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1 MediaService Industries Blog Monat 2018 MediaService Industries online January 2019 www. siemens.com Transformation with added value Cost-effective configuration of multi-purpose hall systems using Siemens technology Saint Hubert/Quebec, Canada. Gala Systems (Gala) is the world s biggest manufacturer of understage equipment and the leader in automation systems for multi-purpose halls. For a new multi-configuration system, Gala has opted to use Siemens technology to ensure the system s scalability and also provide scope for project-related upgrading. All the engineering functions are concentrated in a single platform, considerably simplifying handling. One of OEM (Original Equipment Manufacturer) Gala s key concerns was to cut the time required for commissioning and reconfiguration of a venue to an absolute minimum. The company was also keen to provide an overarching project management tool which would enable programming, monitoring, control and archiving of the entire automation project, encompassing multi-controllers, HMIs (Human Machine Interfaces), networks and VFDs (frequency converters). To meet all these requirements, Gala opted to use Simatic S controllers from Siemens to control its new multi-configuration system. The visualization software Simatic WinCC Advanced based on a Simatic industrial PC IPC277E enables a virtually unlimited number of programmable configurations for hall usage. This scalable solution can also be upgraded as required to include further Simatic ET200S distributed I/Os.

2 MediaService Industries online January 2019 Standardized engineering saves time and money As an integrated project platform, the TIA Portal software framework simplifies the engineering process by significantly reducing both the workload and expenses involved. One example is the communication system, which can be configured without risk of error by a simple mouse click. The Siemens solution also helps simplify the commissioning process. As a result of integrated system diagnostics and use of Profinet as communication standard, Gala is able to save an entire working week per project. As existing software and programs for hall systems can also be re-used for new projects, the company is additionally able to reduce its operating costs. Captions: Gala Systems (Gala) is the world s biggest manufacturer of understage equipment and the leader in automated multipurpose halls. Engineering in the TIA Portal software framework is one way in which Gala has been able to minimize the time required to commission a venue. From a virtually unlimited number of programmed configurations, the relevant one can easily be picked in the PC based visualization system Simatic WinCC. Use of the integrated Siemens solution has reduced Gala s workload for each project by at least a week. For more information: Simatic: TIA Portal: Simatic IPC:

3 MediaService Industries Blog Monat 2018 MediaService Industries online January 2019 www. siemens.com Pilkington Deutschland AG Manufacturing glass 365 days a year Glass manufacturer chooses Siemens automation for production line retrofit Weiherhammer, Germany. Pilkington is part of the NSG Group and produces float glass on two lines primarily for use as architectural glass. After ten years of continuous operation, the Float Two line needed to be modernized with a retrofit in order to ensure production remains economical. Pilkington decided to use its long-term partner, Siemens, in order to be able to achieve this mammoth project within the 100 day time frame. State-of-the-art automation solutions from Siemens were used to upgrade the line. This has allowed Pilkington to reduce energy consumption and exhaust emissions through intelligent controls. The open system architecture also provides a high degree of flexibility. Over a period of ten years, Float Two has produced a remarkable volume of material: With up to 810 tonnes of glass daily, 365 days a year without a break, the line has produced the equivalent of a 3.5-meter wide glass sheet approximately 75,000 kilometers long enough to go around the Earth twice. In light of this achievement and also because spare parts supply is becoming increasingly difficult, the line has definitely earned a retrofit. The line had to be completely shut down for this cold repair. As part of the upgrade, the process control system has also been replaced with a state-of-the-art solution from Siemens which had already been tested and approved in a factory acceptance test in Karlsruhe. By upgrading to a PCS 7 process

4 MediaService Industries online January 2019 control system, we now have a futureoriented investment in place on Float Line 2 which we can operate with complete confidence, says Pilkington Plant Director, Reinhold Gietl. Intelligent, flexible and future-oriented The new decentralized control system guarantees a high-quality production process as the PCS 7 process control system monitors precise maintenance of all variables during glass production. Intelligent controls also contribute to energy savings and to minimizing exhaust emissions. The process control system thus provides an optimum technical platform to be able to meet the growing demands on economy, conservation of resources, and environmental sustainability. At the same time, the open system architecture also provides a high degree of flexibility which is a precondition for further technical upgrades. Success through team work Our central engineering department at Pilkington worked closely with the Siemens specialists and colleagues from the plant at Weiherhammer during the control system upgrade. The combination of automation and project management specialists worked perfectly, adds Gietl. It is only through years of intense and proven collaboration with Siemens that we have been able to complete a project of this complexity without any problems in such a short period of time. Captions: Pilkington is part of the NSG Group and manufactures float glass on two production lines primarily for architectural purposes. After ten years of continuous operation, the Float Two line has been modernized with a retrofit and new automation technology from Siemens. By using a PCS 7 process control system, Pilkington is, amongst other things, able to reduce energy consumption and exhaust emissions through intelligent controls. With up to 810 tonnes of glass daily, 365 days a year, the Line 2 production facility is capable of producing a 3.5-meter wide, 75,000-kilometer long glass sheet over a ten year period. For more information: Simatic PCS 7: pictures: Pilkington Deutschland AG

