool management system, add new functionality, etc.

20 MMC/PCU with DOS MMC/PCU with Windows Analysis - Product Lifecycle SINUMERIK 840D Upgrades OP OP 030, 031, 032, 032S OP 08T,, 010, 010C, 010S, 012, 012T, 015, 015A OP 08T, 010, 010C, 010S, 012, 015, 015A, 019 HMI SW AutoTurn MMC WIN3.11 WIN95 PCU50 WIN NT4 HMI 6. ShopMill ShopTurn ManualTurn V1 PM 490 3/2008 V2 PM 490 9/2018 XP HMI ShopMill ShopTurn V3A PM 490 9/2016 V3B PM 490 9/2018 V5 PM 490 9/2019/24 WIN XP XP HMI 7.x V5 PM 490 9/2019/24 XP / WIN 7 SINUMERIK Operate V5 PM 300 WIN 7 DOS WIN 2000*) *) not for SINUMERIK HMI MMC PCU20 SPC 500 MHz PM490 9/2024 DOS DOS NCU NCU NCU PM490 9/ PM490 9/ PM490 9/ PM490 9/2013 NCU.2 NCU PM490 9/ PM490 9/ PM490 9/ PM490 9/2015 NCU PM490 9/ PM490 9/2014/ PM490 9/2015/ PM /2013 9/2017 NCU.5A PM490 9/ PM490 9/ PM490 9/ PM B PM490 9/ B PM490 9/ B PM490 9/ B PM NCU.5B NCU NCU NCU PM PM Year

21 Analysis - Possible Solutions Analysis Plan Implementation Acceptance Service Solution 1 Upgrade PCU 50 V1/V2 to V5 (XP) SW-Upgrade HMI Advanced SW-Version 6.4 (ShopTurn / ShopMill still running) or 7.6 Upgrade of NCU and NCU-SW (CNC-SW) Consideration of compatibility Emulate old Operating SW OEM, Solution Partner, Transline Emulate OEM-specific functions Windows XP HMI Advanced 6.4/7.6 neu PCU NCU Solution 2 Complete Retrofit to latest HW: SINUMERIK 840D sl SINAMICS S120 SIMOTICS Benefits Lower Cost Faster Implementation Shorter Downtime Operator Familiarity Benefits Newer Technology Like a new machine Warranty Longer Lifecycle extension

22 Analysis - Upgrade Concept for SINUMERIK 840D Powerline Analysis Plan Implementation Acceptance Service Partly Retrofit for a Machine with 840D Powerline to the latest HW/SW Version Scope: Controller (NCU), HMI exchanged incl. necessary SW-upgrade (NCU/PCU) Drive, Motors, Cable and Periphery remain on the Machine Advantage: small investment, short time for Modification & re-commissioning time Disadvantage: Lifecycle max. until. 30.Sep.2024! 840D pl NCU PCU50 V1 Win NT Transline-SW (HMI Pro 2.1 Pro Tool Pro) 840D pl 57x.4 NCU 57x.5 NCU NCU-SW 6.5 PCU50.5 WinXP HMI Adv. 7.6 Transline-SW (HMI Pro v7.3)

23 Analysis - Retrofit Concept Example Analysis Plan Implementation Acceptance Service Prior to the retrofit Following the retrofit SINUMERIK 3 controller New SINUMERIK 840D sl controller SIMODRIVE 610 drive New SINAMICS S120 drive Motors New motors SIMOTICS 1FT7 & 1PH8 Extra Functionalities + SAFETY + IT for Production

24 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

25 Project Phase 2: Project Planning Analysis Implementation Acceptance Service Planning Selling the project to Funders/Decision Makers Capital Funding Planning/Maintenance Budget (Siemens Financing Available) Scheduling with/around Production Planning Typically 3 days to 6 weeks depending upon the scope of the project. Part Lead-time, scheduling resources typically 6-8 weeks minimum for upgrades, 3 month minimum for retrofits. Acceptance Criteria Spare Parts Assessment

