西门子-工厂自动化 建筑施工解决方案 Factory automation - building construction solutions

Factoryautomationmeetsbuildingconstructionsolutions:Howto

streamlineplanningandachievecomplexgoals

Earlyinthebuildingdesignstage,

manufacturingcompaniescanidentify

specificsolutionsthatwillincreaseefficiencyonthefactoryfloorandachievethe

manufacturer’sbusinessgoalsby

leveragingtheirbuilding’sinfrastructure.

Contents

ExecutiveSummary

4

Theproblemwithtraditionalconstruction

incomplexenvironments

5

TheSiemensrecommendedsolution:an

outcome-basedapproachtotechnology

procurementandintegration

7

TheSiemensprocess:identifyingdesired

outcomesandimplementingatechnology

plantoachievethem9

Benefitsformanufacturingcompanies15

Let'stalk!15

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

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ExecutiveSummary

Establishingefficientuseofbuildingtechnologiesiscriticaltohelpingcomplexfacilitiesachievetheirshortandlong-termoperationalgoals.Andtheefficiencybeginswiththebuilding

technologiesprocurementprocess.Overthepast30years,theIndustrialInternetofThings(IIoT)anddigitaltransformationhaverevolutionizedthebuildingecosystem.However,procurement

processeshaveremainedlargelyunchanged.Untilnow.

Today,manufacturingcompanieshaveanunprecedentedopportunitytostreamlineprocurement.Theycanselectbuildingsolutionsthatmeettheirspecificgoalsratherthangenerictechnical

specifications.Insteadofprocuringsolutionsatthecontractorlevelbasedonthelowestpossibleprice,manufacturerscanpartnerdirectlywithabuildingsolutionsprovider.Together,earlyinthedesignstage,theycanidentifyspecificsolutionsthatwillincreaseefficiencyonthefactoryfloorandachievethemanufacturer’sbusinessgoals.Siemenscallsthisconceptan“outcome-based

approach”wheremanufacturerscanpartnerwithusastheir“MasterSystemsIntegrator”(MSI)-andgaingreatertransparencyandbenefitssuchas:

•Defineandachievedesiredoutcomes

•Enhancereturnoninvestment(ROI)andstructureacash-flow-positiveprogram

•Optimizeprojectschedulestoefficientlyachieveoutcomes

•Mitigateriskwhileensuringprojectsuccess

•Enhancesafetyforequipmentandpersonnel

•Ensuremaintainabilityofbuildingsystems

Siemenstakesthisoutcome-basedapproachtoahigherlevel,providingmanufacturerswitha

strategicadvantage.SiemensrecommendedMSIapproachwithuniquebundlesofserviceswill

behighlightedinthispaper.Wewillexplainhowthisapproachunlocksnumerousbenefitsand

positionsmanufacturersforsuccessfullymanagingtheirnewfactories.Thiscomprehensive

approachalsoensuresfunctionalaccountabilitythroughouttheconstructionphaseoftheprojectandtheoperationalphaseofthebuilding.

Wewillalsoexploretheconnectionbetweenwhathappensonthefactoryfloorwiththe

incorporatedSiemensbuildingtechnologies.Thegoalistoprovidemanufacturingcompanieswithanefficientwaytoselectbuildingtechnologiestobenefittheiroverallbusinessgoals.

Theoutcome-basedapproachleveragesmodernprocurementprocessesandunleashesbenefitsmanufacturerscangainateverystageofafactory’slifecycle.

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

Theproblemwithtraditionalconstructionincomplexenvironments

Traditionally,buildingtechnologydesignsandprocurementhavereliedongeneric

technicalspecifications,oftenreusedfrompreviousprojectswithsimilarscopes.ThispracticefrequentlyresultsinRequestsforInformation(RFIs)thatcantaketwoto

threemonthstoresolve(ifatall).

Theprocurementprocesstypicallybeginswithageneralcontractorissuingbidstomultiple

subcontractors—oftentenormore—based

onthesamegenerictechnicalspecifications.Thesubcontractorscompetebyofferingthe

lowestpossibleprice.Theyaren'tfocusedontheorganization'sbroaderbusinessobjectives.

