Tecnomatix® software from Siemens PLM Software delivers speed,flexibility and quality throughout the extended enterprise.

Tecnomatix for theelectronics industryManufacturing process management solutionsfor global electronics manufacturing

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Manufacturing process management solutions

Why you need digitalmanufacturingA company’s biggest cost center –and that of its supply chain –is manufacturing operations.Your product’s competitiveadvantage is squandered whendelays and cost overruns resultfrom inefficient, expensive andunpredictable manufacturingprocesses. The economic successof innovative product designshinges on the performance ofyour manufacturing operations.

Digital manufacturing is acombination of open softwareand manufacturing methodsthat transforms productionprocesses and businessinitiatives. It provides a solutioncovering all manufacturingdisciplines including manufac-turing process design, processsimulation/engineering andproduction execution. Bydoing so, digital manufacturingresults in companies gettingnot only much more from theirproduction operations, butalso more from productdesign investments andsupply chain partnerships.

Digital manufacturing is anessential component of PLMinitiatives because it closesthe gap between productdesign and product deliveryby managing both the designand execution of manufac-turing processes. For example,digital manufacturing allowsmanufacturing process

planners to work in concertwith product designers for trulytransformational productdevelopment improvementsand supply chain advantage.

Helping global electronicsmanufacturers bringproducts to market fasterElectronics manufacturers mustbring cost-effective products tomarket faster than ever whilemeeting a variety of challenges,including the introduction oflarge numbers of new productsin record time; manufacturinga growing mix of complexproducts; meeting customerand regulatory demands liketraceability and lead-freemanufacturing; and introducingnew technologies, such ascomponents, software,equipment or processes.

Beyond these day-to-daymanufacturing challenges, globalelectronics manufacturers facethe challenge of acquiring newfacilities; selecting the rightequipment; balancing workloadsbetween factories; managinginventory and quality on aglobal scale; and managing theoutsourcing business process.

Manufacturing processmanagement for electronics= NPI + executionTecnomatix software forElectronics from Siemensaddresses these critical issues,by providing the most commonlyused manufacturing processmanagement (MPM) solutionsfor designing, managing andintegrating the new product

introduction (NPI) process,production execution on theshop floor and the outsourcingbusiness process at the singleplant, corporation and extendedenterprise levels.

Manufacturers worldwide areusing this complete, end-to-endmanufacturing solution to design,optimize and execute board andbox-level production processes.Tecnomatix solutions helpelectronics manufacturersintroduce new products fasterby more easily programming andoptimizing the widest varietyof assembly machines and testequipment in low- and high-mixscenarios, logging defects inthe repair process and managingall aspects of manufacturingexecution, from materialmanagement to machine moni-toring and quality managementto full product and processtraceability.

MPM is a technology-enabledbusiness strategy that connectsthe NPI and production processesby determining digitally “how” aproduct will be manufactured;evaluating how well the plannedprocess will work and optimizingit; managing the execution of theplanned processes; and providingfeedback and process visibilityacross the manufacturing chain.

In short, MPM is the how: howto design a process and how toexecute its manufacture.

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The most commonly used PCB NPI solution in the industry:Tecnomatix PCB Assembly and Test is the only integrated set ofsolutions covering the entire NPI suite of activities, providing uniquesupport for continuous improvement of NPI processes throughprocess automation. The PCB Assembly and Test system providesbest-in-class, industry-proven solutions for optimizing SMT lines forlow, medium and high volumes and mixes at the machine, line andfactory level.

The leading final assembly line design solution: The TecnomatixBox Build solution is an end-to-end methodology and integratedtoolset for planning and validating box assembly lines and processes.This proven and tailored solution for electronics box assembly isintended for manufacturing engineers and industrial engineeringteams at the corporate level as well as at dispersed plants, andprovides an integrated toolset that increases engineeringefficiencies throughout the organization.