5 MediaService Industries Blog Monat 2018 MediaService Industries online January 2019 www. siemens.com Future-proof mining Hub for creativity and cooperation fosters digitalization of South Africa s mining industry Johannesburg, South Africa. Mining is a critical sector of industry for South Africa with its rich mineral deposits. Despite this vital importance or maybe because of it, the country is faced with the challenge of modernizing its mining industry and also solving its mining engineering skills shortage. The Digital Mining Incubator (DMI) is an important platform for the qualification and recruitment of skilled labor. The initiative was launched by Siemens in close cooperation with Wits University and Tshimologong Precinct. Its aim is to engender enthusiasm for mining among young graduates, to advance the mining industry towards the digital transformation, and utilize the widespread possibilities opened up by digitalization. There is plenty of scope for optimization across the mining industry when it comes to digitalization and its benefits. South Africa, where mining looks back on a long tradition but also has a bright future, is embracing this challenge. Not only is it seeking to address the tangible skills shortage which is particularly prevalent in this sector, but its government and industry are also endeavoring to unleash the benefits of digitalization for the mining industry. The DMI platform is one way of addressing both these needs. Sustainable advancement for mining The Digital Mining Incubator is what is termed a Co-Creation space in which customers and partners are able to focus on the development of

6 MediaService Industries online January 2019 mining-related skills. The DMI is integrated in the Wits Tshimologong Digital Innovation Precinct, part of the University of Witwatersrand. Here, young people interested in mining are mentored by experts from the University and Siemens, with the aim of providing them with the tools and skills to effectively transform and develop the South African mining sector. The aim of the project is to utilize data in conjunction with machine learning, artificial intelligence and additive manufacturing as the basis for developing the smart mines of the future. Digitalization will bring about a sustainable, positive transformation of the value chain in the mining industry. Benefits will include a shorter time to market, increased flexibility in volatile global markets, optimized productivity and the creation of safer operations on site. Creating perspectives Professor Barry Dwolatzky, Director of the Joburg Centre for Software Engineering at Wits University and founder of the Tshimologong Precinct, summarized: Having Siemens open a digital incubator dedicated to promoting innovation in mining is a very significant landmark in bringing the benefits of 21st century digitalization to one of the most critical sectors in the South African economy. The DMI will provide a dedicated platform for developing innovative solutions to some of our mining industry s greatest challenges including health and safety, environmental protection and improved productivity. Captions: The Digital Mining Incubator (DMI) is a co-creation space designed as a platform for the qualification and recruitment of skilled labor for the South African mining industry. The initiative was launched by Siemens in close cooperation with Wits University and Tshimologong Precinct. The aim of the DMI is to engender enthusiasm for mining among young graduates and to advance the mining industry towards the digital transformation. South Africa aims to utilize data in conjunction with machine learning, artificial intelligence and additive manufacturing to develop the smart mines of the future. For more information: Mining:

7 MediaService Industries Blog Monat 2018 MediaService Industries online January 2019 www. siemens.com 50 percent quicker manufacturing Siemens software simplifies and automates the development process for plastic molds Kalamazoo/Michigan, USA. JK Machining (JK) specializes in the design and manufacture of plastic injection molds. The company works primarily in the automotive and medical components industry. JK uses Siemens PLM Software solutions as part of its development process to maintain competitiveness and delivery of highquality molds within short lead times. Amongst other things, this has reduced production times from 22 weeks to 10 and the software solutions also allow frequent changes in design to be completed both smoothly and cost-effectively. A few years ago, JK decided to replace all the different software systems for designing and manufacturing molds with a single solution. The objective was to install a seamless, automated production process - from design to the finished mold. A decision was made to adopt the NX 3D- CAD system from Siemens PLM Software. At JK, the design process for molds starts when customers send in CAD (Computer-aided Design) models of the components they require. This is the start of the 3D design process. Using NX is light years beyond how I used to design molds in 2D, remembers Brian, Mold Designer at JK. The mold analysis tools are great I can easily identify undercuts or places where we need more draft. I can look for thin or thick walls, and automatically determine the total weight of the

8 MediaService Industries online January 2019 mold and its center of gravity. The software also produces the bill of materials automatically which saves a significant amount of time. Simple programming and five-axis machining JK can program all the milling process needed to manufacture the mold in NX CAM (Computer-aided Manufacturing), saving many hours work on each project as the mold design is fully integrated into NX. One of the key benefits for the JK programmers is the tool tilt control function in NX CAM. This makes machining in five axes extremely easy as the tool automatically converts three-axis tool paths into five-axis tool paths. The open automation and customization tools, which allow NX to be easily adapted to JK s individual requirements, are also particularly valuable to the business. NX and robotics pave the way to the future JK s very positive experience with NX has prompted the business to plan the next stage in its optimization process. We are currently considering how we can use robotics to automate the process further. Through automation and continuous improvement with NX, we have been able to reinforce our reputation as a reliable supplier of extremely high-quality tools which allows us to continue to be competitive and grow the business, summarizes Henry Kalkman, President of JK. Captions: JK Machining (JK) specializes in designing and manufacturing plastic injection molds for the automotive and medical devices industry. To maintain competitiveness and to be able to deliver high quality molds within short lead times, JK uses Siemens PLM Software solutions in its development process. The challenge was to set up a seamless, automated production process, from design to the finished mold. Using NX CAM /Computer-aided Manufacturing), JK can program all the milling processes required to create the mold in NX CAM (Computeraided Manufacturing). Mold design is fully integrated into NX which saves many hours work on each project. Mold analysis tools allow the total weight of the mold and its center of gravity to be determined automatically. The tool tilt control in NX CAM automatically converts three-axis tool paths into five-axis tool paths. The Siemens solution allows frequent changes in design to be achieved without any problems and brings production times down from 22 weeks to 10. For more information: PLM: global/en/ NX: