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    Siemens.move up 2010-1-en Siemens.move up 2010-1-en Presentation Transcript

    • The Magazine for Automation in the Automotive Industry moveup Volume 9, Number 1, 2010 Fujian Daimler Automotive, China High Standards, Local Support
    • 2 move up | 1-2010 p Editorial p Cover Emerging Markets 4 Flexibility on a Global Scale Volkswagen Group Rus, Russia 8 High Standards, Local Support Fujian Daimler Automotive, China 10 International Benchmark Renault Nissan Automotive India Pvt Ltd., India 13 Taking the Wheel Emerging market trends 14 Global Partners Volkswagen India 16 Bringing Innovation to Market Faster Automotive Sector, Mahindra & Mahindra Ltd., India 18 The Next Level Zhejiang Geely Holding Group Ltd., China 20 Keys to Success Beijing Foton Cummins Engine Co., China 22 In Brief 23 Dialogue With standard components and expertise from Siemens, Volkswagen is producing a wide range of vehicles in Kaluga, Russia, in a world-class facility Page 4 Fujian Daimler Automotive benefits from both high standards in its automotive production and good support from the local Siemens team Page 8 Renault Nissan Automotive India Pvt Ltd. sets benchmarks in terms of production quality and performance with Simatic technology Page 10 Volkswagen Daimler RenaultNissanAutomotiveIndiaPvtLtd. C o n t e n t s m o v e u p | 1 - 2 0 1 0
    • Thomas Schott Head of Factory Automation Siemens Industrial Automation Systems move up | 1-2010 3 E d i t o r i a l After an extremely difficult year, we and our customers are glad to see a significant market recovery. The emerging markets have certainly played a key role in this recovery; with their dynamic approach they were able to curb and, to a certain extent, even counteract the down- turn in the traditional automotive markets. Countries such as Russia, China, and India were able to maintain steady growth throughout 2009. Plus, the long-term prospects are good: emerging markets continue to be demand-driven. Moreover, manufacturers there are placing greater emphasis on high-quality and efficient production systems. In order to implement these systems, they need partners with the corresponding expertise. We are extremely proud that we can support our customers in emerg- ing markets to achieve their goal of safe, state-of-the-art, and envi- ronmentally friendly automotive manufacturing. Not only do we work directly with automotive manufacturers as a product and solution provider, we also work with international OEMs. Our expert teams working on-site can draw on our extensive and global automotive knowledge. In this edition of move up, which focuses on these emerging markets, you can read about some of the many successful projects we have implemented with our customers in Russia, China, and India. I hope we can give you some valuable ideas. Enjoy the read! Yours,
    • 4 move up | 1-2010 C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 5 Volkswagen Group Rus, Russiap Flexibility on a Global Scale With its new plant in Kaluga, Volkswagen is increasing its presence in Russia – a strategic growth market for the future. The plant has been able to produce up to 150,000 vehicles per year since the completion of the second stage of expansion at the end of 2009. For Volks- wagen, this date marks the successful conclusion of a project lasting nearly four years. One of the central requirements of the factory was the production of a wide range of different models. Today the plant already produces more than 20 models belonging to the Volkswagen, Skoda, Audi, and Volkswagen commercial vehicles brands. The new production facility is located in the Grabzevo technology park in Kaluga, southwest of Moscow. The location is ideal – offering plenty of space, yet close to Moscow as an important hub – and the foundations for the new plant were laid here at the end of 2006. Initially, Volkswagen built a semi-knocked-down (SKD) production facility, which went into operation in 2007. The vehicles are assem- bled from large components in this facility. Follow- ing that, the site was extended for full production by the end of 2009 with the addition of a body shop, paint shop, and final assembly area. A total of five Volkswagen and Skoda models now roll off the production line in Kaluga for the Russian market. With standard components and expertise from Siemens, Volkswagen is producing a wide range of vehicles in Kaluga, Russia, in a world-class facility. Allphotos:Volkswagen
    • 6 move up | 1-2010 The special on-site conditions, with infrastructure under development and relatively limited local resources, and also, to a lesser extent, the specific guidelines from the Russian authorities, meant that project partners were needed that had both the technical expertise from Germany and the local competence to be able to properly implement such a large, international project. In part for this reason, Volkswagen decided to work with Siemens. With a presence spanning 150 years and experience in the country, Siemens is able to implement large and complex projects on time in Russia – while complying with specific guidelines and standards (GOST, etc.). Global standards implemented on a local level Volkswagen has high global standards for the quality of its products and therefore also places high demands on the quality and development of the systems engineering employed. Siemens came up with the right answers for Volkswagen in Russia: setting up the complete electrical infrastructure – from the groundbreaking to the completion of the assembly plant – came under Siemens’ responsibility as the general contractor. The consistent, integrated implementation of the power supply in accordance with Totally Integrated Power (TIP), from power outlets to the 20-kilovolt substation, made an essen- tial contribution to the success of the overall project. Moreover, Siemens was also an important solution partner in equipping the final assembly and supplied the entire conveyor technology, including all compo- nents for the car body conveyor technology and important just-in-time (JIT) parts (doors, dashboard, etc.) using electric overhead conveyors, skillet con- veyors, and belt conveyors. Furthermore, Siemens supplied systems for assembling the dashboard and front end, adjusting the drive line alignment (axle and track), programming the vehicle control units H i g h l i g h t s a t a g l a n c e On-schedule delivery and implementation3 Fulfillment of the global Volkswagen quality3 standards Expert and powerful partner for international3 project management Solution partner for mechanical and3 electrical systems across all products Local project and technology skills in Russia3 with certification (GOST, TÜV) Local maintenance and after-sales service3 C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 7 (checkout with SIDIS pro), and ensuring the assem- bly quality using a worker