Reduce Produced Unit Cost with Condition- Monitoring and Machine Tool Analytics Presented by Vinicius Strey Manufacturing in America March 14-15,

Transcription

1 Reduce Produced Unit Cost with Condition- Monitoring and Machine Tool Analytics Presented by Vinicius Strey 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 Drivers for Digitalization on Machine Tools Challenges for Digitalization on Machine Tools Analyze MyPerformance and Analyze MyCondition Manage MyMachines (MindSphere) Questions

4 Agenda Drivers for Digitalization on Machine Tools Challenges for Digitalization on Machine Tools Analyze MyPerformance and Analyze MyCondition Manage MyMachines (MindSphere) Questions

5 A lot can happen in a year 90% of the data in the world today has been created in the last two years Source: IBM, 10 Key Marketing Trends For 2017,

6 Digitalization in Machine Tools what Machine Tool Supplier Machine Tool Owner Business Purpose The purpose remains unchanged, Machine Tool Supplier Machine Tool Owner Business Purpose how processes but the way how things will be done vv in the future will change! interaction structures data analytics disciplines seamless data flow IT virtual systems vv seamless manufacturing Digitalization collaboration Machining Automation simulation Machining Automation Technology Technology seamless engineering Technology Technology

7 Driver for Digitalization on Industry Source: Industrial Analytics 2016/2017 The current state of data analytics usage in industrial companies

8 Maintenance Strategies: Still Reactive Value & Complexity Act Analyze Prescriptive Analytics Inform Predictive Analytics Diagnostic Analytics Descriptive Analytics What happened? Why did it happen? What will happen? What shall we do? Examples Plant operation report Fault report Sales reports Service statistics Alarm management Root cause identification Fault analysis Power consumption prediction Fault prediction Production prediction Operation point optimization Load balancing Production re-planning Current penetration across all industries (according to Gartner) Adopt by vast majority but not all data Adopted by Still few adopters 99% 30% minorities 13% 3% Very few early adopters

9 Agenda Drivers for Digitalization on Machine Tools Challenges for Digitalization on Machine Tools Analyze MyPerformance and Analyze MyCondition Manage MyMachines (MindSphere) Questions

10 Challenges for Digitalization Source: Industry 4.0 Opportunities and Challenges of the Industrial Internet (PwC)

11 Starting Small is the Best Bet Benefits Verified Determine a phased approach to be rolled out Benefits Unverified Determine adjustments on the your strategy

12 First: Transparency Know the asset Keep the asset running Improve the asset yield Responsive: Have relevant data at your fingertips Improve efficiency of data acquisition, monitoring and exchange Pro-active and predictive: Solve problems before they occur Lower maintenance costs and ensure technical up-time of your asset Business-enhancing: Improve business value of the asset Increase asset yield, support product design, enhance serviceability and business model Intelligence Transparency Reliability Online monitoring, diagnosis / analysis, presentation & reporting

13 Challenges for Digitalization Source: Industry 4.0 Opportunities and Challenges of the Industrial Internet (PwC)

14 Security is the Most Common Unfounded Objection Defense in depth Plant security Physical access protection Processes and guidelines Holistic security monitoring Network security Security threats demand action Cell protection and perimeter network Firewalls and VPN System integrity System hardening Patch management Detection of attacks Authentication and access protection

15 Siemens Vision regarding Vertical Integration Computer-Aided Manufacturing Instructions, NC Programm Gen. Manufacturing Process Planning Standards, Generic Resources Enterprise Resource Planning Orders Product Lifecycle Management Product and Process Data, Engineering Work Flows Manufacturing Execution System Production Management NC Programms MindSphere / Sinumerik Integrate Tools, Resources Status, Performance Indicators

16 Agenda Drivers for Digitalization on Machine Tools Challenges for Digitalization on Machine Tools Analyze MyPerformance and Analyze MyCondition Manage MyMachines (MindSphere) Questions

17 Analyze MyPerformance Full Transparency in Manufacturing Factory-wide data acquisition and evaluation 1 Plant image with machine situation Acquisition of machine statuses Determination of OEE figures Evaluation of machine statuses 2 3 Status analysis over time (GANTT chart) Alarm log and alarm statistics Plant image GANTT chart Availability analysis 4 Fault reason analysis 5 Export of data in Excel format 6 Customized OEE formula Analyze MyPerformance provides the plant / system operator comprehensive evaluation and analysis procedures which allow to display the manufacturing efficiency as a basis for targeted efficiency increase in manufacturing.

18 Analyze MyCondition Condition-Based Maintenance Relevant components Linear axes, e.g. Power consumption Utilization Pneumatic system Pressure Air consumption Tool magazine, e.g. Number and duration of clamping cycles Main spindle, e.g. Vibrations Drive current Automation Configuration of hardware & software Function monitoring Fluid technology, e.g. Temperature Filter monitoring Chip conveyor, e.g. Operating hours Power consumption Focus on the relevant components Causes of long downtimes Driving forces of life cycle costs

19 Analyze MyCondition Condition-Based Maintenance Ball Screw / Bearings Typical Problem Loose fit on bearings Backlash Circularity Test

20 Analyze MyCondition Condition-Based Maintenance Ball Screw / Guideways Typical Problem Misalignment Parallelism Erros Axis Test

21 Analyze MyCondition Condition-Based Maintenance

22 Agenda Drivers for Digitalization on Machine Tools Challenges for Digitalization on Machine Tools Analyze MyPerformance and Analyze MyCondition Manage MyMachines (MindSphere) Questions

23 MindApps Powerful industry applications and digital services for asset transparency and analytical insights MindSphere Open Platform as a Service (PaaS) for scalable, global IoT connectivity and application development MindConnect Secure plug and play connection of Siemens and third-party products and equipment MindSphere - The cloud-based, open IoT Operating System

24 Manage MyMachines Transparency on the Shop Floor The floorplan shows the machine s position in the factory Requests log all machines incidents based on predefined platform rules Production manager Maintenance manager or OEM service manager Machine overview provides a one page summary of operation data. User defined aspects combine critical machine data for meaningful analysis Machine operator Maintenance or OEM machine specialist

25 Start Collecting Data Now! If your end game is to digitalize products and production within next 5 years, you should start collecting data of interest right now. Historic data cannot be recovered and is the key for better predictive models in future. Source: Industry 4.0 Opportunities and Challenges of the Industrial Internet (PwC)

26 Questions? Vinicius Strey Senior Key Consultant Motion Control Services 100 Technology Drive, Alpharetta, GA Phone: (470)

27 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:

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