Siemens.move up 2010-1-en

The Magazine for Automation in the Automotive Industry

move upVolume 9, Number 1, 2010

Fujian Daimler Automotive, China

High Standards, Local Support

2 move up | 1-2010

p Editorial

p Cover

Emerging Markets 4 Flexibility on a Global Scale

Volkswagen Group Rus, Russia

8 High Standards, Local SupportFujian Daimler Automotive, China

10 International BenchmarkRenault Nissan Automotive India Pvt Ltd., India

13 Taking the WheelEmerging market trends

14 Global PartnersVolkswagen India

16 Bringing Innovation to Market FasterAutomotive Sector, Mahindra & Mahindra Ltd., India

18 The Next LevelZhejiang Geely Holding Group Ltd., China

20 Keys to SuccessBeijing Foton Cummins Engine Co., China

22 In Brief

23 Dialogue

With standard components and expertise from Siemens, Volkswagen is producing a wide range of vehicles in Kaluga, Russia, in a world-class facility

Page 4

Fujian Daimler Automotive benefi ts from both high standards in its automotive production and good support from the local Siemens team

Page 8

Renault Nissan Automotive India Pvt Ltd. sets benchmarks in terms of production quality and performance with Simatic technology

Page 10

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C o n t e n t s m o v e u p | 1 - 2 0 1 0

Thomas Schott

Head of Factory Automation

Siemens IndustrialAutomation Systems

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E d i t o r i a l

After an extremely diffi cult year, we and our customers are glad to see a signifi cant market recovery. The emerging markets have certainly played a key role in this recovery; with their dynamic approach they were able to curb and, to a certain extent, even counteract the down-turn in the traditional automotive markets. Countries such as Russia, China, and India were able to maintain steady growth throughout 2009. Plus, the long-term prospects are good: emerging markets continue to be demand-driven. Moreover, manufacturers there are placing greater emphasis on high-quality and effi cient production systems. In order to implement these systems, they need partners with the corresponding expertise.

We are extremely proud that we can support our customers in emerg-ing markets to achieve their goal of safe, state-of-the-art, and envi-ronmentally friendly automotive manufacturing. Not only do we work directly with automotive manufacturers as a product and solution provider, we also work with international OEMs. Our expert teams working on-site can draw on our extensive and global auto motive knowledge. In this edition of move up, which focuses on these emerging markets, you can read about some of the many successful projects we have implemented with our customers in Russia, China, and India.

I hope we can give you some valuable ideas. Enjoy the read!

Yours,

4 move up | 1-2010

C o v e r E m e r g i n g M a r k e t s

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Volkswagen Group Rus, Russia p

Flexibility on a Global Scale

With its new plant in Kaluga, Volkswagen is increasing its presence in Russia – a strategic growth market for the future.

The plant has been able to produce up to 150,000 vehicles per year since the completion of the second stage of expansion at the end of 2009. For Volks-wagen, this date marks the successful conclusion of a project lasting nearly four years. One of the central requirements of the factory was the production of a wide range of different models. Today the plant already produces more than 20 models belonging to the Volkswagen, Skoda, Audi, and Volkswagen commercial vehicles brands.

The new production facility is located in the Grabzevo technology park in Kaluga, southwest of Moscow. The location is ideal – offering plenty of space, yet close to Moscow as an important hub – and the foundations for the new plant were laid here at the end of 2006. Initially, Volkswagen built a semi-knocked-down (SKD) production facility, which went into operation in 2007. The vehicles are assem-bled from large components in this facility. Follow-ing that, the site was extended for full production by the end of 2009 with the addition of a body shop, paint shop, and fi nal assembly area. A total of fi ve Volkswagen and Skoda models now roll off the production line in Kaluga for the Russian market.

With standard components and

expertise from Siemens, Volkswagen is

producing a wide range of vehicles in

Kaluga, Russia, in a world-class facility.

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The special on-site conditions, with infrastructure under development and relatively limited local resources, and also, to a lesser extent, the specifi c guidelines from the Russian authorities, meant that project partners were needed that had both the technical expertise from Germany and the local competence to be able to properly implement such a large, international project. In part for this reason, Volkswagen decided to work with Siemens. With a presence spanning 150 years and experience in the country, Siemens is able to implement large and complex projects on time in Russia – while complying with specifi c guidelines and standards (GOST, etc.).

Global standards implemented on a local levelVolkswagen has high global standards for the quality of its products and therefore also places high demands on the quality and development of the systems engineering employed. Siemens came up with the right answers for Volkswagen in Russia: setting up the complete electrical infrastructure – from the groundbreaking to the completion of the assembly plant – came under Siemens’ responsibility as the general contractor. The consistent, integrated implementation of the power supply in accordance with Totally Integrated Power (TIP), from power outlets to the 20-kilovolt substation, made an essen-tial contribution to the success of the overall project.

Moreover, Siemens was also an important solution partner in equipping the fi nal assembly and supplied the entire conveyor technology, including all compo-nents for the car body conveyor technology and important just-in-time (JIT) parts (doors, dashboard, etc.) using electric overhead conveyors, skillet con-veyors, and belt conveyors. Furthermore, Siemens supplied systems for assembling the dashboard and front end, adjusting the drive line alignment (axle and track), programming the vehicle control units

H i g h l i g h t s a t a g l a n c e

On-schedule delivery and implementation 3

Fulfi llment of the global Volkswagen quality 3standards

Expert and powerful partner for international 3project management

Solution partner for mechanical and 3electrical systems across all products

Local project and technology skills in Russia 3with certifi cation (GOST, TÜV)

Local maintenance and after-sales service 3


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(checkout with SIDIS pro), and ensuring the assem-bly quality using a worker information system (rip cord, Andon board). In addition to the infrastructure and fi nal assembly, Siemens – as a partner of the Volkswagen tool-making unit – was responsible for the complete implementation of the automation technology, including robot programming in the body shop that is equipped with the latest laser welding, geometrical, and respot welding technol-ogy. All the mechanical and electrical fi ttings for the body-in-white fi nishing lines (doors, hatches, etc.) were also supplied by Siemens.