information system (rip cord, Andon board). In addition to the infrastructure and final assembly, Siemens – as a partner of the Volkswagen tool-making unit – was responsible for the complete implementation of the automation technology, including robot programming in the body shop that is equipped with the latest laser welding, geometrical, and respot welding technol- ogy. All the mechanical and electrical fittings for the body-in-white finishing lines (doors, hatches, etc.) were also supplied by Siemens. A Totally Integrated Automation (TIA) concept was implemented for all production facilities, with S7-317/319 Siemens controllers and an integrated visualization system. The sophisticated conveyor process was implemented with Siemens EMSdriver carriage controls and the tailored combination of Sinamics G120 D frequency converters and Flender geared motors. For the first time in a Volkswagen plant, communication between the components was established using only Profinet/Profisafe – even wirelessly, using Industrial Wireless LAN with Scalance W, in the extensive assembly halls. The innovative automation concept was also the inspira- tion for other new Volkswagen plants in Pune, India, and Chattanooga, Tennessee. Heading toward success with standard technology The integrated Siemens mechanical, electrical, and automation technology solutions form the basis for qualifying and training the operating personnel on-site and today can guarantee a uniform, easy-to- understand means of operating the systems. The standardization of the materials used allows a con- siderable reduction in spare parts stock – an addi- tional benefit for Volkswagen. However, expertise and support are needed from the specialists from time to time, and in this case, quick and competent local after-sales service is available from Siemens Russia. Kaluga has been working at full production since October 2009 – with world-class performance, as confirmed by the project team. The expertise and problem-solving ability of Siemens has made a great contribution toward this success. “Thanks to modern technology, the most flexible plant in the Volks- wagen Group worldwide has emerged in Kaluga,” says Dietmar Korzekwa, Russia corporate manager and general director of Volkswagen Group Rus. p info contact www.siemens.com/automotive schmitt.walter@siemens.com Siemens acted as a solution partner for specific packages and the entire power supply als Werksstandard Plant uses a Siemens Automation Concept as a standard solution Plant Cross-sectional functions S7-317/319; Simatic ET 200pro; Profinet; Scalance IWLAN; IWLAN Mobile RFID Moby-E; WinCC; sensors, switching devices, etc.; Sinamics G120 D; Flender geared motors Chassis installation 1–5 Logistics Installation automation Control systems/ MES Building technology/ security Communication/ networks Installation automation for laser, geometric, and respot welding stations Body shop systems and conveyor technology Conveyor technology Dashboard and front-end installation Wheel alignment Universal testing system with SIDIS pro Installation automation Electrical infrastructure and power supply Siemens scope of delivery Power supply from the substation (20kV) to the outlet General lighting for all indoor areas and outdoor installations Control system for the power supply and lighting SKD assembly Final assembly CKD production Press shop Body shop Paint shop Final assembly
    • 8 move up | 1-2010 Fujian Daimler Automotive, Chinap High Standards, Local Support Located in Qingkou, 25 kilometers south of the city of Fuzhou in southeast China, the new Fujian Daimler Automotive greenfield project has been called “Daimler’s South China pillar.” A joint venture between German automaker Daimler AG, Fujian Motor Industry Group Corporation (FJMG), and Taiwan-based China Motors Corporation (CMC), the Fujian Daimler Automotive (FJDA) plant is expected to “raise the technology and quality of the Fujian auto industry,” according to Ling Yuzhang, former chairman of FJMG and the board of FJDA. The plant makes several models of multipurpose vehicles and light vans: the Sprinter, the Vito, and the Viano. The Sprinter and the Vito/Viano models are assem- bled on a so-called mixed production line. This was a particular challenge, as the models not only differ greatly in size but also vary in terms of assembly concepts during assembly and marriage. Conse- quently, FJDA needed a mixed-line assembly solution that could accommodate that. Implementing a higher standard Previously, FJDA had considered using Asian prod- ucts and solution partners for its new plant in China. However, Daimler had had a positive experience with Siemens automation technology and automo- tive manufacturing expertise in its Beijing Benz- When Fujian Daimler Automotive wanted high standards for auto production, the company looked to Siemens for a solution, and also received a good local team to support it. Automotive Co. Ltd. (BBAC) joint venture in China as well as in Europe, where Daimler has also developed an innovative standard for the design and equip- ment of production facilities in Daimler AG assembly plants. This Integra standard also specifies automation and communication technology. Key elements of the automation technology in the Integra standard are proven Simatic components, such as the Simatic S7 controllers. These components form the basis for the standardization of operator panels and control units. The use of this standard results in efficient project realization, a smooth and fast ramp-up, and opti- »Due to its extremely positive experiences in the Daimler and BBAC parent plants, FJDA has decided to use Siemens also in its new plant in Qingkou.« Christoph Rentsch, FJDA C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 9 info contact www.siemens.com/automotive hans.heinl@siemens.com mized lifecycle costs. This means increased produc- tivity and reduced total cost of ownership for the customer. So when FJDA was assessing various alternatives for the new mixed assembly line, it was also evaluating Siemens as a supplier. “Due to the extremely positive experiences in the parent plants, we decided to use Siemens technology in our Chi- nese plant in Fuzhou,” said Christoph Rentsch, FJDA. In November 2007, FJDA planning management in Fuzhou decided to use Siemens technology based on the Integra BBAC standard for all systems in the body shop, paint shop, and assembly. Easy implementation, excellent support For the Fuzhou assembly project, Siemens provided a comprehensive turnkey solution for the entire assembly line, complete with testing and inspection line. Siemens delivered the automation and drive systems, such as Simatic ET 200 distributed I/Os, Simatic S7 controllers, Simatic panels, and Scalance network components, along with all required engi- neering for the chassis installation and preassem- bly, the conveyor technology (electrical overhead monorail