Browsing through Success
A panorama of MES Applications with SIMATIC IT
SIMATIC IT Reference Book
Answers for industry.
In 2011 Siemens will release version 6.5 of its SIMATIC IT product. For almost fifteen years the
Siemens MES system has been used in almost every industrial sector to achieve better quality
and higher efficiency, to reduce costs and energy consumption, to optimize resources and
delivery time and to facilitate new product introduction.
In summary, our mission has been to help our customers to achieve the “Digital Plant”!
Several hundred thousand users within thousands of industrial plants around the world can
testify to the Siemens approach for an MES that is truly innovative and effective.
The reason of this success can be found in three elements: Platform, Integration and
SIMATIC IT is built around an advanced and stable product platform that follows the ISA-95 standard. This ensures that your
investment is protected and has a limited and predictable TCO (Total Cost of Ownership).
In the same way that production is the core of any industrial business, the management of execution (MES) is at the junction of
two key flows: Product Development and Execution Process.
Product Development takes the idea of a new product towards the definition of its components and the process to build it.
Execution combines this product information with business information (orders, delivery time, inventory) to create real goods
using machines and automation.
It is crucial to have a system that offers both the horizontal integration (product development to execution) and the vertical
integration (business to automation). Siemens, a world leader in providing hardware and software to industrial companies, is
the only organization that can offer such a combination of expertise.
Each industry is different and within each vertical market there are industry-specific procedures and regulations. It is therefore
necessary to be able to “verticalize” the product and build a system that is as ready to use as possible. Thanks to its “Library”
concept SIMATIC IT can include industry and even company specific knowledge inside a standardized and repeatable structure.
Manufacturing use cases can be collected and verified from the beginning of the project using the SIMATIC IT Value Framework
This is a structure that only Siemens can offer with its SIMATIC IT MES system and its three industry packages: SIMATIC IT for
Process Industries, SIMATIC IT for Discrete Manufacturing and SIMATIC IT for Life Sciences Industry.
Rather than providing detailed technical explanations I want to have facts speaking for us and so in this book you will find a
small selection of our most recent implementations.
I want to take this opportunity to thank our customers and our partners who have cooperated to write these reports and, much
more importantly, who have contributed to making SIMATIC IT one of the most successful software platforms in today’s MES
“Truth is what stands the test of experience“ ( Albert Einstein)
MES Global Alliances & Partnerships
Siemens I IA AS MES
Process Industry Customer Case
AC Marca 4
Ambar Feed - Mills 7
BAT - British American Tobacco 10
Birra Peroni Spa 13
MES out of the Box 20
IOI Loders Croklaan 26
JTI - Japan Tobacco International 29
Mahou San Miguel 37
Mengniu Dairy Group 42
Palm Breweries 45
Qingdao Tobacco Factory 48
RJ Reynolds 51
Rosen Eiskrem 53
Discrete Industry Customer Case
Alenia Aermacchi 56
Johnson Matthey 59
Siemens Cornellá 64
REC Group 70
Life Sciences Customer Case
SIMATIC IT for Life Sciences 76
Power Generation Customer Case
British Energy 82
Metals Customer Case
Société Le Nickel 85
SIMATIC IT Value Added Services 87
A Selection of SIMATIC IT Partners 93
Grupo AC Marca: MES solution with SIMATIC IT
AC Marca has achieved maximum flexi- The business challenge
bility and efficiency in the production
processes at its new plant in Sant Llorenç To AC Marca it is of greatest importance to
d’Hortons. This was the result of imple- have the flexibility and agility in place to
menting SIMATIC IT MES (Manufacturing meet its customers’ requirements.
Execution Systems) to cover production
management and establish real-time inte- The construction of a new plant in Sant
roperability with SAP. To ensure optimum Llorenç d’Hortons was the ideal occasion
availability of both the plant and the sy- to make this flexibility an integral aspect of
stems AC Marca opted for the production, and gain production efficiency
Agent-based Diagnosis Services offered and operational cost reductions at the same
by Siemens, for predictive and preventive time.
maintenance. The existing manual and paper-based pro-
cesses and information exchange could
The customer not cover this strategy, so it was decided to
bring in a MES to manage the production
Grupo AC Marca is a Spanish manufacturer and automate production orders, mate-
of a wide range of products for home and rial consumption, notifications, production
personal care as well as DIY products. From quantities, pallet labeling, etc.
its headquarters in L’Hospitalet de Llobregat,
near Barcelona, the company operates a From a functional point of view this produc-
total of five factories, two in Spain, one in tion management system had to offer the
France, one in Czech Republic and one in possibility to integrate different production
Mexico, and sales offices in 8 countries. units in one single system. It had to provide
a standard interface with the SAP system to
AC Marca’s extensive product portfolio in- allow real-time mutual data exchange and
cludes a large variety of detergents, floor communication with the machines in pro-
wax, dies, shoe polish, hair gel, shampoo, duction, as well as personnel management
glues, etc. Many of their brands such as and automatic label management.
IBERIA, NORIT, ORION, GIORGI, LIDA, ALEX,
PASO, YAK, BRIL are local market leaders.
The location in Sant Llorenç d’Hortons cov-
ers the production of household products
such as Norit, Gior, Iberia, Yak, Sanytol, and
personal care products including Giorgi,
Lida, Hidrogenesse, Cabello Sano Ecran, etc.
On top of the manufacturing activities the
26.000 m2 premises also house the services
and logistics and R&D departments. All of
which is handled by a workforce of 150.
The solution ready to become operational, so was the such as production output, order status,
MES system. line personnel status, quality control,
Several arguments justified the selection etc. SIMATIC IT visualizes which produc-
of Siemens’ MES SIMATIC IT. SIMATIC IT now covers functionality such tion order is active on which production
Siemens was the only vendor offering as process management, SAP integration, line, and the output quantities.
hardware, software as well as services, personnel management, production or- When the pallet of final products leaves
and able to automate both the discrete der management, material management, the production line SAP is notified and
as well as the process manufacturing downtime management, box and pallet feeds back the product description for
areas, and cover the connection to SAP labeling, traceability, CIP/PIG registering, the labels to MES which functions as the
with an MES system. and basic data collection from process interface to the label printer.
SIMATIC IT offers a single platform and filling lines. All of this is done automatically, no per-
covering the complete MES layer and Process management is handled through sonnel traffic, no paper traffic required.
integrates seamlessly with other Sie- the SIMATIC IT Production Modeler which This increased efficiency, and resulting
mens systems such as the PCS7 process allows to define a clear and integrated cost savings and profit increases make it
control system. This was particularly model of plant operations. more important than ever to guarantee
important to accomplish the predefined system availability and continuity.
integrated production management The SIMATIC IT Production Modeler trig- The people at AC MARCA were well awa-
model. gers the different system components to re of this.
initiate certain operations. This also inclu- In case of a system failure the entire
Siemens was also able to function as the des the functionality offered by PCS7 and production process may come to a halt.
system integrator for the MES system. SIMATIC Batch, such as recipe definition The time it takes to solve the problem is
This reduced the number of involved and management, automatic or manual money lost, so qualified people need to
parties, facilitated the communication batch execution, process control points be available to deliver immediate solu-
during the project and helped speed up and process data acquisition. tions. As work shifts at the plant cover
the start of operations. For instance, equipment and pipe clea- over 16 hours per day, and master data
When starting the production at the ning (CIP/PIG) are scheduled and can be synchronization takes place at night,
new plant in Sant Llorenç d’Hortons the registered to avoid contamination in case ensuring a 24/7 supervision was hardly
management wanted basic MES functio- of product switchovers. an exaggerated measure.
nality covered from the start. The interaction with SAP is bidirectional
The entire system was in fact native to and consists in the downloading from The SIMATIC IT Agent-based Diagnosis
the plant. Being fully embedded from SAP to SIMATIC IT of production orders, Service does just that. And more.
the design phase, when a new produc- master data, and the uploading and no- Not only does it ensure that the system
tion line in the Greenfield plant was tification from MES to SAP of information is constantly monitored. It also offers
At a glance
Grupo AC MARCA
• efficient, paperless data exchange
• plant and system availability
• integrated process and production
• SIMATIC IT Production Suite
• SIMATIC IT Agent-based Diagnosis
• reduced operational and adminis-
• accurate real-time data for deci-
• improved responsiveness (plant,
customers and regulatory)
assistance in the restart or shutdown of The pay-off
an application, ensuring that it is done
properly and sparing the people at AC SIMATIC IT has played an important role
MARCA the trouble of studying the sy- in the introduction of the integrated
stem in detail. management model which in turn
substantially contributed to the reduction
The Agents are installed in the systems of operational costs.
at the customer site analyzing events The scalable and modular approach of
related to the hardware, software and SIMATIC IT allows roll-out and scaling of
applications. the solution towards other plants in the
When a problem is detected at the cu- AC MARCA Group.
stomer site, the agents alert the
SIMATIC IT Technical Support Service The implementation of the integrated
(TSS) people who take immediate ac- production model has not only seriously
tion. reduced the amount of time and costs
spent on administration and paperwork.
Say for instance that a system error It also helps avoid errors in the produc-
prevents the loading of production or- tion management thus improving the
ders, blocking the entire system until a quality of the information.
system reboot is initiated. When Agents
are in place the problem will be reported The first phase in the project was the
to the TSS as soon as it occurs or even implementation of personnel manage-
before it actually happens. Through a ment and production order management,
secure VPN connection the TSS team has material management as well as the
the necessary visibility on the system to integration with PCS7 for quality control.
verify the cause of the problem and, in This is already in place in Sant Llorenç
agreement with the customer, can do a d’Hortons and paying off.
remote reboot of the system within mi- The second phase includes OEE/DTM,
nutes. No data are lost. The downtime traceability and production reporting in
is nihil. Sant Llorenç d’Hortons.
Afterwards this case is analyzed and the This is to be done simultaneously with
necessary steps can be taken to prevent the roll-out of the first phase to other
the problem from occurring again. plants in the AC MARCA Group.
Qualitative and cost effective
manufacturing of live stock
A large-scale deployment of SIMATIC IT enables the complete vertical and horizontal
integration of all IT and control elements at Ambar Feed Mills.
The system’s deployment, carried out by Ardan Control Tech in Israel, brings to life the
complete integration of SIMATIC IT with other Siemens systems (PCS7, Simatic Batch,
Route Control, Step 7) and 3rd Party systems including ERP, TMS & SCM.
Installation of the system is carried out simultaneously in 3 of the company’s sites.
The customer Ambar produces animal-feed for several sec-
tors, including broilers, turkeys, breeders,
Ambar Feed - Mills is one of the biggest layers, dairy herds, calves, sheep and fish.
feed-mills in the Middle East, and it is run in Ambar’s mission is to serve all sectors of
compliance with the world’s most advanced the livestock economy by supplying the op-
manufacturing methods and regulations. timum kinds of feed in terms of economic
Ambar produces and sells over 1.1 Million feasibility and nutrition.
tons of feed yearly. To provide response to each sector’s individ-
Ambar which was founded in 1961 as a ual requirements, Ambar launched a special
regional facility is presently owned by the feed mill for the breeder sector, operating
Granot farms and by over 148 farming com- according to strict bio-security regulations.
munities. Ambar facilities also include a state of the
Ambar owns two major production sites, art laboratory that works closely with the
Ambar North - located in the Granot indus- nutrition department. Its innovative pro-
trial area, and Ambar South - in the north- duction line makes it possible to provide
eastern Negev. solutions for the entire range of customer
The company produces its own vitamins needs, and is fully backed by a dedicated
premix in its independent production plant, technical office. Ambar’s shipping depart-
from totally secure sources, thus ensuring ment operates a large fleet of the latest,
maximum quality and reliability. clean and sterilized trucks.
The business challenge future development of the IT infrastruc- patch, etc., created the need for a 3rd
ture and allow the required flexibility to generation MES system.
The growing demand for both large expand. This to keep in step with the or-
production quantities that would sat- ganizational growth. A system that would be both horizon-
isfy market needs on one hand, and tally and vertically integrated to make
complying with specific demands from Ambar’s requirements demanded full syn- these data available in real time.
individual customers on the other hand, chronization of the business system level
demanded a fully integrated industrial IT (ERP) down to the control level. Ardan Control Tech was asked to carry
system that would ensure both reliable out not only the SIMATIC IT part of the
and cost effective manufacturing. The need to centrally manage all plant project, but also all other Siemens IT
floor elements demanded the deploy- products that are part of the TIA strat-
In order to accomplish such a system ment of a widely distributed control egy: Simatic PCS7, Batch Engine and
Ardan Control Tech applied the Siemens system that would fully comply with Route Control.
TIA (Totally Integrated Automation) ar- regulations and system standards ISA-88
chitecture, enabling an overall integra- & ISA-95, whilst enabling batch based The mission was to carry out all project
tion of floor shop systems with all IT and manufacturing. phases while all Ambar plants were run-
control elements. ning with no obstruction or disturbance
The synchronization with all production to the operations.
Another requirement of Ambar was related activities, such as quality assur-
that the system installed would enable ance, packaging, storage, loading & dis-
Ardan Control Tech
Ardan Control Tech is a leading provider
of Industrial IT and control solutions,
operating in versatile industrial
markets: Process, Discrete, Hybrid,
Energy management, Power plants and
Ardan expertise in the field of industrial
IT encompasses the mastery of a variety
of disciplines required for floor shop
solutions: MES, DCS systems, control &
PLC solutions, Data acquisition, RFID,
HMI systems etc’.
As a long term partner of Siemens,
Ardan masters the execution of the
TIA strategy and is experienced in the
integration and deployment of the
following: SIMATIC IT MES system,
Simatic PCS7, Simatic Batch, WinCC,
Plant intelligence, Rout Control, Step7
PlC’s, RFID and others.