A Totally Integrated Automation (TIA) concept was implemented for all production facilities, with S7-317/319 Siemens controllers and an integrated visualization system. The sophisticated conveyor process was implemented with Siemens EMSdriver carriage controls and the tailored combination of Sinamics G120 D frequency converters and Flender geared motors. For the fi rst time in a Volkswagen plant, communication between the components was established using only Profi net/Profi safe – even wirelessly, using Industrial Wireless LAN with Scalance W, in the extensive assembly halls. The innovative automation concept was also the inspira-tion for other new Volkswagen plants in Pune, India, and Chattanooga, Tennessee.

Heading toward success with standard technologyThe integrated Siemens mechanical, electrical, and automation technology solutions form the basis for qualifying and training the operating personnel on-site and today can guarantee a uniform, easy-to-understand means of operating the systems. The standardization of the materials used allows a con-siderable reduction in spare parts stock – an addi-tional benefi t for Volkswagen. However, expertise and support are needed from the specialists from time to time, and in this case, quick and competent local after-sales service is available from Siemens Russia.

Kaluga has been working at full production since October 2009 – with world-class performance, as confi rmed by the project team. The expertise and problem-solving ability of Siemens has made a great contribution toward this success. “Thanks to modern technology, the most fl exible plant in the Volks-wagen Group worldwide has emerged in Kaluga,” says Dietmar Korzekwa, Russia corporate manager and general director of Volkswagen Group Rus. p

infocontact

www.siemens.com/[email protected]

Siemens acted as a solution partner for specifi c packages and the entire power supply

als WerksstandardPlant uses a Siemens Automation Concept as a standard solution

Plant

Cross-sectional functions

S7-317/319; Simatic ET 200pro; Profinet; Scalance IWLAN; IWLAN Mobile RFID Moby-E; WinCC; sensors, switching devices, etc.;Sinamics G120 D; Flender geared motors

Chassis installation 1–5LogisticsInstallation automation

Control systems/MES

Building technology/security

Communication/networks

Installation automation for laser,geometric, and respot welding stationsBody shop systems and conveyor technology

Conveyor technologyDashboard and front-end installationWheel alignmentUniversal testing system with SIDIS proInstallation automation

Electrical infrastructure and power supply

Siemens scope of delivery

Power supply from the substation (20kV) to the outletGeneral lighting for all indoor areas and outdoor installationsControl system for the power supply and lighting

SKD assembly

Final assembly

CKD production

Press shop

Body shop

Paint shop

Final assembly

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Fujian Daimler Automotive, China p

High Standards, Local Support

Located in Qingkou, 25 kilometers south of the city of Fuzhou in southeast China, the new Fujian Daimler Automotive greenfi eld project

has been called “Daimler’s South China pillar.” A joint venture between German automaker Daimler AG, Fujian Motor Industry Group Corporation (FJMG), and Taiwan-based China Motors Corporation (CMC), the Fujian Daimler Automotive (FJDA) plant is expected to “raise the technology and quality of the Fujian auto industry,” according to Ling Yuzhang, former chairman of FJMG and the board of FJDA. The plant makes several models of multipurpose vehicles and light vans: the Sprinter, the Vito, and the Viano.

The Sprinter and the Vito/Viano models are assem-bled on a so-called mixed production line. This was a particular challenge, as the models not only differ greatly in size but also vary in terms of assembly

concepts during assembly and marriage. Conse-quently, FJDA needed a mixed-line assembly solution that could accommodate that.

Implementing a higher standardPreviously, FJDA had considered using Asian prod-ucts and solution partners for its new plant in China. However, Daimler had had a positive experience with Siemens automation technology and automo-tive manufacturing expertise in its Beijing Benz-

When Fujian Daimler Automotive wanted high standards for

auto production, the company looked to Siemens for a solution,

and also received a good local team to support it.

Auto motive Co. Ltd. (BBAC) joint venture in China as well as in Europe, where Daimler has also developed an innovative standard for the design and equip-ment of production facilities in Daimler AG assembly plants.

This Integra standard also specifi es automation and communication technology. Key elements of the automation technology in the Integra standard are proven Simatic components, such as the Simatic S7 controllers. These components form the basis for the standardization of operator panels and control units. The use of this standard results in effi cient project realization, a smooth and fast ramp-up, and opti-

» Due to its extremely positive experiences

in the Daimler and BBAC parent plants,

FJDA has decided to use Siemens also in

its new plant in Qingkou.« Christoph Rentsch, FJDA


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infocontact


mized lifecycle costs. This means increased produc-tivity and reduced total cost of ownership for the customer. So when FJDA was assessing various alternatives for the new mixed assembly line, it was also evaluating Siemens as a supplier. “Due to the extremely positive experiences in the parent plants, we decided to use Siemens technology in our Chi-nese plant in Fuzhou,” said Christoph Rentsch, FJDA. In November 2007, FJDA planning management in Fuzhou decided to use Siemens technology based on the Integra BBAC standard for all systems in the body shop, paint shop, and assembly.

Easy implementation, excellent supportFor the Fuzhou assembly project, Siemens provided a comprehensive turnkey solution for the entire

assembly line, complete with testing and inspection line. Siemens delivered the automation and drive systems, such as Simatic ET 200 distributed I/Os, Simatic S7 controllers, Simatic panels, and Scalance network components, along with all required engi-neering for the chassis installation and preassem-bly, the conveyor technology (electrical overhead monorail system, slat and skid conveyor), the filling equipment, and the testing systems (roller tester, wheel alignment, headlight aiming tester, etc.).

