Siemens’ Manufacturing Operations Management Solutions Support Digitalization

By Janice Abel

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Summary

Siemens%20MOM1.JPGAcquisitions are often disruptive, and not always in a positive manner.  However, when done correctly, these business disruptions can also be transformative. Siemens recently briefed ARC Advisory Group about the company’s many acquisitions that now enable that company to offer a unified manufacturing operations management (MOM) portfolio.  This portfolio is designed to support successful digital transformation across a broad range of industries.   

Siemens%20MOM2.JPGAs we learned, Siemens’ MOM portfolio is designed to integrate the digital threads of product lifecycle management (PLM) with automation and enterprise resource planning (ERP), connecting data and processes end-to-end from PLM and virtual products through to production and quality management and – ultimately – to post-sale product support.  Readers should note that Siemens considers MES (manufacturing execution systems) to be a subset of manufacturing operations management and this report will reflect that perspective.

Key findings include:

  • Siemens’ manufacturing operations management capabilities span multiple industries
  • The company has extensive domain and industry expertise and has acquired several best-of-breed applications over nearly two decades
  • The MOM portfolio is designed to support end-to-end integration from PLM to automation and to ERP and beyond
  • Enhancements to MOM for the digital enterprise include cloud-based technologies and SaaS
  • Closed-loop manufacturing enables better integration between the PLM, ERP, and CAD systems to help ensure closer alignment between as-planned and as-built products
  • Closed-loop quality (CLQ), in conjunction with CLM, supports Industry 4.0 concepts by leveraging the PLM backbone in combination with QMS and Quality Center products
  • Siemens’ high-availability MOM portfolio includes a graphical workflow designer.  The technology offers a common user interface using HTML 5 for a better user experience

Acquisitions Demonstrate Commitment to Digitalization

Siemens started its MOM digital journey in 2000 with the acquisition of ORSI.  This was followed in 2009 with the acquisition of ELAN, an MES technology for the pharmaceutical industry. 

manufacturing operations management Siemens%E2%80%99%20Software%20Suite%20for%20Manufacturing%20Operations%20Management.JPG

Other related acquisitions followed.  These included Preactor, with its advanced planning and scheduling; IBS for quality tools for execution and planning; CAMSTAR, with its MES for the semiconductor and medical products industries; and Mentor Graphics’ Valor, with its electronics MES.  More recent software acquisitions in this space include Tesis, which has been enhanced to become Siemens MOM-to-ERP integration layer; and Mendix, a leading low-code rapid application development platform that can leverage the manufacturing business logic and data contextualization coming from the MOM/MES for new user applications on IIoT

Siemens’ current MOM portfolio can be broken down into the following application areas:

  • Advanced planning and scheduling
  • MES
  • Formulated product design and LIMS (laboratory information management system)
  • Quality planning and execution
  • Manufacturing intelligence & manufacturing performance
manufacturing operations management Siemens%20Manufacturing%20Execution%20Systems.JPG

Siemens’ industry-oriented MES offering leverages the strengths of and synergies between acquisitions. Other MOM elements cross industries to help address strategies for closed-loop manufacturing and closed-loop quality.

Simatic IT UA for Discrete Manufacturing

The focus of SIMATIC IT UA for discrete manufacturing is to enable integration of regulatory mandates and quality in production, reduce time-to-market, and establish cost-efficient, synchronized, and flexible processes. Typical SIMATIC IT UA customers have complex assembly and job shop environments.  These include automotive, industrial machinery, and heavy equipment suppliers such as Rehau, Vinfast, and Siemens’ own manufacturing plants.

SIMATIC IT UA discrete manufacturing functions include:

  • Order processing and execution
  • Production tracking and monitoring
  • Material and tool management
  • Electronic work instructions (EWI)
  • Non-conformance management and redlining
  • Quality sentencing and escalation
  • ERP integration and automation integration
  • As-built design generation
  • Additive manufacturing support

Simatic IT UA for Process Industries

SIMATIC IT UA for Process Industries addresses vertical integration (e.g., data from DCS and PLCs), process orchestration, genealogy and production reporting, integrated quality management, regulatory data and information, recipe management, and other challenges.  Typical customers are in consumer packaged goods, food & beverage, and chemical industries. Customers include Mahou San Miguel, Reynolds American Inc., and Monsanto.