Ardan’s experience is based not only on
implementing SIMATIC IT but also on its
integration with third party systems in
multi-site, large installations.
The company’s ability to integrate
different technologies through
the project definition, planning,
engineering, supply of equipment,
installation and programming, enables
ACT to supply the customer with a
The solution The data exchanged with the ERP level comprehensive, end-to-end Industrial IT
include order data, master recipes, BOM,
For the realization of a multi integrated material consumption, work order status, Based in Tel Aviv - Israel, ACT performs
floor shop system the choice fell on the lab sampling, freight data, loading data, projects In Israel, Eastern Europe, Asia,
3rd generation MES, SIMATIC IT. etc.. Bulk loading orders and trailer data and Africa.
are exchanged with the transportation ACT was established in 1984 as a
member of the Nisko-Ardan group,
Covering all aspects of the production management system.
whose annual turnover exceeds
process whilst supplying continuous and $ 340 M.
online feedback to the ERP system, was Production data, batch data, execution
made possible through the deployment reporting and alerts are exchanged with The company employs over 130 skilled
of the comprehensive Production Suite. Simatic Batch and Simatic PCS7, thus engineers and technicians, a stuff
aimed at supplying the customer with
enabling continuous monitoring of the the best technical and cost effective
The Production Suite imports and ex- production lines and data acquisition. solutions, combined with a developed
ports data to and from the ERP, SCM and service orientation.
Transportation Management systems Future installations will include the LIMS
through the data integration server. SIMATIC IT Unilab and the Historian, thus
Communication and integration of the broadening the horizontal deployment of Business Development Manager
MES with Simatic Batch and PCS7, is the comprehensive suite. Industrial Control Division
done via the Real Time Data Server. Mobile: +972 52 3228542
Tel: +972 3 6507035
Fax: +972 3 5581311
SIMATIC IT manages all data flows, both
horizontally and vertically and validates Web: www.ardantech.com
all data before exchange with neigh- www.niskoardan.com
Realizing Vision and Value
360° Operational Excellence and Quality
British American Tobacco has successfully The business challenge
completed a pilot MES project at their
Sacheon plant in Korea. The target was to For a company with such rapidly increasing
integrate the business system layer with product portfolios (the Sacheon plant alone
the control system layer and synchronize produces 17 billion cigarettes per year on
all of the production processes. The re- 11 production lines) to combine this growth
sulting transparency of all plant activities with productivity and responsibility, it is
helps align them with supply chain strate- essential to have a system in place that ef-
gies and optimize the overall production fectively manages the production processes
process, through traceability, product and handles the process and quality data.
integrity and cost optimization.
The experience from the pilot project in Highly automated production processes can
Korea clears the path for BAT to shape help the business to improve production
their MES landscape - from both a geogra- efficiency and quality, ensure product and
phical and a functional perspective - with process integrity, and enable tracking and
roll-outs and expanded functionality. tracing along the supply chain.
The customer Over the past years, many factories in the
world invested in production line automa-
British American Tobacco is the world’s most tion, but somehow never tapped into the
international tobacco group and the world’s potential that lies in real-time production
second largest quoted tobacco group by data due to the gap between raw produc-
global market share. tion data and managerial information.
BAT has a product portfolio of more than MES systems can fill this gap and help the
250 brands - including top brands such as business to accelerate the speed of business
Dunhill, Kent, Lucky Strike, Pall Mall, Vogue growth and competitiveness.
and Viceroy. A global MES pilot was a smart way to un-
derstand the opportunities and challenges
In 2009 BAT produced some 724 billion of an MES project - both from a business
cigarettes in 50 cigarette factories in 41 and technical perspective - to evaluate the
countries. Five of these, plus one separate, impact on business and production opera-
dedicated plant also make either cigarillos, tions and to learn how MES could be stan-
roll your own or pipe tobacco. dardized and re-used.
BAT employs over 60,000 people globally. Its
products are sold in more than 180 markets. The South Korean plant was selected as the
pilot plant as it is a young, high performing
The MES initiative fits snugly into BAT’s vi- plant with standardized processes already in
sion strategy, which is to lead the global to- place. Automating these processes was ex-
bacco industry through growth, productivity pected to speed them up while reducing the
and responsibility. error rate, and enhancing their reliability,
traceability and flexibility.
As this pilot project is meant to serve mens MES Delivery Services, Siemens
The solution as a best practice example for the other UK and Siemens in Korea. The mutual
plants, the solution had to be based on commitment and collaboration were
Once it was clear that MES was the way standards and repeatable, yet fully con- one of the success factors for the pro-
forward, a vendor was selected. figurable, which would eventually influ- ject and lay the foundation for future
ence the global ROI considerably. collaboration in the manufacturing IT
Siemens was chosen for its know-how in domain.
the field, its brand strength, its commit- SIMATIC IT offers a business process mo-
ment, but not least due to the complete- deler to define and visualize the plant What was implemented was a fully inte-
ness of its MES portfolio SIMATIC IT and model and create rules to trigger produc- grated manufacturing solution based on
the good match with BAT’s requirements tion operations. The MES functionality to SIMATIC IT – from the primary process to
in terms of functionality and system handle these operations is provided by finished goods dispatch and integrating
properties. software components according to the the quality laboratory.
ISA-95 international MES standard.
Of particular concern to BAT were the The integration between ERP and MES
system’s performance and maintainabili- This modeling platform approach makes ensures a fully automated exchange of
ty, interoperability with other plant and it easy to adapt business processes to product and production data with ERP
business systems, user acceptance, and new requirements and also facilitates (e.g. production orders/material data/
impact on production improvement. roll-outs of the solution to other plants Bill of Materials). Product and process
within a company. data are collected and collated during all
From a functional point of view, the process steps to support full product tra-
new system was expected to handle pro- The global presence and partner network cking with forward and backward gene-
duct and process genealogy, OEE, SPC, of Siemens were another compelling ar- alogy. Real-time production KPI reports
production order management, product gument in this respect. The pilot project (e.g. OEE,) are available based on real-
definition management, WIP manage- for instance involved teams from BAT time and historical data. This helps iden-
ment, palletizing and labeling. Korea and BAT Global HQ, as well as Sie- tify opportunities for improvement and
supports best practice benchmarking. The pay-off At a glance
Advanced quality management features
are also included such as material veri- Together, BAT and Siemens took a unique Company:
fication, defect tracking, SPC (statistical approach in order to design and imple- British American Tobacco
process control) charts. ment a value driven MES solution, map- www.bat.com
ping BAT’s operations strategy with MES
A LIMS system was also included in the requirements, and those with Industry: Tobacco
solution. This automatically collects SIMATIC IT functionalities. This approach
results from quality control instrumen- enables a clear value identification and Key Challenges:
tation such as scales, QTM and GC ma- ROI calculation before and after the • Integrate production with
chines, and analytical smoke constituent implementation. business
capture equipment specific to the tobac- • Full product genealogy
co industry, and then places them in a With this new solution, BAT Korea has • Real-time production key perfor-
central database. realized significant time-savings, reduced mance indicators
manufacturing and material costs, and • Advanced Quality Management
The embedded reporting tool allows the increased asset efficiency and availability.
management and operators to benefit Additionally, the system enables faster Solution:
from a suite of developed reports – as and correct decisions based on real-time • MES + LIMS
well as the ability to ‘customize’ the re- production information.
port ‘view’ and content to suit their own Key Benefits:
particular requirements. This makes it a strong enabler for best • Supply chain agility and tracea-
practice and performance improvement. bility
The project involved teams from BAT The system also allows BAT to quickly • Improved production efficiency
Korea and BAT Global Headquarters address more complex and integrated • Product and process integrity and
(UK), as well as from Siemens MES Deli- supply chain scenarios. Not only this, its quality
very Services in Genoa (Italy), Siemens traceability capabilities strongly contrib- • Reliable and flexible processes
UK and Siemens MES team in Korea. ute to BAT’s corporate responsibility im-
The mutual commitment and collabora- age and brand strength.
tion were one of the success factors for
the project and lay the foundation for This new MES pilot can now serve as best
future collaboration in the manufactu- practice to other BAT factories who are
ring IT domain. considering launching a similar project.
Quenching your Thirst for Quality
Birra Peroni SpA: Quality Management Solution with SIMATIC IT
Birra Peroni SpA implemented Siemens’ The business challenge
LIMS SIMATIC IT Unilab for a centralized
approach to quality management across Before the decision to implement a LIMS so-
several plants and labs. lution, a software interface for quality data
input and output was in place, however this
They have realized substantial improve- was a customized solution and not central-
ments in product quality and are now ized.
well equipped to address regulatory is-
sues. With the growth of the business it became
increasingly difficult to manage and collect
The customer the equally growing quantities of data. On
top of that came the necessity to respect the
Birra Peroni SpA is a SABMiller subsidiary HACCP principles and the desire to obtain
consisting of 3 breweries. The headquarters ISO certification for product quality.
of Peroni as well as the largest brewery are
located in Rome. The other two Peroni brew- This joint trio of requirements highlighted
eries are located in Bari and Padova. the need to centralize product specifications
and quality data management and make it
Birra Peroni is the second brewer in its home easier to change parameters and specifica-
market, whereas its mother company SAB- tions, all located in a common server.
Miller is the world’s second large brewer.
A system was needed that would offer easy
Peroni stands for the style and the exclusive data acquisition for product traceability
taste of Italian beer. The Peroni breweries along the process.
produce two principal brands: Peroni and
Nastro Azzurro. This demands deep understanding of the
processes as well as a centralized system
Where Peroni is the number one beer brand that allows configuration and offers the
in Italy, Nastro Azzurro has become an in- right level of uniformity in recording and
ternational brand and is the most exported reporting on data.
of Italian beers. Nastro Azzurro is also pro-
duced under license in many countries.
The total beer production of the Peroni
breweries is about 6.300.000 hectoliters
with a total of about 800 employees on a
total of 9 production lines at its 3 sites.
The solution Another important aspect of the project
was the harmonization and automation
The SIMATIC IT Unilab LIMS including of reports, based on the Report Manager.
the Report Manager was the most com- After an initial learning and guidance
plete solution and best suited for centra- phase the Lab Manager was ready to run
lized collection and management of la- both SIMATIC IT Unilab and Report Mana-
boratory data in a company with several ger and manage reporting autonomously,
labs and plants. creating and customizing detailed reports
according to the current needs.
The system is configurable and custo-
mizable according to the production The system is able to collect large quan-
needs. Realizing the best possible con- tities of data that allow fast response to
figuration required a deep knowledge increasingly complex regulatory requests.
of the production processes on the one
hand and experience with the system on But the prompt availability of this infor-
the other hand. mation also allows a statistical approach
to quality, which helps support process
This involved strong support from the management and development.
supplier in order to create a good and
effective environment for the users, as
well as involvement and training of lab
managers and analysts, starting from
At a glance
Birra Peroni SpA
• large data quantity handling
• centralized quality management
• harmonized and automated
• SIMATIC IT Unilab
• product quality improvements
• ISO certification for product
• process management support
• product traceability
• regulatory compliance
The pay-off The positive impact of the LIMS does
not only translate in improved quality of
Birra Peroni now has centralized control the product. It also allows for more cost-
on plant performances and product efficient quality, quality standards being
quality of its different plants. met, less non-conformity alerts and inci-
dents occurring, as well as a considerable
This enables full product traceability reduction of time spent on quality and
and benchmarking between plants and process checks.
against historical data to realize contin-
uous improvements in product quality Birra Peroni is constantly evaluating the
and processes. system. An upgrade to a new version was
already carried out, and plans are in the
SIMATIC IT Unilab significantly contrib- pipeline for improved integration with
utes to improved product quality and SAP and other systems to further elimi-
thus played an important role in the nate duplicated data input.
company’s achievement of ISO certifica-
tion for product quality.
Probably the Best…
Carlsberg - MES solution with SIMATIC IT
Carlsberg implements a corporate MES The business challenge
standard in order to optimize the benefits
from a Manufacturing Execution System In the past Carlsberg’s investment approach
in terms of efficiency, quality and trace- was to implement locally selected solutions
ability at the lowest possible IT cost of that would then develop over the years with
ownership. add-on solutions as required.
The choice fell on a solution based on SI- Together with heritages from acquisitions
MATIC IT. The solution was developed by this led to a fragmented landscape of un-
the solution partner ATS based on SIMA- connected systems. And though these sy-
TIC IT libraries. stems work they often require manual input
with the inherent risk for data integrity.
The first part of this solution went live
at the pilot plant in April 2009. A phased Also, the fragmentation of the systems ma-
implementation and roll-out to 15 plants kes it very difficult to measure performance
in 7 countries was planned over the next and gain improvements due to a lack of
4 years. comparable KPIs for benchmarking between
This made it clear at Carlsberg that a corpo-
The Carlsberg Group is one of the largest rate standardization of the MES layer was
brewers in the world, employing over needed to live up to the corporate excel-
43,000 people and selling its products in lence programs for efficiency and transpar-
more than 150 markets. ency.
In 2009 the Group produced and sold more This consistent MES approach is also fully
than 135 million hectolitres of beer, which in line with the ongoing Business Standar-
is about 112 million bottles of beer a day. disation Program at the ERP level and is ex-
pected to optimize the benefits from a MES
The Carlsberg Group’s broad portfolio of at the lowest possible IT cost of ownership
beer brands includes Carlsberg, known as and help achieve the strategic goals of lowe-
‚Probably the best beer in the world‘, and ring costs of production, improving quality
strong regional brands such as Tuborg, Balti- and responding rapidly to changing custo-
ka and Kronenbourg 1664, as well as a wide mer demand.
range of leading brands in local markets.