system, slat and skid conveyor), the filling equipment, and the testing systems (roller tester, wheel alignment, headlight aiming tester, etc.). The entire automation technology solution was produced by Siemens Factory Automation Engineer- ing Ltd. (SFAE) in China. SFAE also provides local after-sales service that is fast, flexible, and in the client’s language. Siemens automotive experts in the headquarters and SFAE jointly developed and successfully implemented the automation concept, including the Andon board system, also providing concept overviews of the automation technology used. In addition, thanks to SFAE it was not neces- sary to bring in support from Germany for the design and commissioning of the automation project. Flexible, high-performance line With the new assembly line, FJDA benefits from the highly flexible mixed-line concept for the Vito/Viano and Sprinter models. For example, the chassis for both models can be assembled with only one type of assembly frame in preassembly and marriage, and the models are transported with only one type of electric monorail system (EMS) hanger using alter- nating adapters. Due to this flexibility, the line does not require any buffers for different kinds of assem- bly frames. This design is space saving, reducing the plant footprint and costs. p K e y p o i n t s The Sprinter and the Vito/Viano3 models differ greatly in size and assembly concepts during assembly and marriage FJDA needed a mixed-line3 assembly solution that could accommodate that Siemens provided a suitable3 turnkey solution for the assembly line with a testing and inspection line FJDA benefits from a flexible3 line solution that is also space saving, reducing the plant footprint and costs o Both the Viano and the Sprinter models are transported using the same type of EMS hanger Allphotos:Daimler
    • 10 move up | 1-2010 Renault Nissan Automotive India Pvt Ltd., Indiap International Benchmark At the new greenfield automotive plant of Renault Nissan Automotive India Pvt Ltd., a standardized automation solution based on proven Simatic technology helps set benchmarks in terms of production quality and performance. Allphotos:RenaultNissanAutomotiveIndiaPvtLtd. C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 11 When Renault and Nissan announced plans for a joint venture to manufacture vehi- cles in India in February 2008, the new automotive production plant in Chennai was pre- sented as a key milestone in the companies’ strategy for the Indian automotive market. “With the estab- lishment of our plant, Renault-Nissan will make major investments in India, reaffirming the growing bilateral economic ties between our respective countries,” said Nissan president and CEO Carlos Ghosn at the plant inauguration in March 2010. Representing an investment of 45 billion rupees (US$990 million) and with the capacity to produce 400,000 units per year at full capacity, the new Chennai plant initially employed 2,000 workers at the start of production in May 2010. The plant is the first dedicated Renault-Nissan alli- ance vehicle manufacturing plant. The first vehicle to be produced at the plant will be the new Nissan Micra, a global subcompact. The Micra, which is also the first vehicle derived from the new V-platform, is destined for the Indian market as well as for export to over 100 countries in Europe, the Middle East, and Africa. In 2011, the plant will start production of the Renault Koleos and Fluence, both destined for the Indian market. A versatile plant Intended to manufacture a variety of car models, the new plant must be able to operate flexibly and quickly adapt to changes in model lineup and pro- duction capacities. While the production equipment for the new plant was delivered by line builders from all over the world, Renault-Nissan opted for a highly standardized solution in terms of production auto- mation. In several of its plants, such as in Batilly in France, Renault had already implemented automa- tion solutions based on the SCUBE concept (see sidebar) developed in coordination with Siemens, and had achieved good results with this approach. So consequently, Renault-Nissan also opted for SCUBE as the basis of the automation technology to be deployed in the new Chennai facility. Siemens provided state-of-the-art standardized automation solutions for all its shops in vehicle operation and powertrain assembly lines. The result was a plant that not only was rapidly built, but quickly produced a high-quality product. One standard for automation Siemens manufactured and delivered the standardized cabinets to the line builders in Korea, Italy, and China that were contracted for the Chennai facility. Conse- quently, all shops in the new plant use a uniform automation architecture that greatly simplifies both the training of staff and the maintenance of the produc- tion technology. The reduced product variety requires lower spare parts inventory and this also leads to lower training effort for the maintenance staff. The automation architecture is based on Siemens products throughout: Simatic controllers at the pro- grammable logic controller (PLC) level, Simatic panels for operation and monitoring, Sinamics and Simotion drive systems, Sirius switching products, and Scalance communication devices. Simatic WinCC flexible is used for visualization tasks. The communication in the plant is based on Industrial Ethernet and Profinet, with Profisafe for safety communication. All shops use Siemens cabinets built to the SCUBE standards – Siemens delivered more than 100 of them. These include control cabinets, which Siemens installed. Siemens also delivered the line builders. The body shop in the plant is a good example of how the automation standard is deployed. The entire body shop is controlled through a main operating panel (MOP) as defined in the SCUBE standard, » The service and support we have received in India from the local Siemens team has been excellent. « Paul Morris, Head of Maintenance Department, Renault Nissan Automotive India Pvt Ltd., Chennai S C U B E The SCUBE concept is based on a structured and modular automation concept and also integrates fail-safe functions into one uniform architec- ture. SCUBE uses standardized software and hardware: Simatic S7-300 PLCs3 Simatic HMI devices3 Simatic Industrial PCs3 Microbox PCs for embedded control3 Sinamics G120/G120 D as standard motor converters3 Safety Integrated3 Additional standard components: Sirius circuit breakers for standard and specific handling applications3 Simatic RFID read/write devices and data tags3 Scalance components for networking and communication3 The automation and HMI units are all contained in standardized cabinets, always using identical interfaces, installation, and design. Depending on the extent of the required functionality, every manufacturing unit or zone is equipped with suitable versions of the specified operator panels.
