digital thread & digital twin: the winning factor in food ...€¦ · manufacturing...

Digital Thread & Digital Twin: The Winning Factor in Food & BeveragePresented by Suzanne Kopcha | Vice President Siemens PLM

Manufacturing in America │ March 20-21, 2019

Unrestricted © Siemens 2019

Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.

“There are no

consequences in

the virtual

world”Anton Huber | 2005


RealVirtual AutomationPLM Software


Siemens saw big change coming in 2007

<1998 2000 2002 2004 2006 2008 2010 2012 2014 2016 2018-19

UGS

MentorMendix

TASSInfolyticaSarokalSolido

LMSTesis

CD-adapcoPolarion

Vistagy PerfectCosting

Kineo

ORSI ELAN VRConnectIBS

Active Camstar Bentley

SIMATIC Totally Integrated Automation

AUTOMATION #1

SOFTWARE #1OUR JOURNEY TO HELP COMPANIESREALIZE THE VALUEOF DIGITALIZATION


Digitalization is changing everything!


`


#1Industrial software

#1Automation


24,500+software

engineers

A top 10global software

company

1 million+connected

assets

250+Digital offerings

incl. digital services

and industrial

applications

Food & Beverage


The Digital Enterprise is a catalyst for continuous innovation in

Food & Beverage….

Digital Twin Product

Digital Twin Production

Digital TwinPerformance


To gain the full advantages of digitalization you must create a

digital thread …and eliminate the boundaries between systems and

organization silos.


Digital Twin Product



Virtualproduct

Virtualproduction

Realproduct

Real productionAutomation

Continuous improvement

Insights from performance with MindSphere

Ideal delivery

Collaboration Platform

Verification Validation

Specification Commissioning

What do you need to realize the full value of digitalization?


Siemens Digital Innovation Platform

New business models


Food & Beverage Digital Enterprise Value Streams

6 Process based value streams across the Digital Enterprise

Product designProduction

Planning

Production

Engineering

Production

ExecutionServices5

Integrated Program Management

Product Development Excellence

Plant Design & Optimization

Flexible Manufacturing

Process Design & Engineering

Quality & Traceability

Product Development

Excellence

Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.Collaboration Platform

Food & Beverage Value Streams

1. Integrated Program ManagementDelivering an intelligent digital thread across program, project and product management

TRACKING

KPI

Updates

PROGRAMProgram Manager

IDEATIONMarketing Manager

PROJECTProductManager

Campaign

Idea

PORTFOLIOPortfolio Manager

Project WBS Root Element

© Siemens AG 2018

June 2018 Siemens PLM Software

PROJECTCHARTER

Process GroupMaster Plan

Scope

SOW

PRODUCTCONCEPT

Brand Equity

Product

InstantiationRule

SKU(Base)

SKU(Variant)

PACKAGEDESIGNProcess Group Leader

Model Engineer Validate

Package

ARTWORKDEVELOPMENTProcess Group Leader

Concept Layout Design

Artwork

FORMULATEDPRODUCT DESIGNProcess Group Leader

Develop Test Comply

Material

MANUFACTURINGPROCESS PLANNINGProcess Group Leader

Transform Validate

BOP

PLANT AND LINEDESIGNProcess Group Leader

Plant

Plan Design Optimize

Program

Project

Brand Portfolio

Expectation

Potential

Release toDefinition

Release toInitiating

Release toClosure

Release toClosing

DISCOVERYMarket Analyst

Release toPlanning & Executing

Release toDelivery

StakeholderProject Approval

Application

Business Case

Market Analysis

Role Assignments

Progress Review Application



TargetRtM Milestone

Delivering discipline execution

Transparency for smarter, faster decision making

Maximize re-use of approved assets

Accelerate product launch

Restricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.Collaboration platform

Digital Thread

Recipe Transformation

Package Design and Simulation

Artwork Development

Integrated Program Management

Formulated ProductDesign

Laboratory Information Management

▪ Full transparency

▪ Fact based decisions

▪ Re-use intellectual

property

▪ Digital Asset Library

▪ Control Collaboration

▪ Tool integration

▪ Modelling and

simulation capabilities

▪ Reduce R&D efforts

▪ Requirements based

▪ Regulatory

Compliance

▪ Better lab efficiency

▪ Real-time

management

▪ Automated guidance

▪ Site Data available to

Development

▪ Recipe Transformation

Digital TwinProduct & Production Management

Lifecycle Management

Restricted © Siemens AG 2018

2018-04-09 Siemens PLM Software


2. Product Development ExcellenceDesigning the finished product in a seamlessly integrated system increases productivity,

quality and efficiency.