The most comprehensive MES solution for electronicsmanufacturing: The Tecnomatix Electronics MES solution is themost comprehensive and mature MES solution, custom-built forthe electronics industry and covering both PCB and box assembly.Primarily an out-of-the-box solution, yet extremely configurable,this web-based point-and-click software covers the entire set ofelectronics MES functions, including: feeder verification; materialtracking and management; lead-free compliance; repair management;machine monitoring; quality management; product genealogy;and full product and process traceability.

The most innovative, end-to-end outsourced manufacturingmanagement solution: Tecnomatix outsourced manufacturingmanagement (OMM) is designed for OEMs using a partial or fulloutsourcing model for their manufacturing. It enables OEMs andsuppliers (EMS/ODM/CM) to establish tight collaboration andcontrolled relations, making manufacturing partnerships work moreefficiently and more productively by: improving financial control;significantly reducing shortages and access inventories; removingdelays and reducing expedite fees; enhancing employee productivityand effectiveness; and improving quality.

Tecnomatix solutions from Siemens can help you enhance yourenterprise competitiveness by allowing your extended teams to:

• Get the NPI process right the first time

• Optimize throughput even in high-mix conditions

• Cope effectively with change

• Tighten your grip on shop floor execution

• Minimize size of product recalls and internal reworks

• Analyze production information and get to the root cause ofissues in real-time, helping to prevent mistakes from eroding yourcost margin

• Meet ever-growing customer and regulatory demands

• Streamline the OEM-ODM/EMS/CM outsourcing businessprocess

Electronic solutions

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The PCB Assembly and Test solution

Tecnomatix PCB Assembly andTestSiemens PLM Software's Tecnomatix PCB Assembly and Testsolution is the most commonly used NPI solution for the designand optimization of PCB assembly and test processes. By coveringthe entire NPI process from CAD import through manufacturingrecipe generation and by supporting single-platform and mixed-vendor lines, this proven solution helps continuously improve yourNPI process and maximize the uptime and throughput of your lines.

Continuously improving the complex NPI processFaster time-to-volume and better NPI accuracy impactsdownstream processes, from higher end-product quality to on-timedelivery. Instituting a cohesive, comprehensive NPI discipline via astandard workflow, consistent knowledge capture and a standard setof tools to automate, program and optimize, provides the means tocontinuously improve the NPI process and is a critical componentof success in this age of on-demand fulfillment. By maintaining aprocess database containing jobs, workflows, machine and partlibraries, the PCB Assembly and Test solution enables the captureof NPI processes and allowes re-use of best practices.

Addressing the NPI complexity: covering the entire processOffline design of manufacturing processes starts by importingand merging CAD and BOM, which becomes the basis for themanufacturing job and is the foundation of an NPI database forfuture revisions and best-practice capture. Automatic upfront

verification checks for correct data versions and for any discrep-ancies between data files. From there, the process is mapped byselecting the line or lines and associated processes, including handinsertion. Documents, in user-configurable templates, can begenerated once the processes are allocated, mapped and verified.Since the documents are based on both CAD and line resourcespulled from libraries, there is no room for ambiguity. And since themanufacturing job is based on upfront CAD and BOM import, anyrevisions in the form of an engineering change will update theentire process.

Addressing the NPI complexity: optimizing the processWith the NPI process mapped, powerful simulation tools enableproduction engineers to optimize the line performance offline andintroduce optimized machine recipes for entire lines, whether theyconsist of single- or mixed-vendor machine platforms. If productionis characterized by longer volume runs, engineers may prefer tooptimize for cycle-time performance and ensure maximum machinethroughput. If production is characterized by frequent productchangeovers or high product mix, then optimization for commonsetup is a more desirable strategy for minimizing machine down-time. Whichever strategy is selected, optimization for high mix orhigh volume, Siemens has developed comprehensive optimizersbased on parametric algorithms and machine kinematics which canperform multiple iterations in minutes and base optimization onvery specific machine behavior.

Flexible user workflowDesign and program PCBassembly offline by leveragingthe NPI process and facilitatecontinuous improvement for fastertime-to-volume, while reducingor even eliminating errors inthe process.

Import and merge CADand BOMCapture of board layout fromnative CAD including parts,shapes, drills, pads, nets andtraces. Support for more than65 CAD platforms with frequentreader updates. Upfront CAD-to-BOM discrepancy checks preventincorrect loading of job versions.

Define assembly sequencesand program SMT linesDesign and program PCBassembly offline by leveragingprogramming interfaces for morethan 150 different machineplatforms. Support for single andmixed platform lines allows greatflexibility in selecting equipment.

Assembly andTest: supporting continuous improvement and process optimization

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Process optimizationDeploy optimization strategiesthat meet business requirements.Optimize for increased cycle-timethroughput during longerproduction runs, or optimize forcommon setup during frequentproduct changeovers or whenrunning product families on asingle line.

Test engineeringComplete test engineering solutionwith upfront testability checks andreporting, as well as automatedfixture fabrication, including nailselection to increase test coverageand tester programming for themost common platforms of ICT,AOI, inspect and flying probeequipment.

Shop floor documentationGenerate complete sets of shopfloor documentation andassembly instructions includingprocess setup and hand-insertinstructions. Import a variety ofpicture and drawing files tocreate unambiguous instructions.All change order introductionsare updated automatically.

Viewing and distributionUse powerful viewers to querymanufacturing jobs and facilitatecollaboration among differentgroups in the manufacturingorganization.Viewers may alsobe used to distribute electronicdocuments to specific stations onthe shop floor for paperlessdistribution of work instructions.

Addressing the NPI complexity: integratingAssembly andTestEffective test engineering can positively impact both productand process quality by upfront capture of test issues that mightcompromise quality and by ensuring appropriate test coveragethat will eliminate false alarms and process bottlenecks at testingstations. Siemens offers its Assembly and Test users an integratedsolution that imports and verifies the manufacturing job just once,but is used for both assembly and test processes. Any updates inthe form of engineering changes will correct the manufacturingdatabase for both assembly and test organizations.

More than 3,000 manufacturing sites around the world useTecnomatix Assembly and Test solutions to manage andaccelerate NPI.

Key benefits of Tecnomatix solutions for PCBAssembly andTest

• Reduce change-over time as much as 75 percent by clusteringboards and optimizing processes

• Increase line throughput by up to 20 percent

• Program all of your SMT machines and lines with a singleprogramming solution

• Achieve test engineering gains of up to 20 times faster on denseSMT boards

• Create an environment with the tools and methodology forcontinuous improvement

Box Build: designing, optimizing and validating NPI processes

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The box-build process design solution

Box-build process designTecnomatix eM-Box Build is an end-to-end solution for designing,optimizing and validating electronic box-build NPI processes andtransferring them to volume-manufacturing plants. Its process-oriented environment allows OEMs, CMs and EMS providers tocollaborate on the development of manufacturing processesand is a major facilitator for outsourcing.

Starting the NPI processTecnomatix provides a powerful 3D environment to create andanalyze a box-build assembly sequence based on 3D MCAD data.Product design errors can be discovered early, when problems arecheaper and quicker to fix. This process also verifies that the BOMand CAD data match.The output is a valid sequence of assemblyor the initial sequence of operations.

Planning an assembly processeM-Box Build tools and methodologies are used to plan assemblyprocesses by means of an electronic bill of processes, or eBOP.

The eBOP contains all the information about your variousprocesses, manufacturing resources and products, as well as therelationships among them. eM-Box Build allows you to plan facilitylayouts in a CAD-embedded environment, estimate assembly timesbased on time and motion standards of your choice, balance thelines, evaluate costs and carry out variant and change management.

Optimizing, detailing and validating the processDiscrete event simulation – where the simulation model isautomatically created from the process plan – allows you to validateand optimize line performance, including throughput, bottlenecks,resource utilization and buffer sizing. These models facilitate theevaluation of different manufacturing scenarios and maximize theirthroughput potential. The eM-Box Build 3D environment is usedfor detailing manufacturing cells and lines and performing humansimulation, including ergonomics analysis.

Time estimationEstimate and allocateassembly operation timesusing any time and motionstandard or your ownin-house tables.

Process planningAllocate parts and operations toassembly stations. Estimate costof the manufacturing process.