The entire automation technology solution was produced by Siemens Factory Automation Engineer-ing Ltd. (SFAE) in China. SFAE also provides local

after-sales service that is fast, fl exible, and in the client’s language. Siemens automotive experts in the headquarters and SFAE jointly developed and successfully implemented the automation concept, including the Andon board system, also providing concept overviews of the automation technology used. In addition, thanks to SFAE it was not neces-sary to bring in support from Germany for the design and commissioning of the automation project.

Flexible, high-performance lineWith the new assembly line, FJDA benefi ts from the highly fl exible mixed-line concept for the Vito/Viano and Sprinter models. For example, the chassis for both models can be assembled with only one type of assembly frame in preassembly and marriage, and the models are transported with only one type of

electric monorail system (EMS) hanger using alter-nating adapters. Due to this fl exibility, the line does not require any buffers for different kinds of assem-bly frames. This design is space saving, reducing the plant footprint and costs. p

K e y p o i n t s

The Sprinter and the Vito/Viano 3models differ greatly in size and assembly concepts during assembly and marriage

FJDA needed a mixed-line 3assembly solution that could accommodate that

Siemens provided a suitable 3turnkey solution for the assembly line with a testing and inspection line

FJDA benefi ts from a fl exible 3line solution that is also space saving, reducing the plant footprint and costs

o Both the Viano and the Sprinter models are transported using the same type of EMS hanger

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Renault Nissan Automotive India Pvt Ltd., India p

International Benchmark

At the new greenfi eld automotive plant of Renault Nissan Automotive India Pvt Ltd.,

a standardized automation solution based on proven Simatic technology helps set

benchmarks in terms of production quality and performance.

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When Renault and Nissan announced plans for a joint venture to manufacture vehi-cles in India in February 2008, the new

automotive production plant in Chennai was pre-sented as a key milestone in the companies’ strategy for the Indian automotive market. “With the estab-lishment of our plant, Renault-Nissan will make major investments in India, reaffi rming the growing bilateral economic ties between our respective countries,” said Nissan president and CEO Carlos Ghosn at the plant inauguration in March 2010. Representing an investment of 45 billion rupees (US$990 million) and with the capacity to produce 400,000 units per year at full capacity, the new Chennai plant initially employed 2,000 workers at the start of production in May 2010.

The plant is the fi rst dedicated Renault-Nissan alli-ance vehicle manufacturing plant. The fi rst vehicle to be produced at the plant will be the new Nissan Micra, a global subcompact. The Micra, which is also the fi rst vehicle derived from the new V-platform, is destined for the Indian market as well as for export to over 100 countries in Europe, the Middle East, and Africa. In 2011, the plant will start production of the Renault Koleos and Fluence, both destined for the Indian market.

A versatile plant Intended to manufacture a variety of car models, the new plant must be able to operate fl exibly and quickly adapt to changes in model lineup and pro-duction capacities. While the production equipment for the new plant was delivered by line builders from all over the world, Renault-Nissan opted for a highly standardized solution in terms of production auto-mation. In several of its plants, such as in Batilly in France, Renault had already implemented automa-tion solutions based on the SCUBE concept (see sidebar) developed in coordination with Siemens, and had achieved good results with this approach. So consequently, Renault-Nissan also opted for SCUBE as the basis of the automation technology to be deployed in the new Chennai facility. Siemens provided state-of-the-art standardized automation solutions for all its shops in vehicle operation and powertrain assembly lines. The result was a plant that not only was rapidly built, but quickly produced a high-quality product.

One standard for automationSiemens manufactured and delivered the standardized cabinets to the line builders in Korea, Italy, and China that were contracted for the Chennai facility. Conse-quently, all shops in the new plant use a uniform automation architecture that greatly simplifi es both the training of staff and the maintenance of the produc-tion technology. The reduced product variety requires lower spare parts inventory and this also leads to lower training effort for the maintenance staff.

The automation architecture is based on Siemens products throughout: Simatic controllers at the pro-

grammable logic controller (PLC) level, Simatic panels for operation and monitoring, Sinamics and Simotion drive systems, Sirius switching products, and Scalance communication devices. Simatic WinCC flexible is used for visualization tasks. The communication in the plant is based on Industrial Ethernet and Profi net, with Profi safe for safety communication. All shops use Siemens cabinets built to the SCUBE standards – Siemens delivered more than 100 of them. These include control cabinets, which Siemens installed. Siemens also delivered the line builders.

The body shop in the plant is a good example of how the automation standard is deployed. The entire body shop is controlled through a main operating panel (MOP) as defi ned in the SCUBE standard,

» The service and support we

have received in India from

the local Siemens team has

been excellent. «Paul Morris, Head of Maintenance Department, Renault Nissan Automotive India Pvt Ltd., Chennai

S C U B E

The SCUBE concept is based on a structured and modular automation concept and also integrates fail-safe functions into one uniform architec-ture. SCUBE uses standardized software and hardware:

Simatic S7-300 PLCs 3

Simatic HMI devices 3

Simatic Industrial PCs 3

Microbox PCs for embedded control 3

Sinamics G120/G120 D as standard motor converters 3

Safety Integrated 3

Additional standard components:

Sirius circuit breakers for standard and specifi c handling applications 3

Simatic RFID read/write devices and data tags 3

Scalance components for networking and communication 3

The automation and HMI units are all contained in standardized cabinets, always using identical interfaces, installation, and design. Depending on the extent of the required functionality, every manufacturing unit or zone is equipped with suitable versions of the specifi ed operator panels.

12 move up | 1-2010

infocontact


which utilizes a Simatic S7-300 fail-safe PLC. This PLC controls all processes in the body shop and connects to the drive control system via Ethernet, I/O modules in a Siemens Microbox PC 42x, a Siemens Scalance Switch, and an ET 200S distributed I/O system.

Each zone within the body shop can be controlled with an HMI suboperator panel (SOP). All cabinets are supplied by Siemens according to the SCUBE standard. Each zone cabinet contains an ET 200S with a frequency inverter. Each zone also has a converter cabinet for the transfer station, which contains an ET 200S, and a Sinamics G120 frequency converter for the drive plate. Zones 1 and 2 also have a converter cabinet for the slat conveyer, which also contains an ET 200S and Sinamics G120.