Formulated Product Design

Supplier Specifications Formula Experiments Lab Quality Transformation

Collaboration ManufacturingResearch DataWorkbenchFoundation Quality

Formulated Product Design


2. Product Development Excellence – Formula DesignNext generation integrated design with an improved user experience leveraging HTML,

Cloud and Mobility



2. Product Development Excellence – Formula OptimizationLeveraging HEEDS optimization to dramatically reduce cost – increase efficiency – and

formulate a new way.



2. Product Development Excellence – Artwork Design 2.0Digital, agile, accurate artwork solution reduces the cost and time of artwork by >50%

BUSINESS PROBLEM

Artwork is the long tail in the

innovation process.

• very manual

• often delaying initiative launch

• increasing recall risk.

• little to no agility



2. Product Development Excellence – Artwork Design 2.0Seamlessly integrate Finished Product elements for speed, quality and efficiency –

dramatically increase reuse of pre-approved assets

Digital Artwork Development

Artwork Development is dependent on input from other process groups,

• Package Design: Use Die Linegenerated by the flattening process from Package Design process group

▪ Formulated Product Design: Link Specification Content for the Product to Digital Assets used in the Artwork Development process group

ARTWORKDEVELOPMENT

PROGRAMLIFECYCLE

PACKAGEDESIGN

FORMULATEDDESIGN

Package Die Line

Formula Recipe Specification

Concept Layout Design



2. Product Development Excellence – Artwork Design 2.0Bringing Digital Artwork to the Designer’s world


Teamcenter Extension: Portfolio Management

Shorten time to market for new product launches by increasing stakeholder collaboration

SAP ERPSales Volume and Regional Stock

TeamcenterNew Product Introduction Process

R&D SuiteLIMS (Recipe Management)

low code platform

Pushnotifications

TeamcenterBOM data

Intuitive tablet dashboard

Ideacreation

R&D Suiterecipe data

Business case creation



3. Process Design & Engineering

Design Alternatives

Validate & Explore DesignsMeet multiple performance constraints

Scale-up & Performance EvaluationVirtual scale-up test

Reduce time & Increase confidence

Evaluate design sufficiency

Evaluate system performance

Reduce Risk & Operational Sweet-spotsControl Strategy & Testing

Virtual commissioning

Safety scenarios evaluation

Operation

•Scheduling

•Quality

•Process Orchestration

•Genealogy

•Logistics and material flow

Troubleshoot

•Reliability engineering

•Predictive maintenance

Data analysis,

experiment design

Conceptual

process design

Catalyst design

and analysis Troubleshooting

Model-based

automation

Design of

operating policy

Detailed

equipment design

Process

optimization

Control design

and verification

Front-end

engineering

design (FEED)

Utilities

optimization




Start CCM+, HEEDS and Virtual Commissioning Solutions

Engineering Time

30%

Technology

Transfer

Virtual Commission of Unit Operation

Time to Martket

Up to 35%

Cost of Trials

$MILLIONSReduce

Cost of trials


10xENGINEERING DESIGN EFFFECIENCY

SPEED OF INNOVATION

OPTIMAL DESIGN DISCOVERED


Siemens PLM Software



Optimized engineering design &

scale-up from months to weeks,

enables global expansion

in record time



4. Plant Design & Optimization

Capital Project Value Chain

feasibility &planning

FEED & detailedengineering

construction &commissioning

Optimization & maintenance

modernization &decommissioning

1 2 3 4 5

Project Planning and Execution Ops & Maintenance

A data-driven, capital asset management solution that

connects the entire lifecycle via a common digital thread

Restricted © Siemens AG 20XX

XX.XX.20XX Author / Department


4. Plant Design & Optimization: Trends in Construction

Increased global

competition

Increased project

size and complexity

Increased rate of

technology

innovation

Decreased labor

force




4. Plant Design & Optimization: Capital Project by the numbers

80%is the average cost

increase of the original

value

98%of projects incur cost

overruns or delays

20 monthsaverage slippage

behind original

schedule

Source: McKinsey Construction Productivity Imperative Source: McKinsey Construction Productivity ImperativeSource: McKinsey Construction Productivity Imperative