Specific functions include:

  • Modeling and executing manufacturing processes
  • Process management work flow and work instructions
  • Equipment management
  • Managing complex and detailed production recipes
  • Planning, executing and tracking production orders
  • Integration with SIMATIC Batch
  • Data collection & acquisition
  • Movement, storage & tracking of materials
  • Integrated quality test execution
  • Performance analysis

Simatic IT eBR

SIMATIC IT eBR adds pharma-specific capabilities for paperless manufacturing and electronic batch records. Typical pharmaceutical manufacturing. customers include Takeda, Baxter, and BioNTech.

Specific functions include:

  • Process management work flow and work instructions
  • Weighing and dispensing and compounding
  • Equipment management
  • Formula management
  • Material flow management
  • Integration to SIMATIC Batch
  • Paperless manufacturing with review by exception
  • Regulatory documentation for compliance

CAMSTAR Medical Devices Suite

The CAMSTAR Medical Device Suite adds the industry-specific functionalities needed to help medical device companies view and build quality proactively into the manufacturing process; set-up error-proofing processes; and support paperless manufacturing, electronic device history records (eDHR) and electronic batch records (eBR).  Typical medical device manufacturing and diagnostics customers include Micro Systems Engineering, Edwards Life Sciences, and Siemens Healthineers.

Industry-specific functionality includes:

  • Track and trace/genealogy
  • Work order management and tracking
  • BOMs and configuration and recipe options (depending upon process)
  • 5M (Man, Machine, Materials, Methods, Measure) enforcement and non-conformance management
  • Quality inspection and sampling
  • Asset monitoring and management
  • Electronic signatures
  • Operator training and certification
  • Electronic work instructions
  • Change management
  • Support for UDI
  • Integration with ERP, PLM, and APS system
  • Statistical process control (SPC)

CAMSTAR Semiconductor Suite

The Camstar Semiconductor Suite provides industry-specific functionality to address the manufacturing needs of targeted industries and segments. The product allows customers to manage and control the 5Ms of manufacturing.

Typical customers are in frontend and backend semiconductor industries as well as solar, display, and photonics industries.  Customers include ON Semiconductor and BRIDG.

Industry-specific functionality includes:

  • Lot, wafer, and die processing
  • Multi-product wafers
  • Flexible and comprehensive workflow management
  • Experiment management
  • Wafer map visualization
  • Tool/mask/reticle management
  • Track and trace/genealogy
  • Equipment tracking and management
  • Process and yield control
  • Dispatch control
  • Multi-chamber tools
  • Recipe selection
  • Slot mapping
  • Statistical process control (SPC)

CAMSTAR Electronics Suite

The recently launched CAMSTAR Electronics Suite combines Camstar with Mentor’s Valor best-in-class electronics MES capabilities.  It focuses on smart manufacturing for the entire electronics value chain, including PCB, mechanical and box build processes.  It supports manufacturing execution, quality management, materials management, planning and scheduling, and manufacturing intelligence, with direct connectivity to machines and production lines.  Typical customers are in electronics printed circuit board (PCB) and box manufacturing.

Industry-specific functionality includes:   

  • Integrated with Valor Process Prep and Unicam FX NPI
  • Standardized interactive Production Client for electronic PCB and box build for inspection, repair, production execution, and work instructions
  • Out-of-the-box interfaces to shop floor and production machines
  • Optimized and automated material management for electronics production
  • Process, quality, material traceability, and interlocking
  • Online reporting and analytics for production data and performance
  • Seamless ERP and PLM interface

QMS and Quality Center

To support the company’s closed-loop quality strategy, Siemens is integrating QMS Professional within its MOM portfolio. This enables closed-loop quality within a single platform, with one system for quality planning and execution.  The Siemens roadmap now includes Quality Center, which leverages Teamcenter and makes quality an integrated part of the digital thread in closed-loop manufacturing.