Excellent position for a growing marketThanks to the standardization achieved by using the SCUBE approach, both the project execution and the commissioning of the equipment in Chennai were completed in a very tight time frame, speeding up overall project execution. The uniform architecture simplifi es training, and systems are easier to main-tain. Moreover, the standardized architecture also has signifi cant benefi ts in terms of future modifi ca-tions and expansion projects: because the entire structure is modular, it can be easily expanded.

Renault-Nissan was pleased with the plant build time and local support from Siemens, as Paul Morris, head of the maintenance department at Renault Nissan Automotive India Pvt Ltd. in Chennai confi rms: “The service and support we have received in India from the local Siemens team has been excellent.“

After just 20 months, the greenfi eld automotive plant has started production. It is one of the most advanced facilities in India in terms of automation, and consequently in terms of performance and productivity quality. At the plant inauguration cere-mony on March 17, 2010, Chairman Ghosn said, “This is the fi rst Renault-Nissan alliance plant, and using Renault’s production method. The plant will be a clear benchmark for the future.” Renault-Nissan is already benefi ting from the mature technology of Siemens and the SCUBE standard: a proven, state-of-the-art automation solution, successfully deployed at Renault in several plants and now also at Renault- Nissan in India, that offers operational benefi ts and can easily be expanded to serve the growing auto-motive market in India. p

Industrial Ethernet level 2



Zone 2

SinamicsG120

Drive plate

SOP HMI

ET 200S withfrequency inverter

Converter cabinet for transfer station

Zone cabinet

ET 200S

SinamicsG120

Drive plate

Converter cabinet for slat conveyor

ET 200S

Zone 3–4

SinamicsG120

Drive plate

SOP HMI



Zone cabinet

ET 200S

Zone 2

MOP

SinamicsG120

Drive plate

SOP HMI



Zone cabinet

ET 200S

SinamicsG120

Drive plate

Converter cabinet for slat conveyor

ET 200S

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PC 42x

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infocontact

www.siemens.com/[email protected]@de.pwc.com

Emerging market trends p

Taking the Wheel

Both India and China have enormous rural populations alongside comparatively affl uent middle classes. Car ownership among the

middle classes is growing fast, creating strong markets for the automotive suppliers operating in the regions. However, these markets will be dwarfed by the opportunities to be unlocked as the rural populations start to embrace car ownership. Here the similarity ends, as the two countries are taking quite different approaches in developing their auto-motive industries. Russia presents quite a different challenge.

Russia: challenges and opportunitiesRussia has a mature industrial economy, but its domestic producers have aging product lines. The global fi nancial crises hit the Russian manufacturers hard, causing a massive decline to just 650,000 vehicles produced in 2009. However, the domestic suppliers are fi ghting back, forming relationships with global brands (e.g., AvtoVAZ with Renault- Nissan) to update their product lines and better compete with incoming global products.

Low-cost models for rural IndiaIndia produced 2.4 million light vehicles (LVs) in 2009 and is forecast to increase production to 5.8 million by 2016.

Most Indian car production is destined for the do-mestic market, and many OEMs, led by Volks wagen-Suzuki and Tata, are now targeting rural India. They are introducing very low-cost models such as Tata’s Nano to lower the bar to car ownership.

China eyeing world marketsChina has a very strong domestic manufacturing sector with brands such as BYD, Chery, and Geely growing sales by about 62 percent during 2009. But the Beijing government has its sights on interna-tional markets and is following a strategic plan for

The economies of Russia, India, and China contain automotive sectors of great

importance to those countries and the surrounding regions. In its Autofacts reports,

PricewaterhouseCoopers reveals that each has its unique characteristics and

prospects for the future.

consolidation of the domestic auto industry into 8 to 10 large Chinese automakers, each capable of sus-taining production of 1–2 million units and ready to compete on the world stage.

As different as their markets and automotive industry landscapes may be, Russia, China, and India have one thing in common: automakers there are looking for innovative solutions that can help them increase their productivity and production quality. With tailored automation solutions, these goals can be reached more easily. Consequently, investments in equipment and technology have also seen signifi cant growth in the last years, and will continue to do so. p

China

Developing Asia-Pacific: Light Vehicle Assembly Outlook by Country

2009 vs. 2016 (Millions)

India

Thailand

Indonesia

Malaysia

Pakistan

Taiwan

Philippines

Vietnam

0.0

Source: Autofacts Q2/2010 Data Release

2016

2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 18.0 20.0

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Volkswagen India p

Global Partners

The plant in Pune is an important milestone for Volkswagen as the company further strengthens its position in India – Volkswagen

has invested around €580 million in the site. This makes the plant the largest investment project ever undertaken in India by a German company. As the only production facility to be operated by a German car manufacturer in India, it encompasses the entire production chain, from the press shop, body shop, and paint shop to fi nal assembly.

The new greenfi eld plant took only 18 months to complete, which was around 9 months less than originally anticipated. Construction of the plant began in the second half of 2007, and it was offi -

To achieve the high standards that are the norm throughout its plants,

Volkswagen chose capable and tried-and-tested technology partners –

such as Siemens – for equipping its new manufacturing plant in India.

cially inaugurated on March 31, 2009. It was pri-marily thanks to the exceptionally close collaboration between the planning department in Wolfsburg and the individual technology partners on-site that such a disciplined approach to project execution was even possible.

Prior to the project, Volkswagen made a deliberate decision to work with partners it had gained previous experience with and that consequently knew pre-cisely where the priorities lay for a Volkswagen plant. The close global collaboration between Volkswagen and Siemens goes back many years, which in itself provided a solid basis for successfully integrating Siemens products into the India project. However,

14 move up | 1-2010


The new automotive plant in Pune

one of the key factors that swung the argument fi rmly in favor of reprising the collaboration in India was the potential to standardize the products across the entire production cycle. In Pune, as elsewhere, Volkswagen could therefore keep employee mainte-nance training to a minimum and warehousing costs down.