    • 12 move up | 1-2010 info contact www.siemens.com/automotive sudhir.bachloo@siemens.com which utilizes a Simatic S7-300 fail-safe PLC. This PLC controls all processes in the body shop and connects to the drive control system via Ethernet, I/O modules in a Siemens Microbox PC 42x, a Siemens Scalance Switch, and an ET 200S distributed I/O system. Each zone within the body shop can be controlled with an HMI suboperator panel (SOP). All cabinets are supplied by Siemens according to the SCUBE standard. Each zone cabinet contains an ET 200S with a frequency inverter. Each zone also has a converter cabinet for the transfer station, which contains an ET 200S, and a Sinamics G120 frequency converter for the drive plate. Zones 1 and 2 also have a converter cabinet for the slat conveyer, which also contains an ET 200S and Sinamics G120. Excellent position for a growing market Thanks to the standardization achieved by using the SCUBE approach, both the project execution and the commissioning of the equipment in Chennai were completed in a very tight time frame, speeding up overall project execution. The uniform architecture simplifies training, and systems are easier to main- tain. Moreover, the standardized architecture also has significant benefits in terms of future modifica- tions and expansion projects: because the entire structure is modular, it can be easily expanded. Renault-Nissan was pleased with the plant build time and local support from Siemens, as Paul Morris, head of the maintenance department at Renault Nissan Automotive India Pvt Ltd. in Chennai confirms: “The service and support we have received in India from the local Siemens team has been excellent.“ After just 20 months, the greenfield automotive plant has started production. It is one of the most advanced facilities in India in terms of automation, and consequently in terms of performance and productivity quality. At the plant inauguration cere- mony on March 17, 2010, Chairman Ghosn said, “This is the first Renault-Nissan alliance plant, and using Renault’s production method. The plant will be a clear benchmark for the future.” Renault-Nissan is already benefiting from the mature technology of Siemens and the SCUBE standard: a proven, state-of- the-art automation solution, successfully deployed at Renault in several plants and now also at Renault- Nissan in India, that offers operational benefits and can easily be expanded to serve the growing auto- motive market in India. p Industrial Ethernet level 2 Industrial Ethernet level 0 Industrial Ethernet level 1 Zone 2 Sinamics G120 Drive plate SOP HMI ET 200S with frequency inverter Converter cabinet for transfer station Zone cabinet ET 200S Sinamics G120 Drive plate Converter cabinet for slat conveyor ET 200S Zone 3–4 Sinamics G120 Drive plate SOP HMI ET 200S with frequency inverter Converter cabinet for transfer station Zone cabinet ET 200S Zone 2 MOP Sinamics G120 Drive plate SOP HMI ET 200S with frequency inverter Converter cabinet for transfer station Zone cabinet ET 200S Sinamics G120 Drive plate Converter cabinet for slat conveyor ET 200S Flat panel PC 42x S7-300 CP343-1 lean Scalance switch ET 200S C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 13move up | 1-2010 13 C o v e r E m e r g i n g M a r k e t s info contact www.siemens.com/automotive jan.maser@de.pwc.com liang.cheng@de.pwc.com Emerging market trendsp Taking the Wheel Both India and China have enormous rural populations alongside comparatively affluent middle classes. Car ownership among the middle classes is growing fast, creating strong markets for the automotive suppliers operating in the regions. However, these markets will be dwarfed by the opportunities to be unlocked as the rural populations start to embrace car ownership. Here the similarity ends, as the two countries are taking quite different approaches in developing their auto- motive industries. Russia presents quite a different challenge. Russia: challenges and opportunities Russia has a mature industrial economy, but its domestic producers have aging product lines. The global financial crises hit the Russian manufacturers hard, causing a massive decline to just 650,000 vehicles produced in 2009. However, the domestic suppliers are fighting back, forming relationships with global brands (e.g., AvtoVAZ with Renault- Nissan) to update their product lines and better compete with incoming global products. Low-cost models for rural India India produced 2.4 million light vehicles (LVs) in 2009 and is forecast to increase production to 5.8 million by 2016. Most Indian car production is destined for the do- mestic market, and many OEMs, led by Volkswagen- Suzuki and Tata, are now targeting rural India. They are introducing very low-cost models such as Tata’s Nano to lower the bar to car ownership. China eyeing world markets China has a very strong domestic manufacturing sector with brands such as BYD, Chery, and Geely growing sales by about 62 percent during 2009. But the Beijing government has its sights on interna- tional markets and is following a strategic plan for The economies of Russia, India, and China contain automotive sectors of great importance to those countries and the surrounding regions. In its Autofacts reports, PricewaterhouseCoopers reveals that each has its unique characteristics and prospects for the future. consolidation of the domestic auto industry into 8 to 10 large Chinese automakers, each capable of sus- taining production of 1–2 million units and ready to compete on the world stage. As different as their markets and automotive industry landscapes may be, Russia, China, and India have one thing in common: automakers there are looking for innovative solutions that can help them increase their productivity and production quality. With tailored automation solutions, these goals can be reached more easily. Consequently, investments in equipment and technology have also seen significant growth in the last years, and will continue to do so. p China Developing Asia-Pacific: Light Vehicle Assembly Outlook by Country 2009 vs. 2016 (Millions) India Thailand Indonesia Malaysia Pakistan Taiwan Philippines Vietnam 0.0 Source: Autofacts Q2/2010 Data Release 2016 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0 20090.1 0.1 0.1 0.1 0.1 0.3 0.3 0.4 0.7 0.5 0.8 0.9 2.7 2,4 5.8 11.0 19.0 0.2
    • Volkswagen Indiap Global Partners The plant in Pune is an important milestone for Volkswagen as the company further strengthens its position in India – Volkswagen has invested around €580 million in the site. This makes the plant the largest investment project ever undertaken in India by a German company. As the only production facility to be operated by a German car manufacturer in India, it encompasses the entire production chain, from the press shop, body shop, and paint shop to final assembly. The new greenfield plant took only 18 months to complete, which was around 9 months less than originally anticipated. Construction of the plant began in the second half of 2007, and it was offi- To achieve the high standards that are the norm throughout its plants, Volkswagen chose capable and tried-and-tested technology partners – such as Siemens – for equipping its new manufacturing plant in India. cially inaugurated on March 31, 2009. It was pri- marily thanks to the exceptionally close collaboration between the planning department in Wolfsburg and the individual technology partners on-site that such a disciplined approach to project execution was even possible. Prior to the project, Volkswagen made a deliberate decision to work with partners it had gained previous experience with and that consequently knew pre- cisely where the priorities lay for a Volkswagen plant. The close global collaboration between Volkswagen and Siemens goes back many years, which in itself provided a solid basis for successfully integrating Siemens products into the India project. However, 14 move up | 1-2010 C o v e r E m e r g i n g M a r k e t s The new automotive plant in Pune