Digital Thread

Digital Enterprise

Engineering Data

Advanced Capital Project

Planning & Execution

Digital Thread

Seamless Handover to

Operations & Maintenance


4. Plant Design & Optimization: Digital Thread



Engineering - the systems view of what

needs to be built & operated “The integration of

engineering and

construction” Construction - the “path of construction”

view detailing how and when to build


4. Plant Design & Optimization: Digital Twin and Digital

Thread are critical



Modernization &

Decommissioning


4. Plant Design & Optimization: Siemens and Bentley

Partnership deliver Digital Twin of Intelligent Plant

Dynamically manages complex capital projects

Removes boundary between plant and enterprise data

Combines Bentley’s iModeland CDE with Teamcenter



Siemens can enable companies to …

• Bringing PLM and plant CAD interoperability to facilities

• Scan existing facilities to accelerate virtualization of their

operations

• Virtually develop plants and lines to improve facility

changes or development

• Simulate operations virtually to evaluate changes or

optimize existing facilities

• Utilize this data to continually maintain and optimize plants

• Leverage factory design management to collaborate among

diverse teams


Collaboration Platform


4. Plant Design & Optimization: ….there’s much more than new

construction



Virtualproduct

Virtualproduction

Realproduction

Realproduct

Digital TwinProduct

Digital TwinProduction


Ideal

delivery

Collaboration platform: Teamcenter

Verification

Specification

Validation

Commissioning


5. Flexible Manufacturing: To become radically Faster, more Agile and

Efficient we need to work in the virtual world of the Digital Twin



Manufacturing digitalization

The widening gap in digital productivity

2001

TOP 5% PERFORMERS

REST OF THE INDUSTRY

Perc

ent

Incre

ase in labor

pro

ductivity

2005 2009 2013 2018

+25%

Source: The future of productivity report, 2015, OECD

0

-10

10

20

30 The top 5%of companies are dominating the

economy by exploiting digital competencies.

Source: It Pays To Be Smart, July 2017, MIT Technology Review

The Best Versus the Rest: The Global Productivity Slowdown, Divergence Across

Firms And The Role of Public Policy, OECD Productivity Working Papers



Realproduct


Ideal

delivery

Virtualproduct

Digital TwinProduct

Virtualproduction

Realproduction

Collaboration platform: Teamcenter

Validation

Commissioning

We’ve seen that working virtually in the digital twin of production can

generate and validate designs with high speed and efficiency

But what’s the point of all that

simulation if your factory operates blindly or by the

whim of the individual operator?

To deliver transformative value to your customer, design and planning

software must always be combined with Flexible Manufacturing


5. Flexible Manufacturing: but virtual without real won’t deliver Flexible

Manurfacturing



MES – Current State

The first step towards Flexible (or Smart) Manufacturing

“…Industrial firms need to look

much wider than just connecting

the shop floor to business

operations. Collecting

manufacturing data is not the

raison d'etre of a program, but

rather a necessary step to

achieve corporate strategic

goals.

© LNS Research, 2017. All Rights Reserved.

More than 50% of the

Installations are “home-grown”



Many customers are operating factories with

machines from the 1970s and margins are tight.

Flexible manufacturing will be a journey.

Customer must determine which stage is most

appropriate.

Capable of executing lot

size one on newly

introduced products with

zero defects.

Equipment is predictively

maintained and downtime is

sold through Smart

Contracts on a Blockchain

marketplaceNo transparency

Data Collection &

Performance ReportingReady to optimize

and systemize

operations

MES Looking to mass

customize whilst

squeezing additional

efficiencies from

production system

Smart

Manufacturing

Level 1 Level 2 Level 3 Level 4


5. Flexible Manufacturing: Maturity Model

Factory of

the Future



The MOM evolution towards Smart Manufacturing

Stand-alone MES• Focus on vertical integration

• Rich set of Industry-specific OOTB functionalities

• Real-time data acquisition

Monolithic MOM• From execution to a broader

coverage of manufacturing disciplines

• Scalable solutions, extensibility and code-less configuration

• Data synchronization and contextualization

MOM for Smart Manufacturing• Focus on collaboration through

horizontal integration

• Cloud-ready technologies

• Orchestration based on principles of Artificial Intelligence

• Augmented data contextualization through IoT

Improved

manufacturing

execution

Manufacturing

digitalization

Digital Enterprise

& Industry 4.0

’90s

’00s

Today



MOM’s evolution towards Smart Manufacturing

Virtual product

Virtual production

Smart orchestrationof manufacturing and quality operationsSmart integration with PLM