26 Project Phase 2: Project Planning Defining Acceptance Criteria Analysis Implementation Acceptance Service Planning Mutually acceptable, predefined criteria that will define successful completion of the upgrade/retrofit must be defined at this stage or sooner. This can include: Speed of machining required / cycle time to produce one part. Comparable or better than a benchmark part. This part needs to be manufactured and quality-checked immediately prior to work beginning to provide an accurate benchmark. Benchmark parts/tests can include, for example: Spider Tests, Circle-Diamond-Square Tests, actual production parts/measurements, any other part mutually agreed upon by both parties. 320mm ISO Circle-Diamond-Square Test Piece

27 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

28 Project Phase 3: Implementation / Execution Analysis Implementation Acceptance Service Planning Measures Function analysis (extensive investigation, collecting data, ghost images, etc.) Configuration work (CNC, drives, software, control cabinet, etc.) Applying retrofit solutions with SINUMERIK 840D sl SINAMICS S120 and SIMOTICS Motors Replacement concepts (examples) Integration of SINUMERIK in the manufacturing group Creation of circuit diagram and documentation Installation, modification work on site or collected, if required (with external partners for the mechanical and electrical systems) Baseline Performance test must be performed immediately before work begins based upon mutually agreed upon Quality/Speed Parameters. This defines the standard for Satisfactory Acceptance. Example: Spider Test, Circle-Diamond-Square, Quality/Speed = Equal to or greater than initial Customer benefits Use of existing drives, motors or measuring systems (after prior technical clarification) Incorporation of own contribution Short machine downtime and fast training of the operators

29 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

30 Project Phase 4: Acceptance / Completion Measures Analysis Implementation Acceptance Service Planning Commissioning on site and test of all relevant functions Creation of a complete data backup Machine handover (schematics, new documentation, specification of any further measures in the report) Instruction of the operating personnel (individual training if required) Performance test and acceptance workpiece as determined by mutually agreed upon Quality/Speed Parameters Spider Test Circle-Diamond-Square Quality/Speed = Equal to or greater than initial. Customer benefits Immediate start of production Plant has the latest technology Dependability through a differentiated range of services

31 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

32 Support & Service Analysis Implementation Acceptance Service Planning Possibilities Service contracts can be included with upgrades or purchased separately with a variety of levels of response time and inclusions to meet your needs Factory Warranty/RSC included with full machine retrofits Field Service/Technical Support/Customer Service Hotline: +1 (800) Homepage: CNCservice.industry@siemens.com CNCparts.industry@siemens.com Customer benefits Our service people know the machine Excellent service from the source Competitive prices for parts

33 Agenda Modernization What is it? Modernization - Benefits Modernization Cost versus New Machine Project - Analysis Project - Planning Project - Implementation Project - Acceptance Support & Service References Questions?

34 We Offer You a Total Project from Start to End Projekt-, Konzept- Erarbeitung Projektabwicklung Koordinierung Inbetriebnahme Maschinentest Analysis Implementation Acceptance Maschinenübergabe Protokoll Machine Analysis General Planning Project team Financing Engineering Functional Analysis Project management Training/Documentation Acceptance test Service

35 Aerospace Client - Droop & Rein Profiler Aerospace CNC Gantry machine Challenge Technical Risk with various black box components Real danger of production standstill Discontinuation of FIDIA controller as spare-part A complex combination of units control the machine Old Indramat drives dating from 1991 FIDIA Controller Unique Customer has 2 concepts to choose from We can offer the full scope of products needed Alternative motor measuring functions avoid standstill Flexible manipulation with additional screens Project management Benefits Elimination of black box components Various functions combined in 1 controller Safety integrated New EPLAN drawings Tool management Implementation into a digital environment

36 Drives/CNC Range of services Complete (mechanics, electrics) References... are Proof of Our Technical Competence FP4 cover SZIM gantry-type milling machine Milling/boring machine PULLMAX laser punching press Machine Plant Complexity

37 And Many More References

38 Questions? David Dupre Requirements Solution Engineer Address: 4170 Columbia Rd, Lebanon, OH Phone:

39 How did we do? Share your thoughts to win! Got 1 minute? Rate this seminar via MiA App for a chance to win Detroit Tigers tickets:

40 Seminar Slides After MiA, seminar slides will be available at: