{"id":2618,"date":"2019-11-19T11:41:13","date_gmt":"2019-11-19T16:41:13","guid":{"rendered":"https:\/\/blogs.sw.siemens.com\/thought-leadership\/?p=2618"},"modified":"2026-03-26T12:06:36","modified_gmt":"2026-03-26T16:06:36","slug":"implementing-smart-manufacturing-for-smart-factory","status":"publish","type":"post","link":"https:\/\/blogs.sw.siemens.com\/thought-leadership\/implementing-smart-manufacturing-for-smart-factory\/","title":{"rendered":"Implementing smart manufacturing for a smart factory"},"content":{"rendered":"\n

With new strides and technological advancements propelling the manufacturing industry to greater innovations, it\u2019s essential to understand how improving machinery operations is dependent upon making your factory smarter<\/em><\/strong>.<\/p>\n\n\n\n

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Bill Davis, Director of Industrial Machinery and Heavy Equipment Solutions at Siemens Digital Industries Software<\/figcaption><\/figure><\/div>\n\n\n\n

A substantial\ncontributor to this series is our resident expert, Bill Davis, who is the Director of\nIndustrial Machinery and Heavy Equipment Solutions<\/em> at <\/em>Siemens Digital Industries Software<\/em>. Bill\u2019s expertise in this\nindustry expands over 30 years, with 20 years as an engineer. <\/p>\n\n\n\n

We continue this\ntopic by having him explain the dynamics of smart manufacturing and smart\nfactories. <\/p>\n\n\n\n

Below, is a\ntranscript excerpt from the final\nportion of this podcast series<\/a>:<\/p>\n\n\n\n

This podcast series stresses the importance of simulation for both the\nmanufacturing environment and the machine build.<\/p>\n\n\n\n

Blake\n(interviewer):<\/em><\/strong>\nA part of taking advantage of being smarter in manufacturing and operations is\nthe assembly layout. For example, you\u2019ve got five machines in one location, ten\nmachines somewhere else, and they’re all very similar, but they also have\nvariance. So, how do you ensure that the correct parts are in the right\nlocation on the assembly floor at the appropriate time? <\/p>\n\n\n\n

Bill:<\/em><\/strong> You need to have a software solution that lets you simulate the machine location on the floor and how to get materials to them. It\u2019s process simulation, which is a novel idea to ensure eliminating high-traffic zones to areas of delay in receiving materials. There\u2019s a need to improve optimization in how the work cell is located, and in the machine builder. However, how do you ensure you\u2019re putting the right materials needed and defined by the manufacturing bill of materials? Also, how do you ensure the materials are arranged on the floor for optimization assembly?<\/p>\n\n\n\n

Everything needs to be within an arm’s reach, so it\u2019s not just the shop layout and simulation, but also process simulation. What’s often overlooked are conflicts in the order of operation. Machinery is about putting ten pounds of functionality into a five-pound bag. So, the assembly process is a compromise that’s a result of the design. However, as we look at all the trends towards adaptability, predictability and extendibility, it’s vital to view the human factor for the assembly process and decipher the necessary tools to achieving high quality.<\/p>\n\n\n\n

For example, we’ve\ngot a machine assembly that’s inside a frame, and you can’t physically move the\ntorque wrench to get to the right spot, so that\u2019s a quality problem. However,\nbeing able to simulate that in the early part of the design process will help\nus get first-time quality with the ability to make changes when it costs less.\nSo, you can move an element of that frame two or three inches to the right or\nleft and torque the bolt properly.<\/p>\n\n\n\n

We need the shop\nlayout capability and process simulation at the human factor level to be aware\nof problems. Sometimes these problems don’t manifest themselves until there’s a\nproblem in the field. For example, a bolt that seems like it was appropriately\ntorqued can loosen up and cause other failures. However, the root cause is the\ncapability of the assembly process. So, being able to simulate it as part of\nthe design process is crucial for continuous improvement into the development\nprocess. And, it\u2019s not just looking at the individual assembly and machine\nassembly process but scheduling multiple machines and multiple product lines at\nthe same time.<\/p>\n\n\n\n

In my previous role, we had high variability in shop floor requirements. One machining center would require a 20 x 20-foot space, and another a
10 x 30-foot space, creating a jigsaw puzzle in terms of the process. There was a physical scheduling challenge throughout the shop in backing it through the part manufacturing. The assembly process for scheduling software capability is vital to know the number of users on each machine and the floor space utilization. <\/p>\n\n\n\n

This information\nculminates in knowing factor acceptance or a side acceptance test. Routinely, a\ncustomer comes in and checks out the machine and is elated with its performance,\nthus signing on the bottom line for us to deliver it. However, simulation can\ninvolve the programmer sitting in front of the machine and testing many\noperating conditions in a stressful environment. The more complex the machine, the\nhigher the probability of not having time to test everything, including the assurance\nthat the machine PLC code meets all requirements.<\/p>\n\n\n\n

You need to have\nsoftware that allows simulating the upfront design process in the software\ndevelopment piece. Thus, simulating the PLC code on the machine floor, running through\nthe use-cases effectively to validate that the codes perform in the way the\nsimulation indicates. You can focus on areas of challenge that you may not be\nable to simulate, to bring that machine into a commissionable state quickly. <\/p>\n\n\n\n

Every time a machine is sitting idle or being tested, it allows time for potential cash. So, the less time in commissioning and debugging, the more rapidly you can get the machine to the customer and perform simulation for movement of parts and kinematics. <\/p>\n\n\n\n

These are items performed from an assembly management operations perspective, to drive value for the company and efficiency in generating more cash flow, reducing margin erosion by errors and quality problems. And, none of this could occur without the executable digital twin. <\/p>\n\n\n\n

Blake:<\/em><\/strong> Do you have examples or use-cases\nwhere companies have implemented the simulation and seen a reduction in errors\nor a reduction in time, while gaining an increase in cash flow? Without\nmentioning company names, do we have examples of improved metrics?<\/p>\n\n\n\n

Bill:<\/em><\/strong> Absolutely! So, there’s a company that\u2019s a Siemens customer and software user that is embracing the digital twin in digitalization of their machining and manufacturing centers. Also, there\u2019s a packaging machinery company that builds bags or boxes in packaging a product, whether it’s chips or bags, and putting them into boxes using the digital twin for the design to increase their production speed-building the world’s fastest packaging machinery. <\/p>\n\n\n\n

The extra-cost they\nspent is justified by having the world’s fastest machine and embracing the\ndigital twin for software development, virtual commissioning and software\nvalidation. The programmer evaluated the machine, testing it out to ensure it\ndidn’t collide and then hit the go<\/em>\nbutton, moving the pick head to the right, then to the left, colliding with the\nframe. So, by leveraging our software from an automation perspective, they’re\nable to:<\/p>\n\n\n\n