Smooth design and engineering transfer

Smart data contextualizationwith manufacturing information

Real

product

Contextualized

Data

Closed Loop Processesfor continuous and proactive improvements

Smart connection to

MindSphere

Tools Process

People

MOM



Consolidated Manufacturing Operations Management

Portfolio

QualityMES

EMIAPS

MOM



Siemens makes 1 product

per second in our Amberg

facility with just 24 hours

of lead time

13x increase in efficiency

99.9999%

1,200quality rate

different products



6. Quality & Traceability

Consumers expect products to be safe, secure & authentic

But how can you

be sure where

they come from,

what they contain

and how they’ve

been handled?

???


1

2

3

4

5

6

78

910

11


6. Quality & TraceabilityComprehensive Quality systems require Product Quality, Manufacturing and

Materials Compliance, and Product Conformity


Quality SystemsCritical Capabilities needed to deliver Comprehensive Quality Systems

Required By Siemens Solution

Compliance“Compliance” is ensuring both the

Product and the Manufacturing

Process meet the rules set by

regulatory bodies. It is enforced

through inspection.

1. Risk Assessment ISO9001-2015, FSMA, HARPC Compliant Pro

2. Regulatory Compliance FDA, ISO, FCC, EPA, TL9000 Compliant Pro

3. Personnel Compliance FDA FSMA, ISO, EPA, HARPC Compliant Pro

4. Supplier Compliance FDA, Market Demands Compliant Pro

5. Materials Compliance FDA, REACH, RoHS Teamcenter & Decernis

6. Quality Planning IATF16949, AIAG QMS Professional

7. Incoming Material Inspections IATF16949, AIAG QMS Professional

8. In-Process Inspections IATF16949, AIAG QMS Professional

9. Final Inspections IATF16949, AIAG QMS Professional

10. Quality Event Analysis FDA, ISO, EPA, etc. QMS Professional

11. Conformity Testing UL, CSA, CE, TUV, JED, etc. Unilab

Quality“Quality“ is act of ensuring the

product being manufactured is

consistently meeting the design

expectations. It is ensured through

in-line, at-line, and on-line

inspections

Conformity“Conformity” is act of ensuring the

product conforms to the safety

expectations set by regulatory

agencies such as UL, CE, TUV,

and CSA. It is ensured through the

destructive testing of samples


Blockchain technology is expected to achieve

widespread, mainstream adoption sooner rather than

later. Retail and CPG businesses need to act now and

plan for future blockchain adoption, or risk being left

in the dust.

- Deloitte ‘18

“


Am I being a good

supplier to my

customers?

Trusted Traceability: Win/Win/Win for every Stakeholder in the Supplychain

Are the ingredients

I’m using safe?

Are my operations

compliant and

efficient?

Are my products

being treated

correctly?


Customers are already breaking down silos…and realizing the value

of digitalization.



Constellation Brands partners with Siemens

to automate and modernize the world’s largest brewery

Standardizationof hardware and

software of more

than 30 different

equipment suppliers

Tripled annual

output while

maintaining product

quality

April 23, 2018 Dr. Jan Mrosik |CEO Digital Factory DivisionPage 48



Headline, Arial Bold, 22 pt, lorem ipsum dolor est

Content page – highlighted text

Digital Enterprise Suite

Unique portfolio for the

digital transformation

Unrestricted © Siemens 2019 All rights reserved. Community. Collaboration. Innovation.

Questions?

Suzanne Kopcha

Presenter Vice President, Siemens PLM |Consumer Products &

Retail Industry

Address: 2000 Eastman Drive, Cincinnati, Ohio

Phone: 513-305-8968

E-mail:[email protected]

digital thread & digital twin: the winning factor in food ...€¦ · manufacturing...

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