QMS Professional features include:

  • Quality planning (with FMEA and quality control plan)
  • Supplier quality management (incoming parts inspection/supplier assessment/audits and complaints)
  • Production quality (inspection planning/inspection during production/SPC)
  • Audit support (supplier/internal)
  • Identifying and evaluating defects/non-conformances
  • Managing customer complaints

For all Teamcenter customers in particular, Siemens will deliver an integrated, Teamcenter-native quality suite called Quality Center designed to support collaboration between engineers, manufacturing planners, and quality managers to significantly reduce time-to-market and costly rework.  

Advanced Production Planning and Scheduling

Preactor APS cloud-based planning and scheduling software supports cross- site planning and scheduling collaboration and order accuracy.   Platform-agnostic Preactor software can run natively in the cloud and enable integration with third-party products and data.  The software provides new visualization tools, reports, and dashboards.  Capabilities include:

  • Long-term planning
  • Detailed scheduling
  • Predictive changes for production, interruptions, machine breakdown, and scrap
  • Supports decision making for overtime, order prioritization, split production batches, due data negotiation, and order promising (CTP/ATP)

Manufacturing Intelligence & Manufacturing Performance

manufacturing operations management Siemens%20Manufacturing%20Intelligence%20System.JPGSiemens’ Manufacturing Intelligence platform can be deployed on-premise, in the company’s MindSphere industrial cloud environment or in hybrid environments.  In all cases, it uses the same data sources.  Manufacturing Intelligence provides a unified platform for both operational and enterprise data to support data analytics, collaboration, and visibility across a manufacturing enterprise.  The software can help improve decision making, predict delivery times, and reduce product failure risks.   Capabilities include:

  • Data governance and integration for MOM partner ecosystem
  • Data management, including third-party data
  • Analytics
  • Scalable from plant to enterprise

Manufacturing Performance provides real-time transparency on equipment efficiency, root cause analysis, and real-time visibility in the context of  MOM data and identifies performance issues proactively, closing the loop with MOM to improve operational efficiency.

Cloud and Manufacturing

Currently, Siemens’ Manufacturing Intelligence and Manufacturing Performance can run either on-premise or in Siemens’ MindSphere cloud environment and offered as software as a service (SaaS).  The short-term roadmap includes extending these capabilities across the entire suite.  

Proven Benefits

Siemens provided ARC with some examples of the benefits its customers across a variety of industries are realizing from their MOM deployments:

  • In chemicals, Kaneka deployed Siemens MES technology to increase capacity, reduce scrap, and improve quality standards across three plants.
  • In food & beverages, Chocolates Valor deployed Preactor APS to increase visibility and transparency of plant information to streamline its production planning.  The company gained 16 hours per week for the planner resource and maximized the product quality.
  • In power generation, Ansaldo Energia, used the technology for integrated information flow from PLM to MES/MOM and ERP and APS.
  • In equipment manufacturing, DAB Pumps reduced lead time, improved product quality and work-in-progress and increased manufacturing efficiency. Here, digitalization helped close the loop between manufacturing and the customer.
  • In electronics manufacturing, Siemens Fürth utilized CAMSTAR Electronics Suite to integrate PLM with ERP.
  • In automotive, Maserati used Siemens MOM technology from design to execution planning to obtain a simplified, streamlined development and manufacturing process.  The software reduced development time by 20 percent and increased production by a factor of three.

Summary

The future of manufacturing requires end-to-end integration and collaboration from PLM and product formulation and simulation to manufacturing and supply chain.  Digitalization can support this, but rarely can it all come from the same supplier.  As we learned, Siemens enhanced its own significant expertise and capabilities with new functionalities from acquisitions and is working hard to enable these to work together for customers seamlessly.

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Keywords: Manufacturing Operations Management (MOM), Product Lifecycle Management (PLM), Digitalization, Siemens, ARC Advisory Group.

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