Assembly sequenceverification andBOM checkingDefine the assembly sequenceand verify product assemble-ability. Check BOM completeness.

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Delivering process information to the shop floorThe solution automatically generates electronic work instructions,including text, pictures (real or virtual), drawings, animations andmovies in the template of your choice. Based on information fromthe manufacturing database, these work instructions can be updatedat the push of a button when changes are made to product parts,resources or operations. Moreover, because they are created fromanimations, they do not require the actual physical prototype. Workinstructions can be published and distributed either in hard copyformat or over the Intranet to monitors on the shop floor.

Transferring processes from NPI centers to mass-production plantsThe eBOP includes all of the data required to build a product.By enabling the sending of the eBOP from the NPI center tomass-production plants, eM-Box Build reduces the time it takesto transfer processes to volume manufacturing facilities, therebyaccelerating demand fulfillment. This time savings applies to boththe number of engineering hours required and the durationof the processes.

Facilitating outsourcing and collaborationTecnomatix eM-Box Build allows for the distribution and sharingof manufacturing data over the Internet – a major facilitator forcollaboration among OEMs, CEMs and EMS providers. Once aprocess is captured in the form of an eBOP, it becomes the basictoken of information and is exchangeable among participantsthroughout the extended product and process designingorganization. The consistency of creating and capturing theprocess means that anyone looking at the eBOP can easilyunderstand the process design.

Tecnomatix eM-Box Build enhances enterprisecompetitiveness by:

• Enabling “plan anywhere, build anywhere” strategies

• Facilitating outsourcing

• Cutting process ramp-up and transfer times by up to 50 percent

• Reducing NPI duration by up to 20-30 percent

• Shortening the time to create electronic work instructions by asmuch as 50 percent

• Reducing time to update and maintain work instructions by upto 80 percent

Cell and line layout anddetailed designLay out the assembly line inan embedded AutoCAD orMicrostation environment.Detail and analyze the line in3D, including human simulationand ergonomic analysis.

Electronic work instructionsand reportingCreate web-based electronic workinstructions and manufacturingprocess-related reports, includingtext, pictures and 3D MCAD-based animations.

Process transfer andcollaborationAllow insight to processes as theyare created. Share eBOPsthroughout the extended enterprise.

Line balancing andperformance analysisBalance lines and analyze lineperformance to optimizethroughput, size buffers andrelieve bottlenecks.

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The electronics manufacturing execution solution

eM-Execution is the Tecnomatix electronics manufacturingexecution system (MES) custom-designed for PCB and box assemblymanufacturers. Provided in modules or as an entire integrated suite,eM-Execution covers the entire range of requirements for electronicsproduction management, including traceability and RoHS-compliancesupport. It is a web-based solution that provides visibility tokey performance indicators (KPIs) for real-time control ofmanufacturing processes at the plant or across an enterprise.

Managing the shop floor: instilling process disciplineElectronics manufacturing has become more challenging than ever –with shorter product lifecycles, more complex product mixes andincreased regulatory and OEM customer requirements. Manufac-turers need to instill a level of discipline on their shop floor toensure that cost and delivery targets are met consistently. Enforcingdiscipline through documented procedures and periodic audits hasalready proven to be insufficient and ineffective. TecnomatixeM-Execution provides automated shop floor management byenforcing key manufacturing rules during setup, assembly, testand repair – thus ensuring that processes are executed asplanned to meet delivery and cost challenges.

Managing the shop floor: decision support thatactually mattersManual methods of data collection and quality management withstandalone systems delay root-cause analysis and result in ineffective“after-the-fact” corrective action recommendations. By automatingdata collection from every resource on the shop floor, includingdirect parsing from equipment and presenting the data in an easy-to-analyze form, eM-Execution allows correction of processes beforethey become out of control. With expanded visibility provided byreal-time collection, notifications and alarms, eM-Execution allowsmanufacturers to make data-driven decisions that actually makea difference.