Single-source automationThe automation solution in Pune is based on tried-and-tested Simatic components. Each of the three production workstations is equipped with a fault-tolerant Simatic S7-300 F controller, which is con-nected to the Simatic ET 200S distributed stations and the Simatic panels via Industrial Ethernet to allow networked operation. The controllers are linked to one another via Profi safe. This architecture enables fail-safe signals to be transmitted via a bus system in parallel with the conventional communica-tion channels. Communication between the individ-ual CPUs takes place via a PN coupler. This coupler in turn interlinks the subnetworks that belong to the various workstations. The production level is con-nected to the network of the production building and the visual display via Industrial Ethernet. A Simatic panel PC serves as the master computer for visualization and welding and enables the operator to gain a quick overview of the production process.

Optimum support on-siteFrom the early days of the project, the team was keenly focused on ensuring that each operation be completed either on schedule or, in some cases, ahead of schedule. This represented a huge chal-lenge for everybody involved on-site – one that, according to Klaus-Dieter Goern, head of mainte-nance at Volkswagen in Pune, they “succeeded in overcoming because of the effective cooperation with the various planning departments at Volks-wagen headquarters and with the system manu-

infocontact


move up | 1-2010 15

facturers, including Siemens – and what’s more, the project was conducted in line with all quality requirements and safety regulations.” Goern con-tinues, “Thanks to Siemens’ presence in India, there were always plenty of specialists on hand to assist in all kinds of areas. The support we received from Siemens was, without exception, extremely effec-tive.” Siemens will continue to act as a partner of Volkswagen when the system is in operation. Not only is the complete range of spare parts readily available from in-house production through the company’s Indian subsidiaries, but there is also guaranteed on-site support from specialists who can

be called in on short notice, thus enabling a fast and effective exchange of information – whether the issue concerns a technical problem, further develop-ment of the production technology, or a production changeover. Volkswagen is therefore in no doubt that it was right to choose Siemens as its automa-tion partner, and the company remains open to the prospect of new ideas and projects in the future. “We feel certain that our decision to work with Siemens was right, and so far we haven’t recorded a single defective component since the start of pro-duction,” concludes Goern. p

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Simatic CPU319F-PN/DP

Panel PC Mobilepanel

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PN couplerSwitch

Industrial Ethernet



ET 200S

PN couplerSwitch

Industrial Ethernet



ET 200S

PN couplerSwitch

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Workstation 1 Workstation 2 Workstation 3

Building networkIndustrial Ethernet (fiber optic)

Panel PCMaster control visualization

and welding

LED display

The automation architecture of the welding and assembly line

T h e a u t o m a t i o n t e c h n o l o g y

The automation technology structure in the three workstations in the Pune plant is identi-cal in each case and comprises the following components:

Simatic S7-300 with CPU 319F-3 3

Simatic ET 200S 3

PN coupler 3

Panel PC 3

Mobile panels for on-site operation 3

The individual programmable logic controllers are interconnected via Profi net with Profi safe. An optical Industrial Ethernet network serves as the main building network.

»We feel certain that our decision

to work with Siemens was right.« Klaus-Dieter Goern, Head of Maintenance at Volkswagen in Pune

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The Mahindra Group’s Automotive Division is India’s fourth largest manufacturer of four-wheeled vehicles and the country’s second

largest independent OEM. The company manufac-tures and markets utility vehicles and light commer-cial vehicles, including three-wheelers. It has led the market in utility vehicles in India since its inception and currently has about half of India’s utility vehicle market. A strong product portfolio and a philosophy of customer satisfaction have driven robust growth in domestic sales (19 percent compound annual growth rate) over the past four years. The company employs over 10,000 people.

Mahindra’s Automotive Division views innovation and customer delight as the keys to continued growth. The company strives to bring new models to market sooner and to create more product variants. It also works to improve its ability to operate at multiple sites in multiple countries in developing its vehicles.

Broadly implemented PLMSince 1998, Mahindra’s Automotive Division has been using product lifecycle management (PLM) technology from Siemens PLM Software to address these challenges and to ensure a product develop-ment environment in which innovation thrives. Specifi cally, Mahindra uses Teamcenter to enable lifecycle data support, platform and variant manage-ment, multisite data notifi cation and synchroniza-tion, change management and support for con-current development, project execution and monitoring, internal value chain support, and sup-port for business partners.

This solution was chosen based on the breadth of Teamcenter functionality. The installation, which was carried out in phases, required minimal customi-zation and was performed by an internal PLM Auto-

Automotive Sector, Mahindra & Mahindra Ltd., India p

Bringing Innovation to Market Faster

Siemens Teamcenter helps the Mahindra Group’s Automotive Sector

substantially reduce development time, so it can continue to delight

customers with product innovation.


move up | 1-2010 17

motive Sector team using implementation method-ology and assistance from Siemens PLM Software. Teamcenter has now been installed in eight loca-tions, with 700 people using its collaboration func-tionality, 100 using its project management func-tionality, and 1,000 using it for engineering-related activities.

Today, Mahindra has a seamless, integrated environ-ment for new platform development. Using Team-center, Mahindra has achieved multisite and multi-CAD interoperability with complete project security and concurrent design across multiple locations. CAD, product, project, and process data are man-aged in a single information vault. CAD data are available to each site on a real-time basis, and the

company can now perform packaging studies and clearance analyses across different CAD systems. Using the JT format and Teamcenter’s visualization capability helps advance the company’s goal of eliminating 2-D drawings.

Compelling, documented benefi tsMahindra credits many improvements to the use of Teamcenter. The company has seen an increase in productivity per employee. It attributes this to effec-tive document management and to automation of routine tasks, releasing personnel to perform their

primary tasks. Activities such as manual CAD data conversion have been eliminated.