The goal is to achieve a full integration of
Carlsberg operates in over 50 countries, systems and obtain standard automated
and in markets where they don‘t have own KPIs as well as reporting across multiple
breweries, operations are handled by the breweries. People at all levels in the orga-
Export division. nisation needed access to this information
Screen 1: Web portal with CAB screen menu with Screen 2: Order handling - overview of filling orders Screen 3: Line efficiency
different functionality available planned, in progress and completed
and these tools to detect areas of im- KPI reporting for three areas: SCADA systems such as WinCC and iFix.
provement and to support best practice • Filling and Packaging This integration allows automatic data
sharing. • Utilities capturing of order, downtime and loss
• Brewing and Processing data when running orders on the pa-
Next to automatic generation of reports ckaging lines.
and KPI data the MES is expected to ena- In essence the new system was designed
ble tracking and tracing and real-time to follow the production process. The in- Downtimes and downtime reasons are
visibility throughout the brewery and so tegration with warehousing systems and logged via integration with the SCADA
result in: ERP lets the system manage orders recei- system. Detailed standard downtime
ved from SAP that are based on customer and performance analysis reports are
• Reduced machine down time orders. This starts by handling orders available with multiple data-filtering
• Reduced energy costs received from customers. options.
• Reduced overtime and labour costs
• Reduced manual data collection and For this purpose Master Data are inter- Standard KPI reports such as Utilization,
report creation faced with SAP, orders are downloaded Line Efficiency and Scorecard, are also
• Reduced inventory from SAP to MES, and confirmations available for packaging lines. These
• Elimination of duplicate processes uploaded. All the while the orders are reports are fully aligned with the Carls-
• Improved equipment utilization available for real-time scheduling and berg Group KPI manual and also include
• Improved data accuracy for decision tracking of order progress. local KPI reporting for supporting lean
• Dynamic response to production or The operators have full visibility on these
quality issues orders and their progress. KPI reports such as water or energy con-
It is of course still possible to manually sumption, waste water, CO2 consumpti-
The standardization and integration select and modify orders or to create or- on/recovery will be available for utilities.
aspects in the project are to help restrict ders to run independently from SAP.
costs of IT software as well as hardware, Full traceability and genealogy helps to
facilitate the implementation of future The full visibility of the production lines understand at all times “when and how
changes and enhancements, and enable offers the manufacturing intelligence the product was made and what of”.
a central support environment, reducing required to continually improve processes
local support costs. and intervene in a timely fashion to avoid Material movements can be traced back-
scrap. ward and forward and full genealogy
The solution reports are available in no time at all,
This is realized by integrating the MES without a scrap of paper in sight.
The choice fell on a solution based on system with SAP for order handling, with
SIMATIC IT that includes functionality for warehousing systems and at the process
Order Handling, Downtime and Utiliza- layer with different control systems inclu-
tion Management, Tracking and Gene- ding Siemens and Rockwell PLCs, process
alogy, At-line quality management and control systems from various suppliers,
The Project Team For this project ATS formed an interna- across plants reduces the time, cost and
tional team to facilitate roll-out and proj- risk of a project.
The selection of a solution was not only ect support. Furthermore ATS engineers
influenced by the characteristics of the are involved in the actual development of SIMATIC IT has an open architecture al-
actual product/solution, but also by the the SIMATIC IT Brewing Industry Library lowing 3rd party applications to be inte-
suitability of the product vendor and the and Filling & Packaging Library. grated and synchronised with MES, and
solution provider as project partners. offers strong connectivity to shop floor
From a product point of view the im- and SAP.
The main factors taken into account for portance lay in product completeness,
partner selection were reliability, also product quality, deployment capabilities, SIMATIC IT is fully based on the ISA-95
towards the future, strategy and service product vision and confidence in long standard for MES and ATS also used
concept, experience in MES as well as term performance and support offered by the ISA-95 MES model to translate the
in the brewing industry and processes, Siemens. functional requirements from users at
plus understanding of the Carlsberg Carlsberg HQ and subsidiaries.
business goals and the capability to SIMATIC IT is a modular system, which
translate these into the technical imple- means that only required modules need From the very start of the project a proj-
mentation. to be deployed. It provides a set of com- ect management structure was set up
ponents, each addressing a specific MES including members of all involved par-
Both Siemens and ATS lived up to these function. These standard functions are ties, Carlsberg, ATS, Siemens.
criteria. coordinated by a graphical workflow.
ATS was selected by Carlsberg as the So- Missing functions can be rapidly devel-
lution Provider for this project. ATS is an oped using the Client Application Builder.
innovative, strategic knowledge partner Components, models and rules are stored
providing products and services for all in a hierarchy of reusable libraries such as
three levels of the automation pyramid; the SIMATIC libraries used in this project.
control, execution and information. The capability to re-use these libraries
At a glance
Web address: www.carlsberg.com
Partner: ATS International
Web address: www.ats-global.com
• Complete system for consistent
• Reduce production costs
• Improve quality
• Increase responsiveness
• SIMATIC IT Filling & Packaging
• SIMATIC IT Secondary Process
• Integrated systems
• Automatic data availability
The pay-off tion costs, improving quality and ensur- • Production visibility
ing rapid response to demand changes. • Continuous improvements in
The solution includes functionality for Implementing a complete and standard- quality and production
Order Handling, Downtime and Utiliza- ized MES solution helps reduce automa- • Reduced IT and automation costs
tion Management, Tracking and Geneal- tion and IT costs, and integrate our sys-
ogy, At-line quality management and tems to provide accurate planning and
KPI reporting for the Packaging areas, production status information.
Utilities and Brewing & Processing.
“Though we have not yet started to
A full roll out of the complete solution measure the savings we get feedback
to at least 15 plants is planned within from the plant about real savings in sys-
the next 4 years in a phased implemen- tem and paperwork costs and consider-
tation approach. able enhancements in visibility of orders
and actual production status.
This provides faster benefits and pro-
vides other breweries with an early op- That, together with clear downtime re-
portunity to start gaining benefits and porting, empowers our people to make
improvements whilst providing input to better decisions, almost on an hourly
the design of the solution. basis, resulting in improvements on pro-
duction and quality levels.”
The connectivity of the MES platform to
a wide variety of existing systems and
the re-usable character of the libraries
guarantee a long term solution.
In the end this project’s success is mea-
sured on its impact on lowering produc-
MES out of the Box
ATS - Siemens SIMATIC IT Library
The Siemens library concept at a generic for Brewing and Processing, Environ-
mental reporting and Filling and Packaging
Traditionally MES solutions require sig- The solution enables the ATS MES Excellence
nificant integration effort. By developing a teams to use these libraries as a standard
solution based upon the Siemens SIMATIC configuration and can be easily adapted to
IT MES product ATS has taken advantage of any Filling and Packaging configuration with
the industry libraries available within the minor configuration changes.
product. Even with the standard software
products on the market most MES imple- Therefore the solution can really be consid-
mentations require considerable configura- ered out of the box and can be deployed not
tion which increases the cost of the imple- just in Food & Beverage, but in any filling
mentation. and packaging environment like for example
in a Pharmaceutical, Consumer Products op-
The return on investment is adversely af- erations etc.
fected when costs increase. By creating a
repeatable and supportable solution we can Integrated Quality is the latest available
ensure that 80% of the customers’ require- functionality which comes with the ATS MES
ments are met. In the majority of cases the Out of the Box solution, and includes in-line
out of the box approach works perfectly fol- and at-line quality with integration to ERP
lowing the classic 80/20 rule. QM:
A real example of the strength of the ATS/ • Quality module gives full control and as-
Siemens partnership is our collaborative ap- surance on quality and manual inspection
proach in library development of the ‘Out of test interlinked with any process order
the Box’ solution with the Siemens library • The quality module has integration capa-
teams in Genoa which has enabled rapid de- bility with ERP QM:
ployments & low cost of ownership. • To receive Product specifications and
The ATS MES out of the box solution is • To send test results from MES to ERP QM
based on the library developments in con-
junction with the projects at Carlsberg to • Workflow management in place to control
create a common operations, plant, lines and guide operators during the produc-
and machine library configuration which is tion on execution tests and inspections
• Exception management is integrated and availability of skilled resources sion control and ATS provides 24/7
within the workflow and is configu- • Rock solid; solution based upon prov- support, proven support verifiable
rable based on the business proce- en Siemens SIMATIC IT platform through strong references
dures • Out of the box; solution preconfigured • Extendable; ATS and Siemens have
• Raw material Quality information for using the SIMATIC IT libraries, leading partnered globally to deliver a full
each delivered batch can be compared to a significant reduction in deploy- suite of MES functions to users, the
with the raw material specifications ment time solution can be extended to meet
• Proven; solution originally developed many other potential customers &
The ATS MES out of the box solution for Carlsberg Breweries with full sup- industry requirements. Examples
ensures compliance with the Siemens port of Siemens MES team, tried, test- include research and development,
product roadmap and development ed and rolled out across multiple sites, laboratory information system, main-
strategy allowing an easy upgrade to already adopted by other companies tenance management, detailed sched-
newer versions. Currently the solution is • Repeatable; the solution is repeatable uling, weighing and dispensing and
available in version 6.4 and 6.5. due to use of architectural design and other modules.
library configuration with extended
Key aspects that stand out: options including response to demand The immediate benefits customers
changes, utility/environmental report- experience:
• Industry standards; solution based ing and quality management integra-
upon ISO 60224, ISA 95, OPC etc., re- tion • One single, repeatable solution will
ducing learning, implementation time • Supportable; Siemens manages ver- reduce the total costs for MES/MIS
compared to individual solutions per
plant, care is taken to take account of
differences in mechanical and control
systems for solution networking and
• Supporting Continuous Improvement
• Product and material tracking and
• Reduction in manual data collection
• Reduction in manual data manipula-
tion and report creation
• Elimination of duplicate processes
• Automatic generation of reports and
• Real-time visibility of production facili-
• Improved data accuracy and decision
The functionality currently covered in the ATS MES out of the Box solution • Dynamic response to production or
• Future changes and enhancements
can be easily implemented
• Replacement of legacy home-grown,
difficult to support systems
World leading companies like
Schweppes, Unilever, Coopers Breweries
and others, have recognised the bene-
fits and are taking a strong business ap-
proach to gain rapid business improve-
ments from the ATS MES out of the box
filling and packaging solution.
SIMATIC IT Libraries used:
CIL-E2S (when communicating with an
SAP system without SAP PI)
Environmental Reporting: the core
products PPA and report manager
Brewing and processing:
ILH-POH Filling and Packaging:
ILH-PRO secondary library collections.
MES Solution with SIMATIC IT at Henkel Sealant Hannover
Why Siemens? The business challenge
„Siemens is a worldwide vendor of a stan-
dard-based product and their modular The Henkel plant in Hannover is one of the
and scalable functionality offers a future- native locations of Henkel and has produced
proof and secure investment. In order to sealants and adhesives since the 50ies.
achieve our business goals we must red- Nowadays the plant produces joint sealing,
uce operational costs. This is where MES assembly glue and PU construction foam for
helps out. DIY and industry applications.
We are really pleased with the SIMATIC IT Both the bulk production as well as the
solution and the Siemens project team. In complex custom cartridge filling underwent
the near future we will be expanding the an optimization of the production manage-
system and integrating it with existing ment. This was achieved with a MES solu-
automation solutions and recipe manage- tion from Siemens.
Henkel Hannover produces 30 million car-
Dr. Breithor – Production Manager in Han- tridges per year and is renowned for its high
nover variety of customized products.
The main goal of the project was to increase
The customer production efficiency, improve order man-
agement and reduce the amounts of paper
With a worldwide workforce of over 50.000 required for production orders.
Henkel is one of the Fortune-500-Compa-
nies. Its 3 business areas: Laundry & Home In the past the 250 to 350 weekly orders
Care, Cosmetics/Toiletries and Adhesive were scheduled in a SAP Add-on and trans-
Technologies operate in 125 countries. ferred to Excel. The production paper was is-
sued and printed by SAP for each production
Henkel is a world market leader in adhe- and filling line. Data acquisition was a time
sives, sealants and surface treatments. Its consuming matter, as all data capturing was
Adhesive Technologies division was good handled manually on a printed production
for a 6,22 billion € revenue in 2009. Brands protocol and a printed OEE capture sheet
such as Loctite, Pattex, Ceresit, Pritt, Ponal, (OEE: Overall Equipment Effectiveness).
Metylan, Sista are widely used by consum-
ers, craftsmen and industrial businesses. Considering there are six bulk production
lines and nine filling lines, times 2 to 15
Woodworking or wallpapering, production papers per production order, this amounted
of cars, books, aircrafts, etc. those are but a to the print, distribution and processing of
few of the applications of Henkel products. 1500 to 2000 production papers per week.