Managing the shop floor: complete final assembly controlManufacturers must be able to verify the build process, manageECO implementation and deliver required work instructions for thebox level just as they would at board level. With increased after-saleservice requirements, along with environmental legislation, it is allthe more important that all components and histories of a productbuild are captured and known. eM-Execution from Siemens enablesmanufacturers to capture and manage changes in the genealogy of afull system build and manages quality, disassembly, reconfigurationand repair throughout the product lifecycle.

Tecnomatix MES: supporting traceability and regulatory compliance

Machine performancemonitoringAggregate machine events intological reports, thereby allowingtraceability and improvedequipment utilization. Gainreal-time web-based visibilitywith alarms when utilizationthreshold drops belowacceptable range.

Material management andinventory trackingGain real-time visibility into actualin-plant material locations whiledetermining which locations arededicated toWIP. Ability toSynchronize with ERP/MRPsystems to achieve moreaccurate material counts.

Part verification systemVerify setup at kitting stationsand on machines to eliminatepart placement and build errors.

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Meeting traceability requirementsNeither ERP/MRP nor disconnected shop floor systems are ableto provide full traceability of the production history as requiredby customers and industry legislations. Tecnomatix enablesyou to capture every aspect of the manufacturing process, frommaterials to production processes, whether at the board level orthe entire system build, thus providing full product and processtraceability. Deploying Tecnomatix helps manufacturers to limit thescope of product recalls and reduces associated recall costs, whileproviding for compliance to a variety of environmental and safetyregulations across all segments of the industry and therebymitigating manufacturing liability.

Supporting lead-free assembly on the shop floorAs the RoHS deadline is fast approaching, electronics manufacturershave focused their efforts on sourcing lead-free parts and solvingtechnical process issues in order to produce compliant product.However, manufacturers are still unprepared for the range of issuesthat will impact manufacturing performance as the industry migratesto lead-free assembly – in terms of material handling, implementingwaves of ECOs to replace tin-lead parts and anticipated qualityand reliability issues. By providing a solution that eliminates partnumber/marking confusion, manages dual inventories (lead-basedas well as lead-free), tracks ECOs, monitors and verifies processesand manages quality, Tecnomatix supports full lead-free traceabilityand compliance declaration.

Managing the shop floor with a complete andintegrated solutionStandalone point solutions traditionally deployed on shop floorsare inadequate for today’s manufacturing environments, due to theexponential increase in shop floor events and transactions whilecoping with challenging delivery and cost targets. Only an integratedset of manufacturing execution capabilities can adequately copewith today’s manufacturing realities. eM-Execution from Siemensoffers manufacturers the leading manufacturing execution system,custom-built for electronics manufacturers, and integrating material,quality, and traceability solutions on a single framework.

Key benefits of theTecnomatix MES solution:

• Win more business by complying with regulatory and traceabilityrequirements

• Minimize size of product recalls and internal reworks

• Meet new challenges, like lead-free assembly and compliancedeclaration

• Analyze production information and get to the root-cause ofissues in real-time

• Eliminate wrong-part placement and build-process mistakes

• Gain instant visibility to your raw material, WIP and finishedgoods to support your inventory reduction efforts

WIP monitoring and routeenforcementEnforce board manufacturingroutes and time-stamp anddate-stamp every pass of aWIPstation for full process traceabilty.WIP progress is monitored inreal-time via a web browser.

Quality managementAutomatically collect data from theshop floor, thereby enabling real-time monitoring of trends. Shouldyields drop below acceptablethresholds, system alarms andnotifications are activated toenable process management.Powerful Pareto and SPCreporting allow root-causeanalysis eliminating guessworkin correcting process defects.

Repair managementPerform graphical defect loggingand defect location.Togglebetween board and schematicfor faster query. Likely root causeand suggested repair routeare advised to accelerate therepair process.

Web reporting anddashboardsLeverage thin client webbrowsers to gain full visibilityonto the shop floor or into aremote location. Enableexecutives to to configure amanufacturing dashboard withreal-time data to make informeddecisions for better productionmanagement.