In the design arena, engineering change time and the time to resolve project concerns have both dropped by 50 percent due to improved collabora-tion. Analysis preparation time has decreased by 40 percent, and digital mock-ups can be created twice as fast due to the real-time multi-CAD data integra-tion and release management handled by Teamcen-ter. The time to create bills of materials (BOMs) for prototypes and variants has also been cut in half.

“For the company as a whole, what Teamcenter means is a huge reduction in the time needed to bring a new vehicle from concept to launch,” says

Prakash Deshkar, deputy general manager, IT, Mahindra & Mahindra. Thus far, Teamcenter has reduced that time frame by 25 percent. For future projects, the company predicts a reduction of as much as 40 percent. p

» For the company as a whole, what

Teamcenter means is a huge reduction in

the time needed to bring a new vehicle

from concept to launch.«Prakash Deshkar, Deputy General Manager, IT, Mahindra Group’s Automotive Division

courtesy

infocontact

Corporate Communications, Mahindra & Mahindrawww.siemens.com/[email protected]

K e y p o i n t s

As a customer-centric company, Mahindra & 3Mahindra’s Automotive Sector wanted to bring new models to market sooner, while increasing the number of product variants

Siemens Teamcenter decreases development 3time through knowledge capture and reuse; multisite, multi-CAD data interoperability; concurrent design across multiple facilities; and the automation of routine tasks

Mahindra has seen a 25 percent reduction in 3the time from con cept to product launch; the engineering change cycle cut in half; quicker resolution of concerns; and bill of materials creation in half the time as a result

Mahindra is a market leader in utility vehicles in India

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18 move up | 1-2010

From its formation in 2001, the Zhejiang Geely Holding Group Co. Ltd., headquartered in Hangzhou, has grown to become a major car

producer, with manufacturing facilities in eight locations across China. The plants in Linhai, Ningbo, Lugiao, Shanghai, Lanzhou, Xiangtan, Jinan, and Chengdu have a total annual capacity of 400,000 vehicles. Geely also has complete-knock-down (CKD) assembly plants overseas in several countries, including Ukraine, Russia, and Indonesia. The com-pany has set its sights on manufacturing two million vehicles annually by 2015, with two-thirds of this capacity being planned for export outside China. To achieve these goals, Geely is transforming its prod-uct lineup from the previous utilitarian designs to high-specifi cation vehicles meeting world-class standards for quality and safety. Through the auto-mation and integration of production processes, Geely enabled its manufacturing plants to reach best-in-class automation levels. World-leading auto-mobile component manufacturers who are working with Geely to achieve these standards have become important suppliers to the Geely production lines. To improve the effi ciency of its car manufacturing facilities, Geely opted for a Totally Integrated Automation (TIA)-based solution.

A new approach for a new plantIn the paint, body, assembly, and press shops in the old plant located at Ningbo, each process had its own stand-alone control system. These systems came from several different suppliers. Consequently, the maintenance teams had diffi culty compiling real-time consolidated manufacturing data. To overcome this limitation and upgrade the Ningbo

plant, a project team was established in 2007 and the planning phase began. In 2008 Siemens Ltd. China was invited to join the team, advise on state-of-the-art automation concepts, and generate inte-grated solutions meeting Geely’s budget and intended degree of automation.

A highlight of the project was the teamwork between the various groups, especially in the area of the body shop, where Chinese and Japanese OEMs were involved. All were requested to use products speci-fi ed by Geely, with Profi bus as the communication network. The body shop’s electrical system consists of three units: main body, side body, and conveyor units. In the main body unit, over 10 robots are employed for the key quality control points in the welding process and complete up to 700 welding spots. The robot controller, with a Profi bus interface, both enables the OEMs to integrate their products into the system much more easily and effi ciently and guarantees real-time data transfer with peripheral devices. In the side body unit, fi eld inputs and out-puts are collected by Simatic ET 200 distributed I/O systems. The systems are suitable for various types of applications and industrial environments and enable third-party devices for safety applications to be linked via Profi bus. The workers on-site monitor the manu-facturing processes via Siemens TP170 touchpanels located alongside the production line. In the con-veyor, Siemens MM440 frequency inverters drive the motors for conveying and lifting. For the vehicle identifi cation system (VIS), Geely has for the fi rst time applied a Simatic RF300 radio-frequency identi-fi cation (RFID) system in place of the previous bar-code system. Using the VIS with RFID, materials are

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eely

Zhejiang Geely Holding Group Ltd., China p

The Next LevelGeely equips its plants with Simatic factory

automation to move up to the world stage.


move up | 1-2010 19

supplied just in time. This enables Geely to achieve better stock control and lower materials costs, giving a fast return on the investment in the RFID system.

At the controller level, three Simatic 317-2DP pro-grammable logic controllers (PLCs) are responsible for controlling the manufacturing processes in the main body, side body, and conveyor units. The large-scale data communication between the PLCs routes via Industrial Ethernet, and a DP/DP coupler facilitates the transfer of real-time data. With dual Simatic PLCs with WinCC servers (for redundancy) and multiple client PCs linked via Industrial Ethernet, operators can monitor the manufacturing process and status of signals and alarms at any location throughout the plant.

Satisfi ed with the resultsTang Sheng Guo, general manager of the body shop at Geely Ningbo, is very satisfi ed with Siemens. He said, “It is important for Geely that the quality of Simatic, Sirius, and Micromaster products is good and that the Siemens system concept meets Geely’s budget and degree of automation.” Tang added that “Siemens provides good communication, strong technical support, and close coordination between Geely and different OEMs, even those located over-seas.”

On the question of training and technical support, he said, “We greatly appreciate that the technical training and documents for Simatic, Sirius, and

Micromaster are all in Chinese and that ongoing technical support and workshops are provided by Siemens’ local offi ces close to Geely.” Follow-ing the successful Ningbo plant project, Geely used Siemens automation products and solu-tions to equip its second new car plant located at Cixi city (near Ningbo city), Zhejiang Province, with a capacity of 150,000 cars per year.