    • one of the key factors that swung the argument firmly in favor of reprising the collaboration in India was the potential to standardize the products across the entire production cycle. In Pune, as elsewhere, Volkswagen could therefore keep employee mainte- nance training to a minimum and warehousing costs down. Single-source automation The automation solution in Pune is based on tried- and-tested Simatic components. Each of the three production workstations is equipped with a fault- tolerant Simatic S7-300 F controller, which is con- nected to the Simatic ET 200S distributed stations and the Simatic panels via Industrial Ethernet to allow networked operation. The controllers are linked to one another via Profisafe. This architecture enables fail-safe signals to be transmitted via a bus system in parallel with the conventional communica- tion channels. Communication between the individ- ual CPUs takes place via a PN coupler. This coupler in turn interlinks the subnetworks that belong to the various workstations. The production level is con- nected to the network of the production building and the visual display via Industrial Ethernet. A Simatic panel PC serves as the master computer for visualization and welding and enables the operator to gain a quick overview of the production process. Optimum support on-site From the early days of the project, the team was keenly focused on ensuring that each operation be completed either on schedule or, in some cases, ahead of schedule. This represented a huge chal- lenge for everybody involved on-site – one that, according to Klaus-Dieter Goern, head of mainte- nance at Volkswagen in Pune, they “succeeded in overcoming because of the effective cooperation with the various planning departments at Volks- wagen headquarters and with the system manu- info contact www.siemens.com/automotive rainer.friess@siemens.com move up | 1-2010 15 facturers, including Siemens – and what’s more, the project was conducted in line with all quality requirements and safety regulations.” Goern con- tinues, “Thanks to Siemens’ presence in India, there were always plenty of specialists on hand to assist in all kinds of areas. The support we received from Siemens was, without exception, extremely effec- tive.” Siemens will continue to act as a partner of Volkswagen when the system is in operation. Not only is the complete range of spare parts readily available from in-house production through the company’s Indian subsidiaries, but there is also guaranteed on-site support from specialists who can be called in on short notice, thus enabling a fast and effective exchange of information – whether the issue concerns a technical problem, further develop- ment of the production technology, or a production changeover. Volkswagen is therefore in no doubt that it was right to choose Siemens as its automa- tion partner, and the company remains open to the prospect of new ideas and projects in the future. “We feel certain that our decision to work with Siemens was right, and so far we haven’t recorded a single defective component since the start of pro- duction,” concludes Goern. p VolkswagenPune Industrial Ethernet Simatic CPU 319F-PN/DP Panel PC Mobile panel ET 200S PN coupler Switch Industrial Ethernet Simatic CPU 319F-PN/DP Panel PC Mobile panel ET 200S PN coupler Switch Industrial Ethernet Simatic CPU 319F-PN/DP Panel PC Mobile panel ET 200S PN coupler Switch Profisafe Workstation 1 Workstation 2 Workstation 3 Building network Industrial Ethernet (fiber optic) Panel PC Master control visualization and welding LED display The automation architecture of the welding and assembly line T h e a u t o m a t i o n t e c h n o l o g y The automation technology structure in the three workstations in the Pune plant is identi- cal in each case and comprises the following components: Simatic S7-300 with CPU 319F-33 Simatic ET 200S3 PN coupler3 Panel PC3 Mobile panels for on-site operation3 The individual programmable logic controllers are interconnected via Profinet with Profisafe. An optical Industrial Ethernet network serves as the main building network. »We feel certain that our decision to work with Siemens was right.« Klaus-Dieter Goern, Head of Maintenance at Volkswagen in Pune
    • 16 move up | 1-2010 The Mahindra Group’s Automotive Division is India’s fourth largest manufacturer of four- wheeled vehicles and the country’s second largest independent OEM. The company manufac- tures and markets utility vehicles and light commer- cial vehicles, including three-wheelers. It has led the market in utility vehicles in India since its inception and currently has about half of India’s utility vehicle market. A strong product portfolio and a philosophy of customer satisfaction have driven robust growth in domestic sales (19 percent compound annual growth rate) over the past four years. The company employs over 10,000 people. Mahindra’s Automotive Division views innovation and customer delight as the keys to continued growth. The company strives to bring new models to market sooner and to create more product variants. It also works to improve its ability to operate at multiple sites in multiple countries in developing its vehicles. Broadly implemented PLM Since 1998, Mahindra’s Automotive Division has been using product lifecycle management (PLM) technology from Siemens PLM Software to address these challenges and to ensure a product develop- ment environment in which innovation thrives. Specifically, Mahindra uses Teamcenter to enable lifecycle data support, platform and variant manage- ment, multisite data notification and synchroniza- tion, change management and support for con- current development, project execution and monitoring, internal value chain support, and sup- port for business partners. This solution was chosen based on the breadth of Teamcenter functionality. The installation, which was carried out in phases, required minimal customi- zation and was performed by an internal PLM Auto- Automotive Sector, Mahindra & Mahindra Ltd., Indiap Bringing Innovation to Market Faster Siemens Teamcenter helps the Mahindra Group’s Automotive Sector substantially reduce development time, so it can continue to delight customers with product innovation. C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 17 motive Sector team using implementation method- ology and assistance from Siemens