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Outsourced manufacturing management

Tecnomatix eM-Outsource, the Siemens outsourced manufacturingmanagement system, is a dedicated solution for the challengingglobal outsourced manufacturing environment. Provided as aperpetual solution or a hosted, on-demand solution, eM-Outsourcecovers the entire range of functionality needed to manage thebusiness relationship, quality and inventory. This unique event-driven solution allows you to bring back the same control levelsof internal, pre-outsourced manufacturing to the distributed,global-outsourced environment, thereby ensuring on-time andon-quality deliveries.

Managing the supply network: streamline youroutsourcing business processAs outsourcing becomes the mainstream, and as supply chainsbecome more complex and span multiple time zones, the needfor a structured and controlled outsourcing business process isevident. eM-Outsource introduces discipline, and streamlinesand automates outsourcing business processes by replacingunstructured business practices (emails, faxes, calls, etc.) withworkflow applications. These allow for standardization for datacollection, rationalization and analysis, and for the raising ofnotifications and alarms. These business control tools eliminatedelays and inefficiencies and significantly increase the responsivenessand economies of demand-to-supply networks, while reducinginventory, improving product quality and reducing returns andwarranty costs.

Controlling the supply network: global monitoringand control in real timeManual data collection results in after-the-fact,“rear-view mirror”analysis and corrective actions. Automating data collection witheM-Outsource – in near real-time – from suppliers, ERP, MES,home-grown shop floor applications, inventory and other systems,allows you to monitor and control the extended enterprise as if itwere a single entity. The solution lets you make more informed,proactive and timely decisions, leading to lower costs on the onehand and more satisfied customers on the other.

Key benefits of Tecnomatix eM-Outsource include:

• Increased on-time deliveries

• Reduced inventory

• Lower expediting fees

• Increased financial visibility and control

• Enhanced employee productivity

Tecnomatix eM-Outsource: supporting global outsourcing

Quality managementAggregate and analyze qualitydata; manage SCAR, CAPA, RMAand more.

Inventory managementProvide visibility and control overfinished goods as well asmaterial/component inventoriesat the CM locations.

Supply networkmanagementManage orders, purchasing,WIPand delivery. Includes capabilitiesto manage availability to promiseand supply chain cycle time.

Global professional services

Maximize the benefits of yourTecnomatix solutionSiemens offers customers much more than depth of expertise.We take great pride in our ability to deliver the highest levelof professional services so that you can achieve maximumbenefits from our Tecnomatix solutions in the shortestpossible time.

Whether you face challenges at home or in a remote part ofthe world, Siemens has the flexibility and the people in place torespond. Our professional service experts share vast experience andbusiness knowledge in project implementation, project design andproject methodology. They are your experts in TecnomatixMPM technology.

We are ready to help you achieve maximum impact on yourbusiness processes by providing end-to-end MPM solutionsmatched with consulting, development, implementation supportand engineering services that fit your environment and objectives.

Prepare, predict, perform better manufacturing processes

The Siemens PLM Software professional services team can help you to:

• Maximize market potential for your products

• Optimize and manage global distributed manufacturing

• Respond quickly to new market opportunities

• Accommodate frequent changes in where and how you produce,as well as what is produced

• Deliver speed and flexibility across the extended enterprise

© 2007 Siemens Product Lifecycle Management Software Inc. All rights reserved. Siemens and the Siemens logo are registered trademarks of Siemens AG. Teamcenter, NX, Solid Edge, Tecnomatix,Parasolid, Femap, I-deas, JT, UGS Velocity Series, Geolus and the Signs of Innovation trade dress are trademarks or registered trademarks of Siemens Product Lifecycle Management Software Inc.or its subsidiaries in the United States and in other countries. All other logos, trademarks, registered trademarks or service marks used herein are the property of their respective holders.

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About Siemens PLM SoftwareSiemens PLM Software, a division ofSiemens Automation and Drives (A&D),is a leading global provider of productlifecycle management (PLM) softwareand services with 4.3 million licensedseats and 47,000 customers worldwide.Headquartered in Plano,Texas, SiemensPLM Software’s open enterprise solutionsenable a world where organizations andtheir partners collaborate through GlobalInnovation Networks to deliver world-classproducts and services. For more informationon Siemens PLM Software products andservices, visit www.siemens.com/plm.

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