On top of efficient traceability in pro- ate a solution based on SIMATIC IT that solution in SIMATIC IT records these
duction and increased online visibility, would synchronize order and material disruptions. The paper OEE record sheet
the integrated data flows in the MES data with SAP and help optimize produc- is now a thing of the past, which saves
were expected to enable real-time feed- tion management. the line operators all the valuable time
back on produced quantities, actual they used to spend documenting the
consumption and equipment status. Also included in this project was the in- line status. The next step is equipment
Based on these data the goal was to re- stallation of Siemens Touch Panels on the connection, which will allow automatic
alize sustainable process improvements mixers in the bulk production area and capturing of error causes.
based on error detection and root cause on the filling lines. The other production
analysis in order to avoid waste and cus- areas as well as the offices were plugged The production manager can carry out
tomer rejects. into the MES solution through standard extensive OEE analyses to support speci-
PCs. This gives production managers an fic improvement processes. The analysis
The reliable calculation of KPIs and OEE immediate view of the current status of tools in SIMATIC IT OEE are clearly a part
monitoring combined with the integrat- all plant assets through the SIMATIC IT of the overall MES concept. They enable
ed data on production and consumption Web Client and the possibility to run real- large-scale analyses on materials and
quantities would offer a solid base for time analyses of production results. orders.
better target versus actual cost analysis. The Henkel standard for OEE reports
It was vital that this approach find Production management was adopted, and what used to require
strong acceptance with the production SIMATIC IT takes over the orders that are time consuming manual data compila-
staff and that they understood the im- planned in the Henkel SAP-Add-on and tions now takes but a mouse click, with
portance of their role in this process. shows them directly on the displays at considerably improved data quality and
An intuitive and user friendly operator the mixing and filling lines. accuracy. On top of the Henkel OEE
interface was required to guide them In the past the operators had to manually report the module offers standard ana-
through the production process. modify the InLine inkjet printer set up lyses such as availability, Performance
according to the order specific print data Rate, MTBA, MTTR, MTBF.
The solution for the cartridges.
Now, SIMATIC IT automatically provides The users were convinced by the MES
The sealant operations in Hannover can the customer specific data to the InLine solution from day one and management
be divided into primary production and printer. Even the most diverse customer as well as staff in production value the
filling. Primary production mainly con- requirements in terms of data formats benefits from using SIMATIC IT.
cerns the production of bulk material in for cartridge IDs and expiry dates can be The know-how of the staff was also
large containers, most of which is then applied to the cartridges without a single captured in the system which can now
transferred to the filling lines to be pa- intervention by the line manager. ensure high quality and a low error rate
cked into cartridges. in production.
Some 700 products are produced based The line operators fill in their order feed- When an operator encounters an error
on over 120 different recipes. These pro- back directly on the Touch Panel where in the master data it needs to be cor-
duction specifications are managed in they can also report shift changeovers or rected only in one instance and then
SAP R/3 according to Henkel standards breakdowns. applied in the next production run. This
and requirements. Each of the 5000 ma- Easy acquisition and aggregation of OEE upgrades the value of the employee’s
terials (raw materials, packaging, finis- data was a major requirement. In case of time and work and stresses his impor-
hed goods) has its unique ID in SAP. a disruption the operator can now choose tance in the realization of optimization
An order was issued to Siemens to cre- from a dropdown list of causes. The OEE programs.
At a glance
Customer: Henkel Sealant Hannover
Industry: Chemicals - Adhesives
System Integrator: Siemens
Delivery Services Process Karlsruhe
& Siemens I&S Köln
• Optimizing production
• Overall integration of ERP, MES
• Reduce paperwork and manual
• Transparency and traceability of
• Reduce waste and rejects
• Increase efficiency based on
integrated data for OEE and root
The pay-off The entire production operations now • Real-time interoperability
run smoothly and more securely. between ERP and MES
The SIMATIC IT MES solution at Henkel Management, supervisors and operators • Reduced paperwork for
Sealant Hannover considerably simpli- are satisfied and would not go without
• Avoid errors through system
fies production management. the system again, even though it’s only guidance of the workers during
been in use for a few months. the production process
Not only did the system rid the plant of • Integration of captured data for
the mountains of paperwork related to Production management now has the vis- OEE
• Flexibility to handle complex
production orders, the production staff ibility it takes to realize sustainable pro- operations
is now securely directed through the cess improvements and to optimize the
production process and errors can thus efficiency of the production staff.
MES scores for Henkel:
No time is lost on administrative tasks Service and Quality
such as printing, distribution, collection Meet customer demands by timely delive-
and management of production orders. ring high quality at a low error rate
It is dedicated instead to production
optimization measures. The expected in- Lean
crease in efficiency resulting from using Relocating the office into the production
MES exceeds 5 %. hall so to speak, increases the efficiency
of the personnel in production. Admi-
Employees from different divisions were nistrative work without added value is
involved at an early stage, starting with practically eliminated and from a logistic
a process workshop organized by Sie- point of view inventory costs can be re-
This approach has also proved success- Operational Excellence
ful in other projects. The users are far The MES solution is a tool for the staff to
more likely to adopt and appreciate a so- improve their excellence. They can incre-
lution that takes their requirements and ase their visibility, deliver better quality
suggestions into account. and reduce the number of errors.
A Well-oiled Machine
IOI Loders Croklaan: MES solution with SIMATIC IT
Loders Croklaan is dedicated to providing ably the largest - integrated palm oil supply
its customers an extensive range of palm- chains in the world, from the palm trees on
based products, comprehensive supply- more than 150,000 hectares of plantations
chain management, and unprecedented to customer delivery of refined oil.
assurance of product safety, quality and
value. The new plant in the Port of Rotter- This vertically integrated business together
dam alone processes 2,500 tons of palm with the experience and scale, gives cus-
oil daily. tomers a competitive advantage, so they
can profit from optimum quality and reliabil-
Its huge capacity and central location ity, as well as increased transparency, sus-
help serve customers at maximum speed, tainability and cost savings. These are major
reliability and cost-effectiveness. To re- assets for a company seeking to be a partner
alize the required level of efficiency and for its customers as Loders Croklaan does.
flexibility full vertical and horizontal in-
tegration and automation of processes in Loders’ primary manufacturing facilities
and beyond the plant were a priority right are located in the Netherlands, the United
from the greenfield stage. States and Malaysia. Its state-of-the-art facil-
ity in the Port of Rotterdam, the Netherlands
Right up Siemens’ alley. The Siemens To- is Europe’s largest palm oil refinery and frac-
tally Integrated Automation (TIA) concept tionation plant.
is now the backbone of the entire supply
chain. The combination of SIMATIC IT Ma- The business challenge
nufacturing Execution System, PCS7 for
Process Control and SIMATIC Batch covers Efficiency was and is the key word at the
processes from raw material intake over Rotterdam palm plant. The idea was to mini-
production to goods shipping, and inte- mize the number of human interventions on
gration from the plant floor right up to the plant floor. This could only be achieved
the ERP system. through advanced process automation
where operator intervention is an exception
The customer rather than a rule.
Loders Croklaan is a subsidiary of IOI Corpo- In view of compliance with regulations such
ration in Berhad, Malaysia and has its head- as the US Bioterrorism Act, traceability was
quarters in Wormerveer, the Netherlands. another major requirement, not only of
It is a key global producer of oils, fats and changes in the processes, but also backward
nutritional ingredients with a strong focus and forward genealogy of the materials and
on palm oil. products.
Since its acquisition by IOI in 2002, Loders Knowing which raw materials are used in
Croklaan has been able to provide custom- a product, and which customers a certain
ers with one of the few complete - and argu- raw material is destined to. In a plant this
size this requires the ability to handle if necessary, of a combination of info Batch to create a lot and carry out the
enormous data volumes and reporting from all systems according to situational actual execution of the order based on
capabilities, which in turn requires com- or functional information requirements. downloaded recipes.
munication between systems in order to The Greenfield situation had allowed
avoid data entry duplication while sav- the engineers to determine beforehand All the while SIMATIC IT Material Mana-
ing time and eliminating errors. which systems and setups would support ger will keep track of all material move-
optimum efficiency in every step of the ments and status changes, resulting in
A clear visibility on plant floor activity process. a full product genealogy. In SIMATIC IT
and material status was essential to Production Modeler, the calculation of
allow analysis and improvement of pro- From the arrival of raw materials right production relevant KPIs is defined at
cesses, and support advanced planning. up to the shipment of finished products particular points in the process.
all process steps are covered. All events,
The solution production operations, equipment, and The KPIs are based on real-time process
tanks are defined in the SIMATIC IT Pro- information collected from the control
The TIA solution was implemented in duction Modeler. From here the neces- layer, captured, validated, and aggrega-
a joint effort with Siemens and Loders sary actions are triggered. For instance ted in SIMATIC IT Historian and appropri-
Croklaan. It consisted of SIMATIC IT MES, thanks to the integration of the LIMS ately associated with quality parameters
including SIMATIC IT Unilab LIMS and SIMATIC IT Unilab sample creation and and process specifications.
SIMATIC IT Historian, in connection with analysis can be scheduled to check the
SIMATIC PCS7 for process control and product quality and release a shipment. SIMATIC IT Report Manager provides an
SIMATIC Batch. advanced functionality to create auto-
This information is fed back to the ERP matic time- or event- based reports, as
SIMATIC IT forms the link between the system which gives the impulse to create well as ad-hoc reports, based on infor-
existing central ERP system (SAP) and a production order through SIMATIC IT mation retrieved from the control layer
the process control system (PCS7). Production Order Manager, and with each through Historian, from Material Mana-
This guarantees the availability, remote process step SIMATIC IT triggers SIMATIC ger, LIMS as well as ERP.
At a glance
Industry: Edible Oils
• efficiency through maximum
• advanced tracking & tracing
• standard, modular & future proof
• SIMATIC IT Production Suite
• SIMATIC IT Unilab
• TIA: SIMATIC PCS7 &
• cost efficiency through limited
• customer satisfaction through
The pay-off Additionally all captured information is flexibility
available to continuously improve pro- • regulatory compliance and pro-
At the Loders plant in Rotterdam 2,500 duction efficiency and speedily and accu- cess optimization through data
tons of palm oil are produced daily by rately reply to information requests from integration
no more than 50 people. Large time-sav- customers or regulatory bodies.
ings are the result of single data entry
and easy and central data accessibility. This greatly improves customer services
as well as regulatory compliance.
The throughput time from raw material
to pure palm oil ranges from 3 hours to The flexible and open character of the so-
just over half a day. lution allows Loders Croklaan to look into
possibilities of further system integration
Such a level of efficiency can only be and process optimization for this plant
obtained because the processes are well that can serve as a blueprint for other
defined and supported by seamlessly and future plants.
integrated systems at all times and all
people involved have easy access to
clear work instructions.
Real-time Plant Scheduling
How a fully automated production order optimization in combi-
nation with decoupled production machines can increase effici-
ency and production accuracy.
„Solving the real-time scheduling problem was one of the big challenges of the entire
project. The highly innovative solution developed in cooperation with Xavo and iFactory
has succeeded in its practical application, because the solution does not require heuristic
input or permanent maintenance of the scheduling algorithm despite frequent changes
to machine configurations.“
Elmar Schlöder, Global Engineering, Japan Tobacco International
Towards the end of the year 2007, Japan To-
bacco International (JTI) developed the idea
of replacing the current concept of a strict
coupling of filter makers to cigarette mak-
ers with a more flexible design. This design
- termed Filter Distribution Center (FDC) by
JTI - decoupled filter and cigarette produc-
tion with the introduction of an intermedi-
ate storage facility. The FDC MES covers a wide range of tasks from master data
management, order management to SAP and WMS integration.
Cutting edge high-speed filter makers,
whose high capacities would be fully lever- These were tasks that could not be managed
aged in the decoupled design, should be manually any longer, at least not with satis-
deployed on the filter production side. factory - or even optimal - results.
Thus, the same throughput was to be Working with our colleagues from iFactory,
achieved with significantly fewer machines. the project team from Xavo developed a
On the make/pack side planning flexibility pilot solution for the automatic optimization
should be increased. of the filter production. This solution called
for a close interaction between iFactory’s
The Development of the Solution iFRP® scheduler and a highly integrated
Manufacturing Execution System.
It quickly became clear that solid IT support
was vital in this design. The goal was to While the MES has to calculate the neces-
produce the same high number of different sary filter batches based on current de-
filter types with fewer filter machines. mand, the scheduler takes care about the
The optimal allocation of production orders optimal distribution of the orders in time
for the filter maker and simultaneous real- and space. In other words, the scheduler
time monitoring of the interim storage facil- calculates when and on which machine a fil-
ity was essential for this solution. ter production order has to be produced.
The simpliﬁed architecture of the IT solution SIMATIC IT Predictive Scheduler Interactive (PDS-i)
A symbiotic unit: Visibility and interaction Integration between business and
shop-floor Real-time scheduling (fully
MES with iFRP scheduler An intelligent scheduling algorithm and automated optimization, manual inter-
the integration of all relevant parameters, vention possibilities with real-time re-
The MES takes into account shift cal- however, were not yet sufficient. calculation of constraints, and real-time
endars and maintenance timetables, monitoring of plan fulfillment) is an es-
calculates set-up times, and ensures The human production staff needed to sential part of this solution.
that the allocated machines meet the be able to see and assess the optimized
production requirements. The scheduler planning results. In addition, manual in- For operational use, a number of typical
then performs an optimizing process on tervention had to be possible in as well. MES applications (such as data mainte-
the production plans according to differ- nance, order management, and auto-
ent criteria. The SIMATIC IT Production Suite had been mated SAP and WMS connections) were
in use at JTI as MES platform for a num- integrated into the solution as well.
Depending on the requirements of the ber of years.
planner, the scheduler can be config- It therefore made sense to integrate The users were thus freed from the tire-
ured to avoid set-ups, save shifts or the brand-new planning tool from this some task of manually allocating each
achieve throughput targets. In this way, Siemens suite, the Predictive Detailed order; and the shop floor and the busi-
Xavo’s MES and the iFRP scheduler are Scheduler (PDS-i) into this solution. PDS-i ness world were connected almost syn-
building a symbiotic unit that meets the enables the visualization of production chronously which avoids mistakes and
customers requirements perfectly. plans and allows users to make manual saves time.