PLM Software. Teamcenter has now been installed in eight loca- tions, with 700 people using its collaboration func- tionality, 100 using its project management func- tionality, and 1,000 using it for engineering-related activities. Today, Mahindra has a seamless, integrated environ- ment for new platform development. Using Team- center, Mahindra has achieved multisite and multi- CAD interoperability with complete project security and concurrent design across multiple locations. CAD, product, project, and process data are man- aged in a single information vault. CAD data are available to each site on a real-time basis, and the company can now perform packaging studies and clearance analyses across different CAD systems. Using the JT format and Teamcenter’s visualization capability helps advance the company’s goal of eliminating 2-D drawings. Compelling, documented benefits Mahindra credits many improvements to the use of Teamcenter. The company has seen an increase in productivity per employee. It attributes this to effec- tive document management and to automation of routine tasks, releasing personnel to perform their primary tasks. Activities such as manual CAD data conversion have been eliminated. In the design arena, engineering change time and the time to resolve project concerns have both dropped by 50 percent due to improved collabora- tion. Analysis preparation time has decreased by 40 percent, and digital mock-ups can be created twice as fast due to the real-time multi-CAD data integra- tion and release management handled by Teamcen- ter. The time to create bills of materials (BOMs) for prototypes and variants has also been cut in half. “For the company as a whole, what Teamcenter means is a huge reduction in the time needed to bring a new vehicle from concept to launch,” says Prakash Deshkar, deputy general manager, IT, Mahindra & Mahindra. Thus far, Teamcenter has reduced that time frame by 25 percent. For future projects, the company predicts a reduction of as much as 40 percent. p »For the company as a whole, what Teamcenter means is a huge reduction in the time needed to bring a new vehicle from concept to launch.« Prakash Deshkar, Deputy General Manager, IT, Mahindra Group’s Automotive Division courtesy info contact Corporate Communications, Mahindra & Mahindra www.siemens.com/automotive vivek.marwaha@siemens.com K e y p o i n t s As a customer-centric company, Mahindra &3 Mahindra’s Automotive Sector wanted to bring new models to market sooner, while increasing the number of product variants Siemens Teamcenter decreases development3 time through knowledge capture and reuse; multisite, multi-CAD data interoperability; concurrent design across multiple facilities; and the automation of routine tasks Mahindra has seen a 25 percent reduction in3 the time from concept to product launch; the engineering change cycle cut in half; quicker resolution of concerns; and bill of materials creation in half the time as a result Mahindra is a market leader in utility vehicles in India Allphotos:Mahindra&Mahindra
    • 18 move up | 1-2010 From its formation in 2001, the Zhejiang Geely Holding Group Co. Ltd., headquartered in Hangzhou, has grown to become a major car producer, with manufacturing facilities in eight locations across China. The plants in Linhai, Ningbo, Lugiao, Shanghai, Lanzhou, Xiangtan, Jinan, and Chengdu have a total annual capacity of 400,000 vehicles. Geely also has complete-knock-down (CKD) assembly plants overseas in several countries, including Ukraine, Russia, and Indonesia. The com- pany has set its sights on manufacturing two million vehicles annually by 2015, with two-thirds of this capacity being planned for export outside China. To achieve these goals, Geely is transforming its prod- uct lineup from the previous utilitarian designs to high-specification vehicles meeting world-class standards for quality and safety. Through the auto- mation and integration of production processes, Geely enabled its manufacturing plants to reach best-in-class automation levels. World-leading auto- mobile component manufacturers who are working with Geely to achieve these standards have become important suppliers to the Geely production lines. To improve the efficiency of its car manufacturing facilities, Geely opted for a Totally Integrated Automation (TIA)-based solution. A new approach for a new plant In the paint, body, assembly, and press shops in the old plant located at Ningbo, each process had its own stand-alone control system. These systems came from several different suppliers. Consequently, the maintenance teams had difficulty compiling real-time consolidated manufacturing data. To overcome this limitation and upgrade the Ningbo plant, a project team was established in 2007 and the planning phase began. In 2008 Siemens Ltd. China was invited to join the team, advise on state- of-the-art automation concepts, and generate inte- grated solutions meeting Geely’s budget and intended degree of automation. A highlight of the project was the teamwork between the various groups, especially in the area of the body shop, where Chinese and Japanese OEMs were involved. All were requested to use products speci- fied by Geely, with Profibus as the communication network. The body shop’s electrical system consists of three units: main body, side body, and conveyor units. In the main body unit, over 10 robots are employed for the key quality control points in the welding process and complete up to 700 welding spots. The robot controller, with a Profibus interface, both enables the OEMs to integrate their products into the system much more easily and efficiently and guarantees real-time data transfer with peripheral devices. In the side body unit, field inputs and out- puts are collected by Simatic ET 200 distributed I/O systems. The systems are suitable for various types of applications and industrial environments and enable third-party devices for safety applications to be linked via Profibus. The workers on-site monitor the manu- facturing processes via Siemens TP170 touchpanels located alongside the production line. In the con- veyor, Siemens MM440 frequency inverters drive the motors for conveying and lifting. For the vehicle identification system (VIS), Geely has for the first time applied a Simatic RF300 radio-frequency identi- fication (RFID) system in place of the previous bar- code system. Using the VIS with RFID, materials are Allphotos:Geely Zhejiang Geely Holding Group Ltd., Chinap The Next Level Geely equips its plants with Simatic factory automation to move up to the world stage. C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 19 supplied just in time. This enables Geely to achieve better stock control and lower materials costs, giving a fast return on the investment in the RFID system. At the controller level, three Simatic 317-2DP pro- grammable logic controllers (PLCs) are responsible for controlling the manufacturing processes in the main body, side body, and conveyor units. The large-scale data communication between the PLCs routes via Industrial Ethernet, and a DP/DP coupler facilitates the transfer of real-time data. With dual Simatic PLCs with WinCC servers (for