a digital approach to panel building · engineering process should generate project data that...
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A Digital Approach to Panel BuildingMike Burke (Siemens) & Sean Mulherrin (EPLAN)
Manufacturing in America │ March 20-21, 2019
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Efficiency
Flexibility
Quality
Speed
Panel builders are facing immense challenges when competing in
today’s market
Shortage of skilled labor
Demand for faster delivery times
Revised standards & directives
Increased price & cost
pressure
Inefficient workflows &
quality issues
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30%Percentage of U.S. Panel Builders that are expected to go out of business in the
next five years due to low margins & obsolete manufacturing processes*.
*Based on a study by EPLAN USA
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How can panel builders optimize their panel
building and overcome these challenges?
A digital approach to panel building
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EPLAN benchmarked 150 panel builders across the world (50 in the
U.S) to better understand manufacturing processes
Basis TS8 70“ / 31“ / 15“
Specifications Average Time (min)
Holes (door) 10
Cut-outs (door) 4
Mounting/DIN rails 10
Wire ducts (sections) 20
Holes/Threads backpanel 100
Devices 90
Wiring connections 500
Labeling (devices) 200
Terminals 130
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The benchmark found that automating panel building processes can
significantly reduce manufacturing times
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Where can panel builders optimize their manufacturing processes?
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EPLAN PAM Assessment
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Optimization in panel building starts with an
efficient digital engineering process
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What is needed in the digital engineering process?
Driven by data
Engineering process should generate project data that creates a complete digital
representation of the control panel – the digital twin
Efficient engineering practices
Increasing amounts of data in the engineering process requires processes that allow
efficient exchange and management of information
Linked into the manufacturing process
The digital twin of the control panel needs to link into the manufacturing process so
that manufacturing efficiency can be optimized
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Automation
components
Electrical
components
Integration of engineering steps allows for the seamless and error-free
flow of data in the engineering process
TIA Portal
Automation
components
Programming
Parameter
assignment
TIA Selection
Tool
EPLAN
Control panel
components
Circuit
diagram
Control cabinet
design
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TIA Selection Tool - The configurator for the complete Siemens
portfolio
A single tool for the complete
Siemens portfolio
Save time with intelligent
selection wizards
Quick start
– create the correct
configuration
Interface with other tools (e.g.
EPLAN, TIA Portal, CAx
Download Manager)
Work flexibly,
how and where you want to
Efficiently engineer and
create your complete project
configuration
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The Engineering Process
High
Quality
Documentation
ERPPDM
PLMPLC
AMT
Fluid power
engineeringElectrical
engineering
Panel
Engineering in 3D
Concept for
Machines &
Systems
Concept Basic Eng. Mechanical Control Production ComissionBuild
2D/3D
Harness
Engineering
Wires / Cables
Nailboards
Labels
Drilling
Copper bending
Manufacturer Device Data
SERVICE
& MAIN-
TENANCE
XMLXLS
TXT
+
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EPLAN Data Portal provides component data integrated into the
engineering platform
Feature Benefit
• Integrated into the EPLAN
platform
• Assign components directly to
engineering schematics and
layouts
• Intelligent product data
• Commercial and technical data
can be used in documentation
and manufacturing
• Over 890,000 data sets
• Provide intelligent product data to
your entire design
• Over 250 manufacturers
• Select products from multiple
manufacturers
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Siemens has over 30,000 parts available (and growing) in the EPLAN
data portal
EPLAN Data Portal
• Product commercial data
• Functional template
• 2D graphical data
• 3D graphical data
• Connection patterns
• Drilling patterns
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How does the engineering process link back
to manufacturing?
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Engineering process drives optimization in panel building
Control Panel Manufacturing• Material Kitting
• Mechanical Installation
• Enclosure Modification
• Terminal Strip Assembly
• Installing Devices
• Labeling Devices
Electrical Engineering & Design• Component sizing
• Circuit diagram design
• Component/material selection
• Panel layout
• Data management & documentation
→ Complete electrical design and documentation
• Wire Fabrication
• Wiring
• Testing
• Logistics
→ Complete control panel
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Engineering and design process links into the control panel
manufacturing
Material Kitting
BOMs with full product data for ordering and kitting30 min.
Mounting Panel & Door Modifications
Mounting location data for drilling templates or cutting machines250 min.
Terminal Strip Assembly
Device configuration data to order or create assembled devices
Device Labeling
Auto generated label sheets eliminates label creation from schematics
Wire Fabrication
Wiring routing information used to cut label to the exact length
130 min.
200 min.
800 min.
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Pioneering automation technologies
Rittal Perforex BC
▪ Time savings compared with manual mech.
Processing approx. 7h 40mins. for one-off products
▪ > 100 control cabinets per year / RoI approx. 3 years
Manual Automated
Manual Automated
Manual Automated
30 min8h 10min
30 min11h 25min
75min 30 min
Mechanical processing
Rittal Perforex LC
▪ Time savings compared with manual mech.
processing approx. 11h 40mins. for one-off products /
stainless steel
▪ > 250 control cabinets per year / RoI approx. 2 years
Secarex
▪ Cutting optimisation for multiple projects
▪ Time savings compared with manual mech.
processing approx. 75 min. by transferring data from
EPLAN Pro Panel (approx. 60 min. for manual data
creation)
▪ > 130 control cabinets per year / RoI approx. 3 years
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Pioneering automation technologies
Athex TC 80 CS
▪ Time savings for one terminal strip:
9.65 mins. = 0.16 h
▪ > 790,000 terminals per year / RoI approx.
4 years
Equipment
Manual Automated
1 min10 mins
Wire Terminal WT 24/36
Time savings for wire fabrication: 500 wires
aprrox. 800 mins.
▪ RoI = approx. 2.5 years
Wire fabrication
Manual Automated
12 Hours30 hours
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Pioneering automation technologies
Crimp machine L8 and R8
▪ Time savings for wiring approx. 4.5
secs.*1,000 crimpings = 4,500 secs. =
1.25h
▪ 90,000 crimpings is therefore approx. 80-
90 cabinets per year / RoI = approx. 2.5
years
Wire fabrication
Manual Automated
1.5 secs5-6 points
Copper bending CW 120-M
▪ High bending and punching accuracy
▪ Simple tool change
▪ Flexible use in the workshop
Copper bending
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How can Siemens and EPLAN support you?
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Siemens provides panel builders with free resources and support for
optimizing control panels
Feature Benefit
• Free resources on panel building
design standards
• Stay up to date on new
standards and get support for
international standards
• Tips for better controls panels
• Be more efficient in your control
panel engineering
• Access to free software tools
• Engineer and manage your data
more efficiently
• Free consulting and training
Controlpanelquestions.us@siem
ens.com
• Get help on standards, design,
engineering and more for your
upcoming projects
usa.siemens.com/controlpanels
Download the White Paper on Engineering
Optimization for Panel Building
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See how you can optimize your panel building operations with a PAM
assessment from EPLAN
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Optimized panel building is possible with Siemens & EPLAN
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Questions?
Mike Burke
Control Panel Consultant
E-mail: [email protected]
Sean-Patrick Mulherrin
Product Manager EPLAN Electric P8
E-mail: [email protected]