In addition to the optimal supply of the MES provides users an overview about
cigarette makers with filters, the system Any change to a plan would be reviewed production orders progress. It also con-
also ensures the proper production of in real time in order to alert users to tinuously calculates stock forecasts for
filters for resale. Planners could chose potential future problems such as safety- the filter warehouse.
priorities in this area as well. stock violations.
Project leader: Andre Goller (Xavo)
Time frame: End of 2007 (Idea) to May
2009 (first go live in Trier)
Productive locations: Trier, St.
iFactory iFRP® for Tobacco
Simatic IT Production Suite v6.3
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quotes and everything else about
Xavo Plant Scheduling
Your primary contact regarding Xavo
Plant Scheduling is Detlef Riedel,
The Implementation For the most part, the scheduler needs Xavo AG, Bayreuth.
less than 90 seconds to calculate a com-
The entire software package was de- plete production plan. This also enables Xavo
veloped and tested between mid 2008 the solution to react with optimal results
Xavo was the first SIMATIC IT Partner
and the beginning of 2009. It went live and in real time to all unexpected events. in Germany. Since 2003 the company
for the first time at JTI’s Trier factory in is creating successful solutions based
May of 2009. The team did a great job In this solution the MES ensures auto- on SIMATIC IT for customers from all
on simulations and field tests which has mated and error-free communication over europe. Xavo is located in Bayreuth
(Headquarters), Nuremberg and Reinach
been confirmed by the productive run- between the SAP system and the ware- (Switzerland). About 35 higly skilled
ning solution. house-management system, thus con- and motivated employees working
necting the shop floor with the business at Xavo. The industry sectors Xavo is
The whole project was a great success. world. focussed on are: Food & Beverages,
Therefore the solution was also rolled Tobacco, Life Sciences, Pharmaceuticals
and Green Technologies. Xavo has many
out in the St. Petersburg factory in Octo- Furthermore, factory staff is informed years of experience in both Production
ber of 2009. immediately if plan deviations occur and Suite and R&D Suite.
is provided with a forecast of the filter
A New Dimension of the inventory for the next hours/days at any Contact:
Order Planning Meistersingerstrasse 2
The combination of the scheduling algo- 95444 Bayreuth, Germany
The development of the complete solu- rithm with a highly integrated MES has
tion for the filter distribution center was proven so successful in practice that, as a Tel: +49 (921) 78 77 79 0
Fax: +49 (921) 78 77 79 29
a complex task. Over a dozen colleagues result, Xavo has begun to develop a stan-
from JTI, Xavo, and iFactory were in- dardized product which integrates the Web: www.xavo.com/plantscheduling
volved in this project. iFRP algorithm into a MES solution:
Xavo Plant Scheduling.
But the advantages gained are well
worth the effort. The number of re- This product provides a model which
quired filter makers has been almost enables entire factories to leverage real-
halved while planning flexibility and ac- time plant scheduling.
curacy increased significantly.
Increased Production Performance
@ Société Beurrière d’Isigny (Lactalis)
The customer The business challenge
The Lactalis group is one of the biggest The main challenges from a business point
family enterprises in France. It regroups of view in this packaging department were
more than 38.000 employees in 120 pro- to increase visibility in order to improve
duction sites worldwide. It was one of the quality and asset efficiency of the plant.
first dairy production enterprises in Europe
and remains one of the world leaders in this From a technical point of view this required
domain. ERP to plant floor connectivity and an easy
to use HMI for operators.
At Isigny which is located in La Manche in
Basse-Normandie, the Société Beurièrre The resulting transparent data synchroniza-
d’Isigny which belongs to the Lactalis group, tion and performance monitoring (KPI &
produces butter of the brand Président. OEE) was expected to enable error avoid-
There are 4 production lines to produce dif- ance and quality labeling.
ferent package sizes.
TECHNORD is a family group of 300 persons
specialized in Electrical Engineering: we are
industrial integrator of services.
Our different business areas are Industrial
Electricity Low and Medium Voltage,
Electrical Cabinets, M.E.S. (Manufacturing
Execution System), Industrial Data
processing, programming of PLC and
supervision system and industrial and office
TECHNORD is certified to the very highest
level by the leading manufacturers on the
Process Control System SIMATIC PCS 7
Human Machine Interface SIMATIC HMI
Manufacturing Exec. System SIMATIC IT
Automation System SIMATIC
Process Control System SIMATIC PCS 7
Human Machine Interface SIMATIC HMI
Industrial Communication SIMATIC NET
Manufacturing Execution System SIMATIC IT
The solution The Results
A combination of PCS7 and SIMATIC IT • Integrated system, less errors (+- 10%) Rue de la Lys 21
was implemented to on the one hand • Higher efficiency > less weekend work BE-7500 Tournai
automate the level 2 functionalities. • Increased quality & traceability of
Phone: +32 (0) 69/25 73 60
The IO-signals are connected through production lots Fax: +32 (0) 69/25 73 53
PROFIBUS DP and other third party www.technord.com
equipment using Modbus or serial inter-
On the MES level, SIMATIC IT was used
to integrate the ERP with the process
control for efficient production execu-
tion and traceability, which results in
ERP downloads production orders which
are recalculated into production orders
based on quality/day.
The production lines are also monitored
by the OEE/DTM module of SIMATIC IT
Historian, to monitor and improve the
utilization of the used equipment.
Mixing and Packaging with
SIMATIC IT and PCS7
A brown field full of flour
Imtech developed a shared vision with Latenstein, a manufacturer of wheat starch and
wheat-protein, for the automation of their Mixing and Packaging lines. The process control
as well as the production management (MES) layer are based on Siemens SIMATIC IT and
the PCS7 platform.
The customer They take special care for the quality of their
service, their manufacturing processes and
Latenstein products are applied for their deliverables.
structural improvement of food or as a
binder or filler in food products. They are Certification such as HACCP, Kosher & Pare-
also used in pet-food. vee and Halal guarantee Latenstein’s inter-
national reputation as a reliable supplier.
Starch is not only applied in the manufactur- For products for pet food Latenstein is
ing of cakes, bread, soups, sauces, snacks, certificated according to GMP+.
beef and pork products,but also in the man-
ufacturing of cardboard, glue and fish feed. Latenstein’s Mixing and Packaging lines
receive raw materials, which are mixed in
Due to their organization, Latenstein can order to create the required product
provide the market with tailor made qualities, buffered. Finally products are
products. They are able to respond swiftly to homogenized and packed.
market demands such as new product
specifications, product quality requirements Latenstein supplies in 25 kilo sacks, big-bags
and product packaging. or in trucks. They have two sack fillers, two
big bag fillers, two palletizers and three
The automation system contributes to excel- docking stations for trucks.
lent control of the basic production process-
es and to a rapid information exchange.
For Latenstein, quality of their products
and processes is of the utmost importance.
The business challenge The new control system does not have The solution
Latenstein’s primary driver for Order intake, the production planning,
introducing a new automation system Instead, it determines the optimal routing quality control including approval by
for the Mixing and Packaging lines was based on availability and contamination quality assurance and release of freight-
the age of their previous system. rules. In any case, the control system documents: all is taken care of by the
Both knowledge and spare parts were provides the possibility to apply any given Latenstein’s control and information
becoming sparse, creating a situation route. system.
where small problems could cause Basic functions of the system include:
unacceptable amounts of downtime. Besides this, new legislation according • Execution of transport orders and
to General Food Law required the adjacent route selection;
The market Latenstein operates in implementation of tracking and tracing. • Mixing orders into big bags;
demands a high level of flexibility. • Handling of retour product flow;
The automation system should never All over the manufacturing process, • Handling, weighing, creating freight
limit the physical capabilities of the tracking of raw materials takes place, documents;
production. Therefore, the opportunity and all material flow properties are being • Quality Control and Quality Assurance
to create a much more flexible system recorded, including the intake and output and approval for product release from
was seized. of raw materials and final products. the lab.
Imtech Industrial Services
With 25,000 employees and 21,000
clients, Imtech realises annual revenues
of over 4.5 billion euro. Imtech offers
added value in the form of integrated
multidisciplinary total solutions that lead
to better business processes and higher
revenue for our own clients and for the
clients that they, in turn, serve.
Imtech also offers solutions that
contri-bute towards a sustainable
society, such as ‘green’ technology
andtechnological solutions in the fields of
energy, environ-ment, water and mobility.
Imtech Industrial Services provides
ap-propriate technical solutions for the
industrial market. Imtech is familiar with
the production, legislation and regulations
in many markets,including chemicals, oil
& gas, food & feed, logistics and energy&
environment and providing services
as engineering, projectmanagement,
installation of automation projects and
industrial management & maintenance to
our customers. Our key word sare safety,
availability, quality and reliability, and
requirements, as our clients are leading.
The business unit Automation Solutions
is the Centre of Expertise for the develop-
ment and implementation of innovative
en reliable automation concepts, which
are a solid base for manufacturing
Imtech took care of the entire design, The pay-off execution systems and process control
build and implementation of the applications. It combines know-how of
complete process control and The benefits of the new system in terms manufacturing processes, information
information solution for Latenstein’s of flexibility and user-friendliness were technology and software packages and
tools to agile solutions for effective
Mixing and Packaging lines. recognized by both Latenstein’s production management and Operational
production planners and operators. Excellence.
The system is based on SIMATIC IT and Automation Solutions provides integrated
PCS7. The system design was written The new automation system enabled ICT services focused on consultancy/
according to the ISA-88 and ISA-95 Latenstein to increase its customer confi- project management, system design,
software implementation services and
guidelines. Orders originating from a dence by enabling quick recipe changes maintenance in the area of industrial
SAP system are processed by the process and batch sizing. It also created a basis automation, manufacturing execution and
control system. The scope of the system for further efficiency optimization by information management.
includes the PLC control system and automating workflow, early warning of Imtech is a certified SIMATIC IT partner
and has strong partnerships with IBM and
field interfaces. deficiencies and data collection for
Microsoft for their business solutions.
The user interfaces are adapted to the Success starts with a good conversation
needs of individual users. Utilizing the Agility and Lean are the key pay-offs from Do you want to know what Imtech can
SIMATIC IT CAB client guarantees a implementing SIMATIC IT and PCS7. provide for your organization?
similar look & feel for all users. Users
Please contact your Imtech account
can both check and activate orders. manager.
The system provides overviews of the T: +31 (0)33 – 453 92 00
currently running orders. E: Info.email@example.com
The production-operator or planner is W: www.imtech.eu
able to create orders himself or accept
orders coming from the ERP system. In
the exceptional cases in which automa-
tic process control is not possible, the
system provides PCS7 process
visualization for the operator in order to
support manual operation.
No Small Beer
Grupo Mahou-San Miguel - Integrated Quality and Traceability
with SIMATIC IT
To strengthen its reputation as a top qua- Laboratory Information
lity brewer, Grupo Mahou-San Miguel has
implemented an integrated quality ma- Management System (LIMS)
nagement and traceability system based
on components from the Siemens MES To enforce this dedication to quality a
portfolio SIMATIC IT. The solution inclu- powerful tool was needed for continuous
des a LIMS (laboratory information ma- improvement of processes and products,
nagement system), a material manage- and one that would support an integrated
ment module, and a product specification quality management approach across all
management system. plants with a structured way of handling
product and process data.
Mahou-San Miguel decided to implement
Grupo Mahou-San Miguel has a history of a LIMS (laboratory information management
more than 100 years. It is the number one system) that would integrate the manage-
Spanish-owned beer group and one of the ment of the existing laboratories in each
major brewers in the world. of the company’s production units, and
could replace the different small home-
The company employs 2100 people at its grown systems for lab management.
headquarters in Madrid and its 7 breweries
in Spain (Guadalajara, Lérida, Burgos, Mál- A thorough screening of the LIMS market
aga, Tenerife, Córdoba and Granada) where turned out SIMATIC IT Unilab, which is
over 11.6 million hectoliters (hl) of beer are Siemens’ LIMS, and forms part of the Sie-
brewed yearly. mens MES portfolio. Decisive factors in the
selection were flexibility, capabilities and
A large part of the produce is destined for performance.
the local market but a fair share also finds
its way to several markets in Europe, SIMATIC IT Unilab was designed to fill the
Africa and America. gap between lab and production environ-
ments. It manages lab workflows and opti-
Product quality and service are top priority mizes collection, analysis and reporting of
at Mahou-San Miguel. The company makes quality data from lab instruments as well as
continuous investments in tools and meth- process data captured from the production
ods to keep quality, security and efficiency lines.
at its plants at world class level.
Mahou-San Miguel is ISO 9001:2000 certi-
fied for its quality management system in
product development and production and
strongly committed to product quality.
The main LIMS functionality in use at In their requirement specification Ma- They also wanted the system to register
Mahou-San Miguel is: hou-San Miguel defined an information the activities of any analyst at any given
• Management of all quality data (raw management system to efficiently ma- time, which is going a step beyond the
material, finished products, environ- nage all quality data and activities in the rules set by the ISO 9001:2000 stan-
mental samples, etc.) labs. The tool had to support compli- dard.
ance with the EU food traceability law
• Full and flexible support for definition that applies since January 2005. And ultimately we needed the ability
and execution of complex test plans to monitor the equipment used for the
This law stipulates that a company must analyses, including interventions and
• Direct connections to lab instruments be able to trace back any substance invol- planned maintenance.”
and equipment ved in the production or distribution pro-
cess of food or feed products. José María Villero Salas, Lab Manager
• Immediate feedback on quality excep- at the Málaga brewery
tions “Above all we were looking for a system
that would enforce quality parameters The first 3 requirements were covered
• Support of quality standards such as and environmental checks in each step by the standard SIMATIC IT Unilab func-
GLP, GAMP, ISO, FDA, HACCP of the production process. tionality. Since Unilab is used to check
the quality during each process step it
• Compliance support to 21 CFR Part 11 Moreover it had to include a flexible re- is also possible to extend the use of its
porting module to let us create different functionality to actually manage tracea-
The labs at Mahou-San Miguel basically reports to evaluate the performance of bility during each production step, from
carry out chemical and physicochemical the plants and the labs. raw material intake to finished and pa-
analyses. Next to the daily environmen- ckaged goods dispatch.
tal analyses the labs take samples at The Quality Management wanted to be
various stages of the production pro- able to consult the quality parameters of
cess. all breweries in real time.