Thisapproachisparticularlyproblematic

forbuildingtechnologies.Itoftenresults

inlow-costsystems,sacrificinginteroperabilityandcustomerbusinessgoals.System

integrationbecomesaproblem,increasingbothtechnicalriskandprojectfriction.

Finger-pointingandschedulingdelaysare

common,alongwithcostlychangeorder

claims,whichoccurafterinstallation(whentheyaremostdisruptive).Gapsandoverlapsinscopefurthercompoundthechallenges.

TypicalApproachtoTechnology

ChallengesOccurThroughoutManufacturingPlant'sLifecycle

5

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

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Eventually,plantengineersmustdealwith

operationsandmaintenancefallout.They

faceawidevarietyofequipmenttomanage,differentnetworkinfrastructuresand

numerouscybervulnerabilities.Overtime,

themanufacturer’stechnologyrefreshplan

goesoutofsyncandsystemsnolongerworktogether.Thisdrivesfactoryownerstogiveuponthetechnologyprematurely,causingthemtoloseadvantageslikeenergymanagementamongotherissues.

Factoriescarryabiggerriskthanothertypes

offacilitiesfromtheoldprocess.BecausetheirOEMmachinesuseanextensivearrayof

automationcontrols,plantequipmentusually

can’ttalktoeachotheroutofthebox.

Therefore,thesemachinescan’tproducethe

datathatsupportsoperationsandhelpsownersmakebetterbusinessdecisions.Different

machinesandsystemsfromdifferentvendorscreatechaosinafactoryenvironment.Withoutanoutcome-basedapproach,factoryowners

anddevelopersendupwithafragmented

collectionoftechnologyproductsfrommultiplesuppliers.Theplantisleftwithdisparate

networksandmultipleservicecontracts.

Thissiloedapproachresultsinacross-the-boardinefficiencies,increasedcostsandoperationalcomplexitiesthroughoutthemanufacturing

plant’slifecycle.

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

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TheSiemensrecommendedsolution:

anoutcome-basedapproachtotechnologyprocurementandintegration

TheSiemensoutcome-basedapproachreducescomplexitiesbeforesysteminstallationand

integration.Italsoenablescompaniesto

worksmarterthroughoutthefacility’slifecycle.Todeterminedesiredoutcomes,key

stakeholdersworkcloselywithabuilding

solutionsproviderearlyinthedesignphase.WithSiemensestablishedportfoliospanningfactoryfloorcontrols,software,andbuildingtechnologies,weareuniquelypositionedasthetrustedexpertsinorchestratingsuch

designworkwithkeystakeholders.

Thisapproachestablishescollaboration

betweenallpartiesinvolvedatthestartof

theplanningprocesstomakesuretheirspecifictechnologygoalsareachieved.Itinfluences

alltechnologydecisionsgoingforward.

Thisapproachalsoimmediatelyaffectsaplant’soperationsaswellsincemanymanufacturing

machinescan’tberunwithoutthesupport

offullyfunctioningbuildingsystems.For

example,firepumpsandgasdetectionsystemsareneededbeforemanufacturingequipmentisusedinhazardousenvironmentsormaterials.

Outcome-BasedApproachtoTechnology

ChallengesOccurThroughoutManufacturingPlant'sLifecycle

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

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Byfocusingonoutcomes,facilityownersanduserscanidentifyearlyonwherebuilding

technologiesimpactthefactoryfloor—and

wheresynergiesorefficienciescanbecreated.

Forexample,certainmanufacturingprocesses,suchasintermittenttesting,mayrequire

changesinairfloworpressure.Traditionally,theseneedsaren’tdiscovereduntilafter

construction,whenthefacilityisalready

operational.Atthatpoint,factoryteamsmust

trackdownthefacilitiesteamtomanuallyadjustHVACsettingseverytimetheuniquetestorprocessoccurs.

Withanoutcome-basedmodel,theseneedsareaddressedupfront.IntegrationsarebuilttoallowtheHVACsystem’sPLCcontrollerstocommunicatedirectlywiththemanufacturingequipment’sSCADAsystem—eliminating

downtimeandthedisruptionofmanualHVACadjustments.