Geely will employ its advanced plants at Ningbo and Cixi to manufacture the new fl agship Emgrand series of cars, sport-utility vehicles, multipurpose vehicles, and high-end pickups. The company associates its new Emgrand brand with the core values of “Chinese wisdom, world quality.” With technology from Siemens, the plants at Ningbo and Cixi are ready to produce cars to refl ect these core values. After the Cixi plant comes fully onstream, Geely plans to build a series of additional greenfi eld car plants in various cities. Siemens, with Simatic, is ready to support Geely in these expansion plans. p

infocontact

www.siemens.com/[email protected]@siemens.com

From left: Li Ping, Yang Xiao Hong, Tang Sheng Guo, Hua Ming, Ma Xin Hua

System architecture of the Geely Ningbo body shop plant

Industrial Ethernet

Profibus

Distributed I/Os Distributed I/Os

DP coupler

MES SCADA

Press shopserver

Main bodyprocesscontrol

S7-317-2DP

HMI

Side bodyprocesscontrol

S7-317-2DP

HMI

Profibus

Conveyorcontrol

S7-317-2DP

HMI

ASM456

RF300reader

RF300 tag

MM440

MotorsRobots

Dataserver

Paint shopserver

Dataserver

Body shopWinCC server(redundant)

Switch

WinCC clientApplication

server

20 move up | 1-2010

Beijing Foton Cummins Engine Co., China p

Keys to Success

Solutions for Powertrain – Transline is a special integrated solution for the automobile indus-try. The solution is based on modularization

and standardization. It is broadly used in the power-train fi eld and has already set a standard for power-train customers. Transline is successfully used in a Foton-Cummins engine project to produce two types of Cummins light-duty, high-performance diesel engines in a Beijing manufacturing plant.

The plant has an annual capacity of 400,000 units and will produce Cummins 2.8-liter and 3.8-liter diesel engines, which will meet worldwide emission standards, including Euro IV and Euro V. The project is based on a joint venture between Beiqi Foton Motor Company and Cummins Inc., forming Beijing Foton Cummins Engine Company Limited (BFCEC).

BFCEC represents a further expansion of Cummins’ product line in China, where the company is already the leading foreign producer of heavy-duty and mid-range diesel engines. While Cummins is a lead-ing diesel engine supplier, Foton Motor is a strong player in China’s commercial vehicle industry.

Smooth integration within existing technology frameworkBFCEC decided to support the new manufacturing lines and processes by implementing Solutions for

The tools provided by Solutions for Powertrain – Transline give the management of

the Chinese automaker confi dence in high machine and plant availability as well as

optimal productivity.

Powertrain – Transline from Siemens. The solution was chosen partly because of its many successful installations around the globe. This gave the man-agement confi dence in Siemens’ technology and deployment expertise. The company also preferred Siemens’ extensive process management functional-ity as well as its ability to work with the company’s range of product information formats. In addition, the fl exibility of Transline was important to ensure smooth integration within BFCEC’s existing technol-ogy framework. The Transline concept decreases technical risk and complexity and enhances the ability to manage change. The project included a cylinder head machining line, a cylinder body machining line, and an engine assembly line.

The machine centers for the machining line from MAG are equipped with Sinumerik 840D. The drive-based control system offers graduated performance, from simple positioning tasks to complex machining processes. Safety functionality provides reliable personnel and machine protection without addi-tional monitoring devices.

The assembly-line equipment from Dalian Haosen is supported by a Simatic S7-300 controller. This pro-grammable logic controller (PLC) is also integrated in the Sinumerik 840D CNC systems. With performance from various central processors, the system is capable


move up | 1-2010 21

infocontact


Transline minimizes the total cost of op-eration through its modular automation concept based on standard hardware

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of resolving complex control tasks. Handling is sim-pli fi ed by integrated functions such as automatic parameterization, expanded diagnostic options, passwords, and ease of assembly.

For identifi cation, the machining line uses the Simatic VS 130-2 vision sensor system, while the engine assembly is equipped with the Simatic RF300 radio-frequency identifi cation (RFID) system. The uniform Siemens technology solution yields enor-mous benefi ts in terms of standardization. For example, Foton-Cummins can work with just one engineering tool for the PLC in the machining and assembly lines.

Solutions that fi t individual needsThe Solutions for Powertrain – Transline automation concept is custom made but at the same time based on proven yet innovative standards. It has been developed specifi cally for mass production in the powertrain fi eld of the automotive industry. The modular design concept principally manifests itself in quicker commissioning, minimized spare parts requirements, effi cient service, lower training costs, and a more fl exible labor force. For example, the use of a component list reduces the number of automa-tion components employed, thereby also minimizing the necessary spare parts stocks. Standardized interfaces greatly facilitate data communication with

the control level, while uniform operating screens lend all control panels a consistent look and feel.

The Transline concept also addresses project management, which relieves customers of time- con suming coordination work, as well as providing services for the entire operational phase, leading to sustainable cost reduction and higher availability and productivity. The Siemens joint venture Siemens Factory Automation Engineering Ltd. (SFAE), with its well-trained service engineers, is very close to its customers to ensure this availability and produc-tivity.

Solutions for Powertrain will not only improve prod-uct quality but also reduce project lifecycle costs and time to market. At the same time, it will also provide the company with the high level of effi ciency neces-sary to succeed in an increasingly competitive mar-ket. The management believes that the successful implementation will be the foundation for long-term collaboration between Siemens and BFCEC. p

K e y p o i n t s

Optimum project management 3eliminates time-consuming project coordination by the customer – for higher availability and productivity

Customized solutions based on 3standard modules – for faster commissioning, reduced spare parts requirements, and more effi cient servicing

One contact person – from 3design to commissioning and start-up to operation – for global deployment

Reduced total costs of operation 3through building engineering and operation staff know-how, as 80 percent of costs are caused by spares and service and support

22 move up | 1-2010

Worldwide Contacts

Always Close

Across 13 countries, the Siemens account managers for the automotive industry are always available as a central contact point. They handle all matters related to the global production processes of their automotive accounts. Every account manager has excellent process expertise and offers the entire

portfolio of Siemens services from a single source. Working as team members with other experts, the account managers develop the right strategy, con-nect all necessary contacts on-site, coordinate the implementation, and ensure that the project is executed smoothly and rapidly.