At a glance
Grupo Mahou-San Miguel
• enforce quality procedures
• integrate quality in production
• regulatory compliance
SIMATIC IT Unilab manages sample ta- These information cards render the LIMS • SIMATIC IT Unilab
king for each phase in the brewing pro- very configurable and offer a simple • SIMATIC IT Material Manager
cess. Each sample gets an information and user-friendly interface to the end- • SIMATIC IT Interspec
card specifying which steps it has under- users.”
gone, and storing all the related trace- Key Benefits:
ability information. José María Villero Salas, Lab Manager • cost-efficient quality operations
at the Málaga brewery • enterprise-wide Quality Management
“In case of raw materials for instance, • brand value
the information card describes the sam-
ple information, such as the date of re-
ceipt, the supplier, the material type,
the lot number, the supplied quantity,
the allocated tank, etc.
For an intermediate product the user
has to specify what raw materials were
used to make it and in which quantities.
During each step in the process the user
has to fill out the information card spe-
cifying what was used.
After the implementation of a manufactu- Integration capabilities and
ring execution system based on
SIMATIC IT, the Monsanto site in Antwerp flexibility
benefits from Totally Integrated Automa-
tion (TIA) through seamless vertical inte- The Monsanto project team with Christophe
gration and greatly improved traceability. Laureys (production systems engineer),
Alois Kimpe (master operations scheduler),
The customer and Danny Van Looveren (project leader)
performed a thorough screening of different
Monsanto is a leading global provider of ag- suppliers in the MES and warehouse man-
ricultural products and integrated solutions agement systems (WMS) market and de-
that bring together chemicals, seeds, and cided that the SIMATIC IT MES environment,
biotechnology traits to improve farm pro- a solution utilizing the benefits of Totally
ductivity and food quality. In terms of crop Integrated Automation, was best suited to
protection, the company is best known for meet the company’s current and future
its Roundup, the world’s topselling herbi- needs, as Van Looveren states: “The MES is
cide. The Antwerp production site consists the key element to guarantee the integra-
of a formulation units and several herbicide tion of all our components, ensuring opti-
canning- and bagging lines. mal production efficiency.
In 1995, Monsanto implemented a com-
bined manufacturing execution and ware- SIMATIC IT will help us by doing exactly
house management system at the Antwerp that. It consists of a collection of highly in-
production facility. This system, developed tegrated components, designed to integrate
specifically for Monsanto Antwerp, was with our third-party systems, standardize
modified and extended several times over our production, and keep our manufactur-
the years and has suffered from a lack of ing processes aligned with our supply chain
flexibility, as Danny Van Looveren, process activities. The product provides a high-level
control systems team lead at Monsanto, framework concept that enables the descrip-
confirms. tion of our manufacturing processes and
“We were faced with a system that was not
performing well compared to the ‘best of Another point in favor of SIMATIC IT was
breed’ systems available and that needed the fact that the system can be easily inte-
extensive and expensive maintenance,” he grated with the other TIA components such
says. Consequently, in late 2007, Monsanto as Simatic WinCC, which is used as a stan-
Antwerp decided to install a new manufac- dard on the Antwerp site, as well as with the
turing execution system (MES) to control Simatic PCS 7 process control system and
and optimize the production. Van Looveren the Simatic Batch batch control.
explains: “We wanted a solution that was With SIMATIC IT, Monsanto was also able to
compliant with the ISA S95 standard, and implement the project in phases, reducing
we wanted a system that was configurable, the impact on production and enabling a
not a customized solution.” smooth transition to the new system.
Staged implementation The project was developed on a virtual All settings are established through the
server infrastructure and was then trans- MES, eliminating manual processes –
In January 2008, Siemens received the ferred to the physical system. and that means we make fewer mistakes
order for the installation of the new than before. Another important aspect
solution. Siemens delivered a compre- “The project followed the Siemens project is traceability – that is greatly improved
hensive MES solution covering func- approach, and it went well”, says Van compared to what we had before.”
tional areas such as production order Looveren. “We enjoyed excellent colla-
management as well as goods tracking boration between the Siemens team and The replacement of the MES legacy sy-
and tracing. the Monsanto team and greatly benefited stem with SIMATIC IT enabled Monsanto
from having different people with diffe- to lower its total cost of ownership.
The SIMATIC IT solution consists of the rent competencies on the teams.”
standard-components Production SIMATIC IT also enables vertical inte-
Modeler, the Order Manager, and Pro- Christian Derck, projectleader of the Sie- gration between the process control
duct Manager. The MES is used as the mens team, experienced the same and and SCADA systems and the enterprise
standard integration platform for the replied “Through the high involvement of resource planning level, thus reducing
production machines and the various both Monsanto and Siemens team, duri- manual operations and manipulations.
business systems. ng all the phazes of the project, a smooth
and succesfull start up was realised.” Accurate tracking and tracing functiona-
Siemens was also responsible for the lity increases production visibility, resul-
requirements analysis, design and Higher operational efficiency ting in faster production cycles, avoiding
construction, and site acceptance tests. possible handling errors on production
And because the installed solution is Van Looveren is quite satisfied with the runs, and leading to fewer production
considered a mission-critical produc- results of the implementation: losses. After the successful implementa-
tion system, Siemens guarantees the “The thorough testing ensured that we tion of the first MES project, Monsanto
solution’s operation by means of a 24/7 had the system up and running with little intends to roll out the SIMATIC IT soluti-
support contract. effort and in a short time. From start-up, on on other lines as well.
we have had a system that runs smooth-
In the first stage of the implementation, ly, and it was very stable after only some Planned future steps also include expan-
starting in May 2008, SIMATIC IT was in- minor interventions.” ding MES functionality by implementing
stalled on the filling lines. In the second the OEE module for monitoring overall
phase, which was completed in Decem- The impact on production has also been equipment efficiency, and linking the
ber 2008, SIMATIC IT was linked up with positive: “The new system improves our MES with the WMS.
Simatic PCS 7 in the formulation unit. degree of automation in operation.
Growth Vitamins for Chinese Dairy
Mengniu Dairy Group - Quality Management solution with
SIMATIC IT Unilab LIMS
To be able to reconcile the exceptional Mengniu is known as ‘the dairy manufac-
growth of Mengniu Dairy Group with turer devoted to human health’. Several of
their strict quality policies and aim for its innovative products have received quality
continuous production efficiency impro- excellence awards.
vement, it was decided to replace the
existing traditional information systems The business challenge
with a single enterprise-wide quality in-
formation platform based on SIMATIC IT “A cow runs as fast as a rocket” is a pun that
Unilab. expresses very well the exceptional speed
Now the people at the Mengniu Helingeer of growth and innovation at Mengniu Dairy
site, including 5 production plants, 4 QC Group if you know that Meng means Inner
departments, and an R&D Analysis Cen- Mongolian, Niu is Chinese for cow.
ter, a total of 13 labs, carry out their daily The resulting production capacity increase
work on the SIMATIC IT Unilab platform. and the strict quality control put a heavy
Features such as direct instrument con- burden on the lab personnel.
nection, advanced reporting and easy and The traditional paper and spreadsheet based
secure data access are already contribu- information systems could not meet the in-
ting to lab efficiency, data accuracy and creasing management information require-
continuous quality improvement. ments.
The customer Mengniu needed a quality information man-
agement platform to replace the time-con-
Mengniu Dairy was established in 1999 suming and error prone manual download
with headquarters in Helingeer County, In- and data entry of instrument test results
ner Mongolia, the Chinese Dairy Capital. and manual collection and merge of dis-
The Mengniu Dairy Group employs 30,000 tributed quality data from different quality
people and booked a revenue of 16.25 bil- control departments for reporting purposes.
lion yuan in 2006. The system had to be compatible with the
Their production capacity is 5 million tons current Mengniu Group quality manage-
per year. This makes Mengniu the world’s ment system and offer full LIMS functional-
largest producer of UHT milk and China’s No ity, including sample management, equip-
1 for liquid milk, ice cream and yoghurt. ment calibration, personnel management,
More than 200 different products and material management and related cost
product variations including liquid milk, calculation and management.
ice cream, milk powder, and milk tablets
are produced at the production plants in It was expected to meet the requirements
Helingeer as well as at more than 20 other of different types of labs and support corpo-
Mengniu production sites in over 15 Chinese rate quality control through flexible report-
provinces. The market for these products ing and tools to improve work efficiency,
includes China, USA, Canada, Mongolia, and standardize lab workflows, and optimize
Southeast Asia. data analysis.
The solution strong IT skills but can be done by the lab bility are guaranteed by the Electronic
personnel themselves. Signature and Audit Trail rules defined
The pilot project was started at the He- within SIMATIC IT Unilab.
lingeer site in March 2007. The system This drastically reduced the programming
went live in the first QC Department and customization efforts and allowed Unlike other LIMS systems SIMATIC IT
in July 2007, and was fully operational the lab users to be involved from the Unilab is not just a stand-alone LIMS
to replace the old system after another early design phase and ensure maximum but also a component of SIMATIC IT,
month. coverage of their requirements. the fully integrated MES solution that
One important function was the direct is currently already active at one of the
Now, SIMATIC IT Unilab manages the instrument connection to SIMATIC IT Helingeer plants, ensuring an efficient
quality workflow and resources in diffe- Unilab. Take for example, the FT120 ana- exchange of plant quality data between
rent Helingeer labs, including produc- lyzer located in one of the production LIMS and MES.
tion labs, quality labs, and R&D labs, for labs. This instrument alone generates
raw material, semi-finished product, fi- about 400 samples a day. Through its open concept, SIMATIC IT
nished product, packaging material, and Unilab can also interface with 3rd party
environmental tests. Now all the test results from all instru- software such as the current Raw Milk
ments in different locations are auto- Management system that provides raw
This amounts to over 1,500,000 matically sent to SIMATIC IT Unilab and milk sample information.
samples per year. stored there. This automatic data transfer
resulted in more accurate and real-time Finally, the flexible and convenient
The system offers a user friendly inter- quality data. And without the need for reporting tools ensure real-time avai-
face and flexible configuration tools. manual interruption, the analyst wor- lability of quality data throughout the
The configuration of main objects, such kload was greatly reduced. company and display these data in a
as sample types, info cards, parameters, structured way for management infor-
methods, specifications, test frequen- At the same time, for regulatory compli- mation purposes.
cies, sample lifecycles does not require ance purposes data integrity and relia-
At a glance
Mengniu Dairy Group:
Siemens Industrial Automation Ltd.,
• increase work efficiency
• standardize workflows
The pay off • enhance quality control
• improve data analysis and reporting
The result is an advanced LIMS solution
that saves time and reduces errors. Also Solution:
• SIMATIC IT Unilab
thanks to the system’s open and flexible • SIMATIC IT Report Manager
architecture, the solution could be rolled
out quickly to other sites after the pilot. Key Benefits:
• corporate shared quality
Now, a centralized system serves all of
• guaranteed data accuracy and safety
the sites in China, which does not only • reduction of paper based activities
limit system maintenance efforts but • reduction of operational cost
also makes it possible to share quality • integration of data and information
data in real time throughout the compa- • improved quality and productivity
ny across plants.
This provides Mengniu Dairy with the
right tools for continuous quality and
How many Bottles of Beer on the
MES solution at Palm Breweries
In 2008 Palm Breweries equipped its sites The business challenge
in Steenhuffel and Roeselare (Belgium)
with an MES system based on SIMATIC IT Palm Breweries is a growth-oriented
by Siemens and implemented by Actemi- company and doubles its volume every 10
um. years. Realizing this ambition and combin-
ing it with their high standards in terms of
An evaluation of the system shows that quality motivated Palm Breweries to want
the strategic project targets, traceability, to become an example of wall-to-wall trace-
integrated quality and process improve- ability.
ments, have been reached or even excee-
ded. Before, a custom made production informa-
tion system had been in place and served
The customer its purpose quite well for over ten years.
But come 2006 it was getting obsolete, no
Palm Breweries is a brewer of genuine Bel- longer suitable to cover evolving business
gian Beers and the only brewer in the world needs such as increasingly strict tracking en
to brew using all 4 fermentation methods tracing requirements. It also lacked the ca-
(top, bottom, spontaneous, mixed). Palm pabilities to supply reliable information that
Breweries is an independent family-run was needed for continuous improvement
brewing group headquartered in Steenhuffel and cost savings, such as raw and auxiliary
(Belgium) with breweries in Steenhuffel and material consumption and quality costs.
Roeselare (Belgium). Palm also operates Making that kind of information available in
a joint venture with brewer Frank Boon in the old system took up to three days, which
Lembeek (Belgium). was discouraging, and often resulted in lost
The brewery group has made relentless ef-
forts over the years to maintain the unique It was clear: the time had come for a new,
and regional styles in their original form. standard solution. A reliable system that
Their beers, such as Rodenbach, Palm, would facilitate regulatory compliance, help
Brugge Tripel and the Geuze Beers by Boon, reduce and rationalize consumption of raw
contribute to the beer culture that makes material and additives, as well as energy,
Belgium so unique. and avoid costs of non-quality.