redundancy) and multiple client PCs linked via Industrial Ethernet, operators can monitor the manufacturing process and status of signals and alarms at any location throughout the plant. Satisfied with the results Tang Sheng Guo, general manager of the body shop at Geely Ningbo, is very satisfied with Siemens. He said, “It is important for Geely that the quality of Simatic, Sirius, and Micromaster products is good and that the Siemens system concept meets Geely’s budget and degree of automation.” Tang added that “Siemens provides good communication, strong technical support, and close coordination between Geely and different OEMs, even those located over- seas.” On the question of training and technical support, he said, “We greatly appreciate that the technical training and documents for Simatic, Sirius, and Micromaster are all in Chinese and that ongoing technical support and workshops are provided by Siemens’ local offices close to Geely.” Follow- ing the successful Ningbo plant project, Geely used Siemens automation products and solu- tions to equip its second new car plant located at Cixi city (near Ningbo city), Zhejiang Province, with a capacity of 150,000 cars per year. Geely will employ its advanced plants at Ningbo and Cixi to manufacture the new flagship Emgrand series of cars, sport-utility vehicles, multipurpose vehicles, and high-end pickups. The company associates its new Emgrand brand with the core values of “Chinese wisdom, world quality.” With technology from Siemens, the plants at Ningbo and Cixi are ready to produce cars to reflect these core values. After the Cixi plant comes fully onstream, Geely plans to build a series of additional greenfield car plants in various cities. Siemens, with Simatic, is ready to support Geely in these expansion plans. p info contact www.siemens.com/automotive wei.ch@siemens.com stephen.sung@siemens.com From left: Li Ping, Yang Xiao Hong, Tang Sheng Guo, Hua Ming, Ma Xin Hua System architecture of the Geely Ningbo body shop plant Industrial Ethernet Profibus Distributed I/Os Distributed I/Os DP coupler MES SCADA Press shop server Main body process control S7-317- 2DP HMI Side body process control S7-317- 2DP HMI Profibus Conveyor control S7-317- 2DP HMI ASM456 RF300 reader RF300 tag MM440 MotorsRobots Data server Paint shop server Data server Body shop WinCC server (redundant) Switch WinCC client Application server
    • 20 move up | 1-2010 Beijing Foton Cummins Engine Co., Chinap Keys to Success Solutions for Powertrain – Transline is a special integrated solution for the automobile indus- try. The solution is based on modularization and standardization. It is broadly used in the power- train field and has already set a standard for power- train customers. Transline is successfully used in a Foton-Cummins engine project to produce two types of Cummins light-duty, high-performance diesel engines in a Beijing manufacturing plant. The plant has an annual capacity of 400,000 units and will produce Cummins 2.8-liter and 3.8-liter diesel engines, which will meet worldwide emission standards, including Euro IV and Euro V. The project is based on a joint venture between Beiqi Foton Motor Company and Cummins Inc., forming Beijing Foton Cummins Engine Company Limited (BFCEC). BFCEC represents a further expansion of Cummins’ product line in China, where the company is already the leading foreign producer of heavy-duty and mid-range diesel engines. While Cummins is a lead- ing diesel engine supplier, Foton Motor is a strong player in China’s commercial vehicle industry. Smooth integration within existing technology framework BFCEC decided to support the new manufacturing lines and processes by implementing Solutions for The tools provided by Solutions for Powertrain – Transline give the management of the Chinese automaker confidence in high machine and plant availability as well as optimal productivity. Powertrain – Transline from Siemens. The solution was chosen partly because of its many successful installations around the globe. This gave the man- agement confidence in Siemens’ technology and deployment expertise. The company also preferred Siemens’ extensive process management functional- ity as well as its ability to work with the company’s range of product information formats. In addition, the flexibility of Transline was important to ensure smooth integration within BFCEC’s existing technol- ogy framework. The Transline concept decreases technical risk and complexity and enhances the ability to manage change. The project included a cylinder head machining line, a cylinder body machining line, and an engine assembly line. The machine centers for the machining line from MAG are equipped with Sinumerik 840D. The drive- based control system offers graduated performance, from simple positioning tasks to complex machining processes. Safety functionality provides reliable personnel and machine protection without addi- tional monitoring devices. The assembly-line equipment from Dalian Haosen is supported by a Simatic S7-300 controller. This pro- grammable logic controller (PLC) is also integrated in the Sinumerik 840D CNC systems. With performance from various central processors, the system is capable C o v e r E m e r g i n g M a r k e t s
    • move up | 1-2010 21 info contact www.siemens.com/sinumerik voss.carsten@siemens.com Transline minimizes the total cost of op- eration through its modular automation concept based on standard hardware BeijingFotonCumminsEngineCo. of resolving complex control tasks. Handling is sim- plified by integrated functions such as automatic parameterization, expanded diagnostic options, passwords, and ease of assembly. For identification, the machining line uses the Simatic VS 130-2 vision sensor system, while the engine assembly is equipped with the Simatic RF300 radio-frequency identification (RFID) system. The uniform Siemens technology solution yields enor- mous benefits in terms of standardization. For example, Foton-Cummins can work with just one engineering tool for the PLC in the machining and assembly lines. Solutions that fit individual needs The Solutions for Powertrain – Transline automation concept is custom made but at the same time based on proven yet innovative standards. It has been developed specifically for mass production in the powertrain field of the automotive industry. The modular design concept principally manifests itself in quicker commissioning, minimized spare parts requirements, efficient service, lower training costs, and a more flexible labor force. For example, the use of a component list reduces the number of automa- tion components employed, thereby also minimizing the necessary spare parts stocks. Standardized interfaces greatly facilitate data communication with the control level, while uniform operating screens lend all control panels a consistent look and feel. The Transline concept also addresses project management, which relieves customers of time- consuming coordination work, as well as providing services for the entire operational phase, leading to sustainable cost reduction and higher availability and productivity. The Siemens joint venture Siemens Factory Automation Engineering