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

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TheSiemensprocess:identifyingdesiredoutcomesandimplementingatechnologyplantoachievethem

Theoutcome-basedapproachemploysawell-defined,well-managedprocess.Inthisexample,

SiemensistheMSIandworksdirectlywithpartners,OEMs,toolbuilders,andgeneralcontractorstohelpachievethespecificstrategicgoalssetbyeachkeystakeholder.Siemensensures

closecollaborationamongallpartiesthroughouttheconstructionlifecycle—asshowninthefollowingchart—fromvisiondefinitionandconceptplanningthroughwarrantyandoperationandmaintenance.

Outcome-BasedFrameworkforConstruction

HolisticCollaborationThroughoutProjectLifecycle

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

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Specifyingoutcomeswhendesigningschematics

Theoutcome-basedapproachbeginsatthestartofthedesignprocess.Specificationsthatmakeitpossibletomeetuser-basedgoalsmustbedefinedbeforeanytechnologypurchasesoccur.

Thishappensearlyinthefactory’sdesignphasewhenSiemensholdsco-creationmeetingswiththeowner,designteamsandkeycompanystakeholders.Theseideationsessionsareespeciallydesignedtofindoutwhatdrivestheparticipantsandthecompany’smanufacturingprocesstosuccessfuloutcomes.

ThesedriversformthebasisoftheoutcomesandusecasesthatSiemenswillemploytoinformtechnologysystemdesign.Anoutcomeisanobjectivethatexplainswhatneedstobeachievedandhowsuccesswillbemeasured.The“userstory”supportstheoutcomeandpaintsause-casescenario.Duringtheideationsessions,participantsfillintheblanksofthefollowingoutline:

•Asa(Persona)

•Iwanttodo(Action)

•Sothat(Result)

•Using(Tool/Technology

Forexample,theuserstoryforaprojectwithelectricalswitchgearandbuildingautomation,withafocusonresiliency,mayreadsomethingandbuildingautomationprojectwithafocusonresiliencymayreadsomethinglikethefollowing:

•Asa:ChiefOperationsOfficer,VPofFacilities

•Iwantto:Haveuninterruptedpowersupporttocriticalsystems(CMMS,IndustrialHVAC,IT,Switchgear,BAS)

•Sothat:Icancreatearesilientinfrastructurethatcandetect,respondto,andrecoverfrompower-relatedissuesinreal-timetoavoidcostlyinterruptions.

•Using:Automatedpowerfailoverandloadshedding;Faultdetectionandrapidresponse;Predictivemaintenanceandhealthmonitoring;Real-timedatavisualizationand

reporting;andEnergyoptimizationduringgridevents

Siemenshasadeepunderstandingofwhathappensonthefactoryfloorandhowittiestothe

building.Thisknowledgehelpsdesignthebuilding’sinfrastructureandutilitiesaroundthekey

requirementsforfactory-floorsuccess.RegardlessofwhethertheequipmentorsystemhasDDCorPLCcontrols,Siemenscansupportandintegrateeverythingtoreducecomplexityandimprovemodularity,repeatabilityandscalability.

Factoryautomationmeetsbuildingconstructionsolutions:Howtostreamlineplanningandachievecomplexgoals

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Creatingafeasibilitystudyandtechnologyroadmapduringdesign

Oncethemanufacturingcompany’sdesiredoutcomesaredefined,Siemensdevelopsafeasibilitystudythatcompilestheuserstories,theirROIandlifecyclecosts.Siemenscanaugmentthestudywithbuildinganalyticsandinformationaboutdigitalindustries,smartbuildinginfrastructureandoptimizationplatforms.Thestudyallowsownersandgeneralcontractorstomakeeducated

decisionsaboutwhichtechnologiesandproductstoprocure.

Siemensisalsoresponsibleforcreatingatechnologyroadmapforthefacility.Thetechnology

roadmapidentifiesthetypesoftechnologiesneededtomeetthedesiredoutcomes.Aspartofthisprocess,SiemenscreatesanoperationsarchitecturethatlinksthebuildingmanagementsystemswithSCADAsystems.Thisensuresaseamlessintegrationandcommunicationbetweenbuilding

andfactorysystemsandhelpsfurtherdrivepositiveoutcomes.