Screen 1: Planning Brew Orders Screen 2: Stock Overview
The project The solution At the end of the bottling line finished
products are palletized and labeled with
At Palm Breweries a dedicated MES The functional focus of the implementa- a pallet label generated by SIMATIC IT.
project team was put together consi- tion lay in production and quality. Related information is captured and fed
sting of production management, logi- The implemented solution is based on back to the logistic system to ensure
stics management, lab management, SIMATIC IT Production Suite and SIMATIC traceability towards the customers.
and a number of IT people. IT Unilab (LIMS).
Reporting during each production step
They made up a business case by ca- SIMATIC IT Production Suite receives pro- is covered by SIMATIC IT Report Manag-
refully mapping and calculating the duction orders from the production plan- er. A number of the reports used at Palm
expected costs and advantages of such ning application based on sales forecasts. Breweries were made by Actemium.
a new system so as to justify the invest- These production orders are visualized But the tool is an intuitive one and al-
ments with the board of directors. in a graphical way to facilitate detailed lows for authorized users at Palm to cre-
This business case was the basis for de- production planning and issue orders (to ate their own reports.
tailed user requirement specifications. the brew hall, fermentor, bottlling line,
Palm Breweries chose to work with a etc.). Operators receive their orders on- The reporting on KPIs is now fully au-
business consultant (S&V) in this phase screen at the production line, together tomated and it is possible to further
to help them select a system that fitted with all relevant details, such as which analyse and drill the data from different
their overall IT strategy. In retrospect, quality checks to perform, and the Bill of angles. This enables benchmarking and
this is considered a strong success fac- Materials. Data for tracking and tracing root cause identification, f.i. by compar-
tor. purposes are registered per lot. ing the same process step in different
lots during a certain period. The system
The user requirements were drawn up Upon production order creation is also set up to make hourly compari-
according to the ISA-95 standard. SIMATIC IT Unilab determines for each sons and send email notification alerts
This proved very useful during the ex- production step, including end products, in case of deviations.
ploration of the MES market, ISA-95 which samples need to be taken, and
being the common “language” of MES which tests to be carried out by whom The historian functionality of the system
vendors and system integrators. (e.g. by the operator, or by a qualified lab will allow Palm Breweries to realize pro-
Eventually the choice fell on a combina- analyst). Lab analysts as well as operators cess and quality improvements by inter-
tion of Actemium as system integrator now get clear work lists from the system preting, correlating, contextualizing and
with a solution based on Siemens soft- and know which samples to take and trending historical data.
ware. The chemistry with Actemium which analyses to perform.
worked very well for Palm Breweries and This has already been put to good use in
the standard-based SIMATIC IT software Thanks to the connection of the lab in- the case of two beer types when it was
was a good match for the user requi- struments to the system the capturing of possible to indicate that a modification
rements. The future proof automation test results is automated. This saves a lot in the recipe would result in more con-
concept also anticipated the growing of time, and helps improve data quality stant quality.
complexity within the company. by avoiding errors through manual data
entry. The end user is unencumbered by the
Throughout the project the steering underlying systems and modules. Each
group kept a close eye on project timing All analysis results are checked against user has an integrated screen that dis-
and budget, making sure both were parameters and stored in SIMATIC IT Uni- plays all required information according
realistic from the start, and that they lab. The release or hold of raw materials to his specific user profile, combining
were stuck to until the end. or products is based on these test results. data from different systems.
Success factors 2.5% cost reduction packaging
A key success factor in this whole story Interfacing the planning module in the At a glance
was the composition and continuity of MES system with the purchasing module
the project team and the consistency in in the ERP system facilitated planning and Company:
their requirements. The people who de- reduced the need for rush orders. Palm Breweries (Belgium)
fined their requirements to the system That put the brewer in a better position www.palmbreweries.com
remained available throughout the proj- for sourcing packaging material.
ect to see to it that they were met. This Industry: Brewing
strongly benefited mutual understand- 25% reduction in cost of non-quality
ing between Palm Breweries and their Quality tolerates no compromises at Palm System Integrator: Actemium
system integrator and made the project Breweries. That was the main motivation www.actemium.be
actual fun. in the implementation of the LIMS (labo-
ratory information management system) Key Challenges:
Furthermore 3 employees of Palm SIMATIC IT Unilab. Together with produc- • Traceability
Breweries spent a week at the SIMATIC tion monitoring, this led to improved • Process improvements
IT training centre in Genoa to enable quality consistency and an increase of the • Consistent high Quality
them to understand the standard sys- in-house quality index at Palm.
tem and actively contribute in the solu- Solution:
tion design phase. Improved Service level in B2B • SIMATIC IT Production Suite
In case of contracting for other breweries • SIMATIC IT Unilab
The Results the MES contributes to B2B customer
satisfaction thanks to the ability to Key Benefits:
1% reduction in raw material, 2% in provide quick and accurate reports about • Cost savings (material usage,
auxiliary material consumption the production of their goods. work force efficiency)
In the past one had to use Excel to • Improved quality at lower cost
compare purchased quantities of mate- Having the same level of insight in • Corporate image and brand
rial with sold end products and deduce production at your contractor’s as in your enforcement
loss quantities from that. But finding own production inspires confidence. • Customer satisfaction
out exactly when and where the losses • Regulatory compliance
occurred was complicated if not impos- Job satisfaction • Reduced energy consumption
sible. This was solved through storage Having a reliable system in place con- • Happy workforce
of historical data in a historian. The re- tributes to a professional environment
sulting link between process and quality that empowers the workforce to be more
data makes it possible to relate losses to efficient and inspires self-confidence.
a specific lot, process step, or period and Working with such a system enables
make comparisons in order to reveal po- people to help reveal new potential for
tential for material and energy savings. improvement.
Continuous quality and innovation
Qingdao Tobacco Factory: MES solution with SIMATIC IT
After an in-depth analysis of MES vendors The customer
Qingdao T.F. chose Siemens, based on its
domain knowledge and global experience Qingdao Tobacco Factory is the largest to-
in the tobacco industry and its specific bacco company in North China, with 1,600
expertise with tobacco industry work pro- employees.
cesses and production practices.
The factory has an annual production ca-
SIEMENS automation products are imple- pacity of more than 1.2 million boxes ciga-
mented throughout the plant, which faci- rettes. Fiscal year 2006 generated 5.42 bil-
litated system integration, reducing the lion RMB (0.7 billion USD) in sales, with 570
cost, time and risk of the project. million RMB (74 million USD) margin.
SIMATIC IT delivers all of the functions Qingdao T. F. has in-depth knowledge of the
defined by ISA-95 and leverages the Chinese Tobacco market and leverages that
work-flow management concept knowledge together with its industry-lead-
(Production Modeler), and fully supports ing manufacturing capabilities to rapidly
a Service Oriented Architecture (SOA). respond to trends and opportunities.
This unique combination of capabilities, This success is supported by their ongoing
architecture and tobacco-specific know- quality management efforts as well as their
ledge fulfilled the requirements defined research and development innovations.
by Qingdao T.F.
The business challenge all the other applications, creating a tor every key performance indicator.
seamless IT “fabric” where each applica- Through the tight integration between
Strong market competition led Qingdao tion is equally accessible. ERP and MES, the generation of the pro-
T. F. to the realization that they needed duction plan was reduced from 4 hours
to reduce manufacturing costs and stan- Qingdao T. F.’s challenge was to over- to 10 minutes.
dardize manufacturing operations. come a disparate IT architecture and
replace it with a collaborative architec- Through the implementation of a
MES became the logical solution for ture that could accommodate the work centralized product specification system
controlling costs and streamlining op- processes unique to the tobacco industry, (SIMATIC IT Interspec) natively integra-
erations. while embracing international standards. ted with SIMATIC IT Production Suite
(that handles production execution), the
MES solutions enable decision making Their solution needed to completely release of the production process speci-
across multiple levels of the organiza- cover the functions addressed by the ISA- fication dropped from 4 hours to 1 min-
tion. Qingdao T. F.’s goal is to produce a 95 specification. This level of complexity ute.
digital plant supported by what they call is a significant challenge for vendors and
a CIMS System. customers alike. By streamlining the production process-
es as defined in SIMATIC IT workflows,
CIMS supports the concept of Collabora- The solution the production department realized an
tive Manufacturing, where individual average of 1 hour drop in the cycle time
plant applications interoperate in real Qingdao T. F. entrusted Siemens with the for each complete production cycle.
time, orchestrated by workflows. challenge of improving their manufactur-
ing information systems by implementing Siemens has provided Qingdao T. F. with
Collaborative Manufacturing increases SIMATIC IT modules. a SIMATIC IT library which delivers stan-
overall production profitability, by im- dardized information through reports
proving an individual plants’ efficiency SIMATIC IT provided the framework that and browser screens. These reports
while improving decision support at the spanned the gap between the ERP, and provide real-time information such as
headquarters with real-time, focused the controls layer. SIMATIC IT linked efficiency data.
key performance indicators (KPI). Within together all other applications and
this CIMS system there are 11 subsys- delivered almost all of the functionalities The production departments use this
tems. In such a complicated IT environ- mentioned in ISA-95. information to optimize the process and
ment, chaos could easily occur. to guide continuous production efforts.
Thanks to SIMATIC IT, the factory manag-
MES, serving as an interoperability and ers can now easily get the information
coordination layer, communicates with from each production step and can moni-
At a glance
Qingdao Tobacco Factory:
Siemens Factory Automation
Engineering Ltd., Beijing:
• reduction of operating costs
• improvement of production
• enhancement of product features
• accelerated new product
• improvement of enterprise
The pay-off The time saved during operations and the
dramatic reduction of errors during data Solution:
• SIMATIC IT Production Suite
Improving production management, input (now handled automatically) made • SIMATIC IT Historian
increasing product quality and introduc- the SIMATIC IT solution pay back very • SIMATIC IT Report Manager
ing new products to market faster were shortly. In the end Qingdao T. F. found • SIMATIC IT Interspec
• SIMATIC IT Unilab
the main objectives set forth by Qingdao that SIMATIC IT came out as the perfect
T. F.. They knew that a lot of the data solution. Key Benefits:
they needed existed but was not readily • strengthening of the competitive
accessible. • enhance product features and
And, a lot of information was the result • rapid Return on Investments
• total Cost of Ownership reduction
of the correlation of data from disparate • integration of data and information
applications. Siemens, with SIMATIC • optimization of Production Pro-
IT, gave them the tools they needed to cesses
most effectively manage their produc- • improvement of Asset utilization
• reduction of paper based activities
tion data and processes, streamline their • quality and Productivity Improve-
work processes and deliver decision sup- ment
port information to their workers.
Blending SAP with detailed
R.J. Reynolds: Specification Management Solution
with SIMATIC IT
R.J. Reynolds Tobacco Company deploys The business challenge
SIMATIC IT Interspec as their Product
Specification Management Solution in Following its 2004 merger with Brown &
parallel with SAP deployment. SIMATIC IT Williamson Tobacco Corporation, the “new”
Interspec is managing all Product Speci- R.J. Reynolds Tobacco Company was faced
fications, is fully integrated with SAP and with managing the complex specifications
supplying tremendous results in support of a diverse product portfolio.
The customer Product specifications had previously been
managed in legacy (internally developed
R.J. Reynolds Tobacco Company, an indirect and supported) applications.
subsidiary of Reynolds American Inc. (NYSE:
RAI), is the second largest tobacco company The legacy applications had expansion limi-
in the United States, manufacturing about tations and obsolescence issues and needed
one of every three cigarettes sold in the to be replaced.
Additionally, a new Product Specification
R.J. Reynolds is based in Winston-Salem, Management solution was required that
N.C., and has about 5,800 employees. could interface to both their new ERP imple-
It has approximately 30 percent of U.S. ciga- mentation as well as other legacy systems.
rette sales. The company’s brands include
five of the 10 best-selling U.S. cigarette A more contemporary specifications man-
brands: Camel, Kool, Winston, Salem, and agement solution was required, that could
Doral. provide more versatility and reduce the
complexity of the processes required to
manage and maintain product specifications
from conception to finished product.
R.J. Reynolds made the decision to imple-
ment SAP as their new ERP system and
made the selection of Siemens SIMATIC IT
Interspec to manage specifications for all of
The solution SIMATIC IT Interspec also helps speed
new products to market by streamlining At a glance
An aggressive schedule of implementing review processes and eliminating manual
SAP with SIMATIC IT Interspec and data entry into multiple disparate sys- Company:
R.J. Reynolds Tobacco Company:
SIMATIC IT Data Integration Services tems. www.rjrt.com
(DIS) was undertaken. SIMATIC IT Inter-
spec was deployed as an enterprise solu- SIMATIC IT Interspec fully supports key Industry: Tobacco - Cigarettes
tion and the sole source for all product functional elements such as planned Key Challenges:
specifications. packaging rotations, global updates, • replacement of Legacy Solutions for
change versioning, and multiple bills of Product Specification Management
Tight integration with SAP was vital to material versions. • enterprise moving to SAP - new so-
lution must integrate well with SAP
the success of this project and R.J. Reyn- • SAP being deployed in parallel with
olds utilized the SIMATIC IT Framework, The pay-off tight timeline
with Data Integration Service (DIS) and • Integration of brands from
R.J.Reynolds and Brown &
Production Modeler (PM), to manage R.J. Reynolds now has SAP and SIMATIC IT Williamson
this interaction with SAP. Interspec up and running and producing
excellent results. Solution:
• SIMATIC IT Interspec
The tight integration allows for the • SIMATIC IT MIS Bundle:
detailed material and production bill Detailed Product Specifications are now • SIMATIC IT Data Integration
data to move in near real time seam- managed for all products. Specification Services
lessly between SAP and Interspec. changes are being implemented in record • SIMATIC IT Production Modeler
• SIMATIC IT Historian
SIMATIC IT Interspec as a Product Speci- time and time to market for new products • SIMATIC IT Report Manager
fication Management solution supports is being impacted in a very positive way. • SIMATIC IT Client Application Builder
the creation and maintenance of the
definition of all specifications used in • speed time to market for new prod-
the manufacturing process. ucts and product changes
• tight Integration with SAP
• flexible Specification Approval Pro-
SIMATIC IT Interspec provides a very cess
flexible approval process, in which all • quick collaboration between all De-
relevant parties can quickly collaborate partments
on any required changes to existing • Interspec as a sole source for all
products. • streamlining of specification review
Product changes can be communicated
and approved quickly, as it is easy to
determine who still needs to take action
for final specification approval.