Ltd. (SFAE), with its well-trained service engineers, is very close to its customers to ensure this availability and produc- tivity. Solutions for Powertrain will not only improve prod- uct quality but also reduce project lifecycle costs and time to market. At the same time, it will also provide the company with the high level of efficiency neces- sary to succeed in an increasingly competitive mar- ket. The management believes that the successful implementation will be the foundation for long-term collaboration between Siemens and BFCEC. p K e y p o i n t s Optimum project management3 eliminates time-consuming project coordination by the customer – for higher availability and productivity Customized solutions based on3 standard modules – for faster commissioning, reduced spare parts requirements, and more efficient servicing One contact person – from3 design to commissioning and start-up to operation – for global deployment Reduced total costs of operation3 through building engineering and operation staff know-how, as 80 percent of costs are caused by spares and service and support
    • 22 move up | 1-2010 Worldwide Contacts Always Close Across 13 countries, the Siemens account managers for the automotive industry are always available as a central contact point. They handle all matters related to the global production processes of their automotive accounts. Every account manager has excellent process expertise and offers the entire portfolio of Siemens services from a single source. Working as team members with other experts, the account managers develop the right strategy, con- nect all necessary contacts on-site, coordinate the implementation, and ensure that the project is executed smoothly and rapidly. Anticorruption Alliance Collective Action To make a positive change to the corrupt envi- ronment in the global markets, Siemens is partic- ipating in alliances against corruption, through what is termed Collective Action. There are various forms of Collective Action. With Compliance Pacts, for example, competitors reach an agreement on long-term anticorruption initiatives. Then there are Integrity Pacts, which involve contractors speaking directly or indirectly to other potential contractors to conclude project- specific alliances. An independent organization supervises all processes, from the invitation to tender through to the conclusion of the contract, and ensures that everything takes place under transparent and fair business conditions. In Country Name Contact France Marc De Volder marc.devolder@siemens.com Korea Hyung-Mo Koo hyungmo.koo@siemens.com Canada Karl-Philippe Clement karl-philippe.clement@siemens.com United States Timothy Shepherd timothy.shepherd@siemens.com Japan Yuji Hirai yuji.hirai@siemens.com Brazil Rolf-Peter Hofmann rolf-peter.hofmann@siemens.com India Nitin Nair nitin.nair@siemens.com Spain Javier Pizarro javier.pizarro@siemens.com Mexico Hans-Albert Ratzka hans.ratzka@siemens.com Republic of South Africa Martin Taverner martin.taverner@siemens.com China William Cui weiguo.cui@siemens.com Russia Dmitry Matveev dmitry.matveev@siemens.com Great Britain Stuart Moran stuart.moran@siemens.com Sweden Micael Amandusson micael.amandusson@siemens.com addition, all persons involved commit to accept- ing sanctions should a breach of contract occur. “Many customers and competitors have already united with Siemens within the framework of Collective Action,” explains Joerg Flath, Siemens Compliance Officer for the Industry Automation and Drive Technology divisions. Flath cites the example of the tender to expand Berlin-Schönefeld airport: “The value of this particular tender was around €2.5 billion. On the initiative of the mayor of Berlin, Siemens con- cluded an Integrity Pact with its competitors. This guaranteed fair competition and transparent processes.” You can find out more about Collective Action from the contact for the Industry Automation and Drive Technologies divisions: Dr. Joerg Flath IA&DT Compliance Officer Tel: +49 (911) 895-5769 E-Mail: joerg.flath@siemens.com I n B r i e f SiemensAG
    • move up | 1-2010 23 D i a l o g u e move up 1-2010 Publisher Siemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg Drive Technologies Division CEO Klaus Helmrich Industry Automation Division CEO Anton S. Huber Editorial Responsibility in Accordance with the German Press Law Arno Hoier Responsible for Technical Contents Thomas Schott In-house editorial staff Elitza Daloukova E-mail: elitza.daloukova@siemens.com Jürgen Nolde E-mail: juergen.nolde@siemens.com Publishing House Publicis Publishing, Part of Publicis PRO P.O. Box 32 40, 91050 Erlangen Telephone (0 91 31) 91 92-5 01 Telefax (0 91 31) 91 92-5 94 publishing-magazines@publicis-erlangen.de Editor: Kerstin Purucker Layout: Jürgen Streitenberger Copy editor: Désirée Bambynek Job number: 002800 24710 DTP: der Döss für Kommunikation, Nuremberg Printed by: Wünsch, Neumarkt Title: Daimler Circulation: 8,600 ISSN 1610-7802 (Print) © 2010 by Siemens Aktiengesellschaft Munich and Berlin. All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper. The following products are registered trademarks of Siemens AG: EMSdriver, ET 200, MICROMASTER, MOBY, S7-300, SCALANCE, SIMATIC, SIMATIC HMI, SIMATIC Microbox PC, SIMATIC Panel PC, SIMOTION, SINAMICS, SINUMERIK, SINUMERIK – Safety Integrated, SIRIUS, TOTALLY INTEGRATED AUTOMATION, TOTALLY INTEGRATED POWER, WinCC If trademarks, technical solutions, or similar are not included in the list, it does not imply that they are not protected. The information provided in this magazine 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. An obligation to provide the respective charac- teristics shall only exist if expressly agreed in the terms of contract. IWI: TMOD Order No.: E20001-MC110-B100-X-7600 info Safeguarding the Future with IT As a key segment of the economy, the automotive industry is one of the most innovative sectors. Increasing global competition is chall- enging companies to continually reduce their costs while at the same time maintaining innovation and quality leadership. Siemens IT Solutions and Services is the professional partner to help compa- nies face these challenges, thanks to its extensive industry knowledge and many years of experience in the automotive industry. Learn more about our automotive IT solutions: move up online At the address www.siemens.com/read-moveup you can download the latest issue as a PDF file. The electronic archive also gives you access to all previously published issues. Furthermore, you will find a form in which you can write your sugges- tions and comments on the issue and the individual articles. Your feed- back will be included in the next issue of move up. Finally, you can also make changes to your subscription. info If you want to know more about Siemens automation and drive technology, visit our online information platform in the Internet: www.siemens.com/ automation www.siemens.com/it-solutions/automotive
    • 24 Industrial identification with SIMATIC Ident: perfect solutions for all requirements – with flexible expansions any time. Answers for industry. What optimizes your individual automation steps today and your entire company tomorrow?