Anticorruption Alliance

Collective Action

To make a positive change to the corrupt envi-ronment in the global markets, Siemens is partic-ipating in alliances against corruption, through what is termed Collective Action.

There are various forms of Collective Action. With Compliance Pacts, for example, competitors reach an agreement on long-term anticorruption initiatives. Then there are Integrity Pacts, which involve contractors speaking directly or indirectly to other potential contractors to conclude project-specifi c alliances. An independent organization supervises all processes, from the invitation to tender through to the conclusion of the contract, and ensures that everything takes place under transparent and fair business conditions. In

Country Name Contact

France Marc De Volder [email protected]

Korea Hyung-Mo Koo [email protected]

Canada Karl-Philippe Clement [email protected]

United States Timothy Shepherd [email protected]

Japan Yuji Hirai [email protected]

Brazil Rolf-Peter Hofmann [email protected]

India Nitin Nair [email protected]

Spain Javier Pizarro [email protected]

Mexico Hans-Albert Ratzka [email protected]

Republic of South Africa

Martin Taverner [email protected]

China William Cui [email protected]

Russia Dmitry Matveev [email protected]

Great Britain Stuart Moran [email protected]

Sweden Micael Amandusson [email protected]

addition, all persons involved commit to accept-ing sanctions should a breach of contract occur.

“Many customers and competitors have already united with Siemens within the framework of Collective Action,” explains Joerg Flath, Siemens Compliance Offi cer for the Industry Automation and Drive Technology divisions.

Flath cites the example of the tender to expand Berlin-Schönefeld airport: “The value of this particular tender was around €2.5 billion. On the initiative of the mayor of Berlin, Siemens con-cluded an Integrity Pact with its competitors. This guaranteed fair competition and transparent processes.”

You can fi nd out more about Collective Action from the contact for the Industry Automation and Drive Technologies divisions:

Dr. Joerg Flath IA&DT Compliance Offi cer Tel: +49 (911) 895-5769 E-Mail: joerg.fl [email protected]

I n B r i e f

Siem

ens

AG

move up | 1-2010 23

D i a l o g u e

move up 1-2010PublisherSiemens Aktiengesellschaft, Gleiwitzer Str. 555, 90475 Nuremberg

Drive Technologies DivisionCEO Klaus Helmrich

Industry Automation DivisionCEO Anton S. Huber

Editorial Responsibility in Accordancewith the German Press LawArno Hoier

Responsible for Technical ContentsThomas Schott

In-house editorial staffElitza DaloukovaE-mail: [email protected]ürgen NoldeE-mail: [email protected]

Publishing HousePublicis Publishing, Part of Publicis PROP.O. Box 32 40, 91050 ErlangenTelephone (0 91 31) 91 92-5 01Telefax (0 91 31) 91 92-5 [email protected]

Editor: Kerstin Purucker

Layout: Jürgen Streitenberger

Copy editor:Désirée Bambynek

Job number: 002800 24710

DTP: der Döss für Kommunikation, Nuremberg

Printed by: Wünsch, Neumarkt

Title: Daimler

Circulation: 8,600ISSN 1610-7802 (Print)

© 2010 by Siemens Aktiengesellschaft Munich and Berlin.

All rights reserved by the publisher. This edition was printed on environmentally friendly chlorine-free paper.

The following products are registered trademarks of Siemens AG:EMSdriver, ET 200, MICROMASTER, MOBY, S7-300, SCALANCE, SIMATIC, SIMATIC HMI, SIMATIC Microbox PC, SIMATIC Panel PC, SIMOTION, SINAMICS, SINUMERIK, SINUMERIK – Safety Integrated, SIRIUS, TOTALLY INTEGRATED AUTOMATION, TOTALLY INTEGRATED POWER, WinCC

If trademarks, technical solutions, or similar are not included in the list, it does not imply that they are not protected.

The information provided in this magazine contains merely general descriptions or characteristics of performance which in case of actual use do not always apply as described or which may change as a result of further development of the products. An obligation to provide the respective charac-teristics shall only exist if expressly agreed in the terms of contract.

IWI: TMODOrder No.: E20001-MC110-B100-X-7600

infoSafeguarding the Future with IT

As a key segment of the economy, the automotive industry is one of the most innovative sectors. Increasing global competition is chall-enging companies to continually reduce their costs while at the same time maintaining innovation and quality leadership. Siemens IT Solutions and Services is the professional partner to help compa-nies face these challenges, thanks to its extensive industry knowledge and many years of experience in the automotive industry. Learn more about our automotive IT solutions:

move up onlineAt the address

www.siemens.com/read-moveup

you can download the latest issue as a PDF fi le. The electronic archive also gives you access to all previously published issues.

Furthermore, you will fi nd a form in which you can write your sugges-tions and comments on the issue and the individual articles. Your feed-back will be included in the next issue of move up. Finally, you can also make changes to your subscription.

infoIf you want to know more about Siemens automation and drive technology, visit our online information platform in the Internet:

www.siemens.com/automation

www.siemens.com/it-solutions/automotive

24

Industrial identification with SIMATIC Ident: perfect solutions for all requirements – with flexible expansions any time.

Answers for industry.

What optimizes your individual automation steps today and your entire company tomorrow?

Siemens.move up 2010-1-en

Business

simatic rf300

grammable

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totally integrated

totally integrated

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