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At the end of last month, the 2018 Hannover Fair in Lower Saxony, Germany, came to an end. Five years ago, the German Industry 4.0 strategy was released at the world's largest industrial exhibition. At this time of the year, there will always be waves of people walking into the Siemens Amberg factory, which is more than a hundred kilometers away from Hanover, a factory called the world's closest industry 4.0.
Since its establishment in 1989, 30 years later, the Siemens Amberg factory has increased its production capacity by 13 times in terms of floor space and the number of employees. Behind this proud figure, thanks to the ongoing digital transformation at the Siemens Amberg factory.
“The Accenture CEO Mr. Nan Peide once said that since 2000, half of the top 500 companies have disappeared from the market because they are not digitized in time,†said Jan Mrosik, CEO of Siemens AG’s Digital Factory Group. .
So, what is the secret of Industry 4.0 in this factory equipped with 1,000 scanners and 50 million data per day?
Produce one product per secondOn the banks of the Wells River to the east of Nuremberg, Germany, there is a “special†factory consisting of three red brick façades – the Siemens Amberg factory.
This 30-year-old factory, even the “replicaâ€, has aroused the aspirations of many industrial people around the world – five years ago, in Chengdu, China, more than 7,000 kilometers from Amberg, the sisters of Amberg The factory, Siemens' first digital factory in China, Siemens Industrial Automation Products Chengdu Production and Research Base (SEWC), which set a record of over 100 people per day in just one year.
“Compared with the Chengdu SEWC factory from a blank sheet of paper, the Siemens Amberg factory is actually a digital transformation step by step.†Gu Xin, director of digital enterprise business of Digital Factory Group of Siemens (China) Co., Ltd. said.
As a German factory that started with a simple mechanical production line at the beginning, the Siemens Amberg factory is now recognized in the industry as the world's closest factory to Industry 4.0.
Into the Siemens Amberg factory, more than 15 million programmable logic controllers and related products are born from the second floor of the plant every year. Seen from the workshop, the blue-and-white equipment with high chest height is connected by one fast-moving robot. At the front end of the production process, several operators quickly assembled the product against the front screen.
What makes the Siemens Amberg factory truly proud is the digital transformation beyond automation.
Since its establishment in 1989, the Amberg factory has maintained a total area of ​​10,000 square meters and more than 1,200 employees, the production capacity has turned 13 times.
On the one hand, this is a highly automated factory. The plant currently maintains a 75% level of automation, which is already the data that Amberg can achieve in 2000. “In production, we have been able to achieve 75% automation,†said Deng Bo, senior engineer at the Siemens Amberg plant. This is reflected in the fact that for all operators at the Siemens Amberg factory, only 30 minutes of safe operation training is required before taking up the job. And after 30 minutes, they have to operate a programmable logic controller that is as complex as a computer CPU.
On the other hand, there is still a high speed of producing one control device every second, and the product pass rate is as high as 99.9989%. Karl-Heinz Büttner, head of the Siemens Amberg factory, bluntly said, "As far as I know, there are no similar factories in the world with such low defect rates."
"Virtual Factory" synchronized with realityBehind these is the power of digitalization.
Below the production workshop on the second floor of the Siemens amberg plant, there is a material distribution conveyor belt of more than 5 kilometers.
"You can understand it as if it is baggage sorting at the airport." Deng Bo said. In the production process of the Siemens amberg factory, once the equipment on the production line still needs to be dispensed in 15 minutes, the relevant information is quickly communicated to the central warehouse. After receiving the instruction, the central material library uses the automated stacker to pick up the required materials and deliver them to the required material carrier trays, and then sorts them by robots and uses the lower material center to transfer them upstairs.
Such a design was taken 30 years ago at the beginning of the establishment of Siemens Amberg. The factory has set up RFID (radio frequency identification technology) for all materials, and completes the digitization work by scanning RFID, which promotes the real-time matching of material distribution and production demand.
More than just the material distribution end, in the past 30 years, the Siemens Amberg factory has realized the digitization of the entire value chain from product to manufacturing.
The complete life cycle of a typical product includes product design, production, and application to the market. “In the digital age, all the cores of the value chain are connected in series by digital curves.†Gu Xin said that Siemens has opened all the links through digitalization and integrated the obvious value links of the original boundary barriers.
This integration has greatly increased the efficiency of manufacturing companies. Take the R&D link as an example. In a traditional manufacturing enterprise, a product may arise from the generation of ideas to the first test article, and the intermediate needs may be several years to ten years. However, in the digital factory, the simulation software can be used to design and develop in the virtual link. Compared with the traditional practice, the development cycle is shortened by at least half.
This is a “digital twin†that emphasizes the combination of virtual and reality. That is to create a "virtual factory" corresponding to the real image through digitization.
This combination of reality and virtual is not only reflected in the R & D design, manufacturing and other aspects. In the Siemens Amberg factory, a digital collaboration platform is also used to assemble all the data, so that the data in all value links can be classified and managed in this collaboration platform.
At the same time, using platforms such as Mindsphere, remote data can be collected through the Internet of Things and fed back to all value links.
A large number of different links of data can achieve closed-loop value feedback. This means that these data will be an important basis for optimizing the entire product life cycle. The system will use this data to achieve a performance-optimized digital “twin†for product manufacturing and manufacturing.
Mass production of 50 million pieces of data per dayAnother important benefit of digital transformation is the change in the factory model of large-scale production in the past, making production more flexible.
“Because of the complexity of the products produced by the factory, we have to make about 5,000 work plan changes every year.†Gu Xin said that the Amberg factory needs to produce more than 120 products every day, so the whole production process is very complicated.
A production line within the Siemens Amberg plant can be switched over 350 times a day to produce more than 1,000 different products. The production line that continues to operate for 24 hours has maintained a product pass rate of 99.9989%. Such flexible production, relying on the same is digital.
For example, Deng Bo said that when the Siemens Amberg factory is going to start producing new products, then in the virtual production line of the computer, the production process of the new products will be simulated, and the production line should be allowed to accept the new one. member".
Relying on virtual manufacturing, a production line produces different products at the same time, so the scene of mixed line production is very common in the Siemens Amberg factory.
A large amount of data becomes the “language†of communication between equipment and equipment within the factory. The Siemens Amberg factory has generated massive amounts of data every day.
It is understood that as early as 1995, the Siemens Amberg factory had a daily process data volume of 5,000, and by 2000 it had increased to 50,000. At this stage, the amount of data generated by the factory has reached 50 million. Correspondingly, 1000 scanners were installed in the Siemens Amberg factory for online inspection.
“The Amberg factory is indeed an outstanding example of Industry 4.0,†said Jan Mrosik, but he emphasizes that digital is a never-ending process. As technology advances, the Amberg plant will continue to be updated and optimized. .
Reading the Siemens Amberg factory13 times
Since its establishment in 1989, 30 years later, the Siemens Amberg factory has increased its production capacity by 13 times in terms of floor space and the number of employees.
99.9989%
Even in a production line at the Siemens Amberg factory, 350 switching trips a day can be made to produce more than 1,000 different products. The production line that continues to operate for 24 hours has maintained a product pass rate of 99.9989%.
50 million
As early as 1995, the Siemens Amberg factory had a daily process data volume of 5,000, and by 2000 it had increased to 50,000. At this stage, the amount of data generated by the factory has reached 50 million.
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