SimpleSystemArchitecture

LinkingSCADAandBASSystems

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Collaboratingholisticallythroughouttheconstructionphase

Siemenswilldevelopanecosystemofdedicated,high-performancepartnersthatprovide

importantbenefitsforthecompanyandthemanufacturingplant.Thesepartnershelpcreate

aone-stopshopfordigitaltransformation,anever-evolvingprocessthatkeepsplantsuptodate.Effortssuchasthismaximizecustomervalueandleadtotheco-creationofnewsolutionsand

newbusinessmodels.Inshort,thesepartnershelpdrivetheevolutionofSiemensopenbusinessecosystem.

Theneedtostandardize

Animportantoutputofcollaborationandtechnologyselectionisstandardizinginterfacesanddatamodelsbetweenmanufacturingequipment.Thekeyelementisthecontrollerselectedforeachpieceofequipment.OEMshaveavarietyofcontrollerstochoosefromandmaketheir

selectionwithoutconsideringthewiderfactoryecosystem.Eachcontrollerrequiresspecific

traininganduniquepartsthatmustbeunderstoodbyacompany’splantengineers.Theresultiscomplexityatalllevelsofinstallation,operationandmaintenance.

Tosolvethisproblem,SiemensconsultswithpotentialOEMstostandardizethecontrollersbeingusedbeforeanyequipmentisordered.Standardizationdefinestherulesoftheroadabout

thewaydifferentmanufacturingassetsandsystemstalktoeachother.Otherwise,eachsupplierwouldbeoperatinginitsownway.Sincetheseconversationstakeplaceearlyinthesalesprocess,OEMsaremoreadaptableandwillingtostandardize.

Throughoutthelifecycleofaplant,standardizedcontrollerssavetimeandexpensesbyenablingstandardizedinterfacesandmodularity.Italsoallowsthecompanytousethecost-savingPlug&Produceoption,enablingseamlessintegration,automaticpartidentificationandreducedmanualadjustmentsforthewholeplant.

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Valueofstandardizedinterfaces

Thevalueofhavingstandardizedinterfacescan’tbeoverstated.Fromthebeginning,when

SiemensworkswithOEMstostandardizecontrollers,standardizationprovidesclarityfor

everyonetodotheirjobseffectively.Ithelpsensuretheuseofvalidatedinterfaces.Italso

increasesopennessandfacilitatesintegrationofmachinesintoexistingsystems.Importantly,

standardizationenablesfastercommissioningofawholeline,whichbecomesahugeandcostlyoverheadduringinitialimplementationotherwise.ItalsoreducesovertimecostsbyallowingthePlug&Produceoption.Inaddition,standardizationsavestimewhenintegratingwith

manufacturingsystemsintohigherlevelITsystemslikeMES,QMSorERP.

AligningControlandDataAccessforManufacturingEquipment

Standardizedinterfacesareneededtoaligncontrolanddataaccessformanufacturingequipment.Factoryengi-neeringisverticallyintegratedwhilemachineengineeringishorizontallyintegrated.

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Challenge:Differentmachines/systemsfromdifferentvendorshavetoworktogetherinafactoryenvironment.

Withoutstandardization:Companies

mustdealwithindividualmachinesthatarerequiredtoworktogetherinharmony.Therefore,companiesmustcustomizeallinterfacesatcommissioning.

Result:Companiesfaceincalculablerisksandcostswithoutstandardizedinterfaces.

Solution:Thankstostandardizedmachinebehavior,standardizedinterfacesand

standardizeddatamodels,machines/systemscanbeeasilyintegratedwiththeplant

environment.

Whenmachineandsysteminterfacesaredefined,itreducestimethrough

commissioningandincreasesflexibilityinproduction.

Standardizedconnectivityanddatamodelsformthebasisforverticalintegration.

Solution:

•Uniformsafetyconceptforproductionline

•Definitionofshutdownzonesbasedonriskassessment

Astandardizedsafetyconcept:

•Reducescommissioningtime

•Increasessafetyofstaff

•Increaseinperformance-shutdownzonesonlyshutdownareasinthedangerzone

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Benefitsformanufacturingcompanies

Byparticipatinginthiscollaborativeprocess,ledby