Cream of the Crop
Rosen Eiskrem, Germany
Rosen Eiskrem, Europe’s largest private ice cream producer, has thoroughly modernized its
process control and connected it with goods management in the ERP system.
The customer and beverage industry. Rosen Eiskrem can
handle complete orders in the new MES.
Rosen Eiskrem GmbH has been developing
and producing ice cream for the European Customer orders are created in the enter-
consumer food market for more than 40 prise resource planning (ERP) system and
years. transferred to the MES, which generates
the appropriate batches. The batches are
With four factories in Germany and an an- created fully automatically in Simatic Batch.
nual capacity of 230 million liters, the tra- The operating personnel merely start the or-
ditional company is Europe’s largest private ders in the MES and monitor the execution.
ice cream producer and can make any prod-
uct the market wants within a short time on The Simatic PCS 7 process control system
31 production lines. controls and visualizes the entire weighing
and mixing process.
The existing process control and control
system of the ice cream mixing plant at the The status of the batches and information
company’s Nuremberg site were to be re- about consumed material and finished
placed after 15 years in operation. products are archived in the MES during run-
time and can be traced continuously.
There were other goals connected with this
upgrade: quality improvement, a reduction A considerable improvement in quality was
in manual work, an increase in flexibility achieved by the introduction of a radio
and process efficiency, absolute production scanner solution that makes sure that addi-
transparency, batch processing on several tives can be added manually only at specific
levels, and long-term archiving. In addition, recipe times and checks the manual inter-
the new solution was to be commissioned ventions for plausibility.
This largely rules out the faulty feeding of
Modernization with Siemens additives. The MES reports all order and
consumption information to the ERP system
After an extensive comparison of available automatically.
solutions, Rosen Eiskrem chose a combina-
tion of standard products from Siemens: This communication prevents double entries
SIMATIC IT Production Suite, Simatic PCS 7, and input errors and allows the automatic
Simatic Batch, and a special manufacturing creation of reports and evaluations of pro-
execution system (MES) library for the food duction and quality.
Proven benefits Redundant server systems make the solu-
tion highly available. The system can also Project facts
The system was successfully commis- be extended easily without impairing ex-
sioned in January 2009, and Rosen isting configurations. Challenge:
To replace the old process control and
Eiskrem now produces up to 450 tons of control system and integrate the new
ice cream mix based on approximately This secures the investment for the fu- solution at the ERP level
400 recipes every day. ture. Georg Hassil, CEO of the Central
Supplies Department at Rosen Eiskrem, Solution:
• Simatic IT Production Suite
All the production and material data are sums up: “We are very pleased with the
• Simatic PCS 7
archived and are available clearly and entire Siemens system and the company’s • Simatic Batch
consistently at the push of a button. service throughout the project. Our main • MES food and beverage library
goals were all achieved, and we would
The new system reduces manual work, not hesitate to give this contract to Sie- Results:
• Improved quality and process control
improves the quality and effectiveness mens again.”
• Improved data quality and data
of production, and is also an important transparency
step in the direction of a paperless envi- • Production know-how available in
ronment. the MES at any time
• Less manual work
Flexible and user-friendly Web interfaces • Lower production costs
allow company-wide MES access via the
The SIMATIC IT portfolio holds all the cards to enable responsiveness and openness, and
link the manufacturing environment into the supply chain.
SIMATIC IT Production Suite is a plant tion at every level in the organization with and including post-installation technical
centric yet fully scalable collection of MES advanced role-based visualization based support. The cooperation with certiﬁed
functionality designed according to the on the latest Microsoft technologies. partners ensures a worldwide service and
ISA-95 standard. The scalability applies to maintenance network with an outstanding
the scope of functionality as well as the SIMATIC IT also includes speciﬁc packages skill level and expert know-how. This entire
number of plants within an organization. that cover the requirements of the process, portfolio ﬁts within the Siemens concept
SIMATIC IT R&D Suite, an offering dedi- the discrete or the life science industries. of Totally Integrated Automation’ – linking
cated to process industries, is a software These are best practice solutions bun- shop ﬂoor to top ﬂoor, as well as offering
platform managing all work and dataﬂows dling dedicated functions and operational the possibility for a ‘one stop shop’ from
related to R&D in an integrated way. It links expertise for these speciﬁc industries. The control and automation, to MES, ERP and
the R&D environment with the production SIMATIC IT offering comes completed with even PLM activities from order creation to
ﬂoor and speeds up time-to-production an innovative offering of Value Added ﬁnished goods. Seamlessly integrated with
and time-to-market. Services. These cover the entire product automation and business systems, MES
SIMATIC IT Intelligence Suite translates crit- and project lifecycle, from the consultative helps you manage your entire plant opera-
ical, real-time manufacturing information analysis of the investment requirements tions on a global scale.
into business-level performance indicators, with the value framework tool, over the
managing and distributing the informa- project implementation, product training
Swift Take-off, Smooth Landing
Alenia Aermacchi: MES solution with SIMATIC IT
Alenia Aermacchi implemented SIMATIC to the customers. In this considerably com-
IT as their MES solution, and integrated it plex organization it is especially hard to of-
with the existing IT infrastructure. fer their customers the complete traceability
The modular approach of SIMATIC IT has they require.
allowed Aermacchi to adequately cover The previous production information system
their extremely complex production envi- consisted of a solution developed in-house
ronment and address the resulting requi- and offered very precise rules and functions
rements. that allowed to manage the complex pro-
duction in a dynamic and at the same time
The customer accurate manner.
However, being an own creation, the system
Alenia Aermacchi is a world leader in the posed some major limitations in terms of
design, production and support of military technological obsolescence and was heav-
training and civil aircrafts. The company has ily encumbered by the alphanumeric user
built over 7,000 aircrafts including about interfaces.
2,000 trainers, distributed to more than 40 A specific requirement of Aermacchi to the
countries. They also collaborate with major system was that, unlike its predecessor,
international military programs. Aermacchi it should operate in a Windows environ-
was acquired by Finmeccanica in 2003. The ment because this allows information flows
company is based at Venegono Superiore throughout the company. The system also
(Varese province), with facilities of about had to be able to accommodate new tech-
274,000 m² including airfield, extensive nologies, such as RFID.
structural laboratories and workshops, wind With the previous system it was possible,
and water tunnels. Aermacchi has always based on the ‚part number‘ to trace all re-
deployed highly qualified personnel and lated information but it was not possible to
leading edge technology. take into account new requirements arisen
Their workforce totals 1,880 people. in the meantime. Besides, the system was
unable to manage personnel in relation to
The business challenge the production operations and could not
handle the numerically controlled machines
Aermacchi produces training aircrafts and the company had recently introduced.
nacelles, or aircraft engine housing. Basically, the old solution used to be a good
Though for aerospace standards the com- one but proved absolutely unfit for the new
pany is a small to medium-sized one, they millennium. A system was needed that
produce several thousands of units to cover would stand the test of time. And that is
the orders of a couple of dozen of large precisely why the choice fell on SIMATIC IT.
customers. Their activities range from the
production of individual parts up to the as- Being part of the Finmeccanica Group, the
sembly of complex machines, galvanic coat- choice was also driven by the need to meet
ing and structural assembly of the aircraft, the group’s demand for standards both on a
as well as the delivery of the aircraft or parts national and an international scale.
The solution „A constant communication between this results in a monthly delta of only
SAP and MES is essential. It is not easy to 18 hours between worked hours and
The set up was thus that the production find a system that speaks with SAP at the production hours, over a total of 650
cycles are managed by SAP, and though, same speed and with the same readiness workers, and this discrepancy is mainly
under aviation law, they must still be as SIMATIC IT“, reaffirms Tomassini. “The due to the fact that the system rounds
produced in hard copy the system was alignment of the two systems also allows them off.“
designed to support electronic signature for accurate evaluation of workloads,
already to facilitate the eventual switch which is one of the toughest ones to The pay-off
to the so-called ‚paperless factory‘. manage.”
The project was carried out by Elsag, so-
What is rather unusual at Aermacchi is An important matter at Aermacchi has lution provider within the Finmeccanica
the fact that SAP manages the produc- always been the evaluation of product group together with TXT e-solutions and
tion times, which are not set values but cost. The relation between job tickets and supported by Siemens for consulting
are calculated based on actual work registered operators is closely monitored. in terms of development and technical
cycles. This allows for a real assessment All people in the factory must be opera- support.
of the lead time for a part. tional and working on a job-ticket.
Though generating cycle times in SAP This helps the production management SIMATIC IT was optimized to enable
is not obvious, it does have great ad- at the end of each month to demonstrate intelligent handling of the huge data
vantages when it comes to MRP and that the number of worked hours coin- quantities and the relations between
inventory because with this approach cides with the production hours. This is a them. In terms of production volumes
the MRP is based on actual lead times, major information requirement from the Aermacchi completes about one aircraft
which eliminates the risk of over-sched- management. per month in comparison to two na-
uling and procuring too much material. celles per day.
This may seem simple but one should
“Aermacchi gains a strong competitive not forget that Aermacchi manages an When looking at the speed of produc-
edge from integration of all information enormous number of parts, (e.g. a plane tion the difference is significant, the as-
systems: SAP for the administrative and is made up of about 40,000 part num- sembly cycle of an aircraft taking up to
financial aspect, Catia, the system for bers). Each part number has its own work a year, versus that of a nacelle taking a
virtual factory, and Siemens SIMATIC IT, cycle which can in turn consist of 10 to couple of days.
for the MES level”, confirms Tomassini 15 steps.
(former Head of Engineering, Final As- Managing these different types of pro-
sembly). This means the system had to enable op- duction within the same factory creates
With regard to quality issues, rework erators to switch between job-tickets in a considerable complexity because the
operations are managed by SIMATIC IT. linear fashion and prevent discrepancies throughput time and the duration of the
All the hours spent on damage recovery between worked hours and production production steps are so different.
or other problems are detected by hours. „We have maximized the poten- An individual worker must be able to
SIMATIC IT and fed to SAP. tial of SIMATIC IT“ says Tomassini. „and work on several steps, but it must also
At a Glance
be possible for a team to work together The various phases of the process can
on a single production step, such as as- then trigger the SIMATIC IT components Company:
sembly. Therefore the system must be to perform the basic functionality. Alenia Aermacchi:
able to manage both teams and indi- www.aermacchi.com
viduals. This way it is possible to change the
logical rules of the factory simply by Industry: Aereospace
On top of this complexity comes the changing the connections between the
difference in handling between military different functions or components with- System Integrator:
and civil orders. out having to intervene in the actual TXT e-solutions:
“It is not easy to reconcile all this in one software. www.txtgroup.com
system”, confirms Tomassini, “What has
convinced us for SIMATIC IT is that it An important feature of SIMATIC IT is the Elsag Finmeccanica
consists of various modules which can fast access to technical data in formats www.elsagdatamat.com
be built together, and in case of changes such as PDF or Word, and to the design
in plant layout and thus in information system. Key Challenges:
flows, it only takes some changes to one • Manage large data volumes
module to change the downstream in- This way people do not have to search • Manage different production
formation flow.” and collate different types of information types and speeds
when they need it, because it is always • Real-time traceability
The complexity of the project at Aer- up to date and available with a simple
macchi required nearly all the double click: another step towards the Solution:
SIMATIC IT components to cover order paperless factory. • SIMATIC IT Production Suite
management, material management,
personnel management, cost manage- A further future development is the sup- Key Benefits:
ment, SAP interoperability, performance ply chain management. SIMATIC IT will • Flexible manufacturing processes
analysis, reporting. Each module corre- allow suppliers to access the system at • “Paperless factory” enabled
sponds with certain operations. certain stages and Aermacchi to check • Real-time production cost evaluation
the progress of the work.
Now, the logical and functional aspects
of the factory and production process Having suppliers around the world this
are defined in the SIMATIC IT Modeler. will surely be a strategic tool.
Johnson Matthey, Germany
Johnson Matthey gives its performance a double boost: with the SIMATIC IT
manufacturing execution system (MES), the company improves process safety
as well as productivity and makes employees’ jobs easier.
The customer availability. The order was won by the Bay-
reuth software company Xavo AG, which is a
Johnson Matthey is a global leader in manu- longtime certified Siemens Solution Partner
facturing selective catalytic reduction (SCR) with many years’ experience with the SI-
converters for heavy goods vehicles. The MATIC IT MES.
company operates an ultramodern manu- “We opted for SIMATIC IT because we are
facturing plant for catalytic disk and hon- certain of its technical suitability. It is an
eycomb converters in the German town of excellent platform that can be readily
Redwitz. Production must comply with strict configured to meet almost any customer
guidelines from both offi cial regulatory requirement. A further important consider-
authorities and customers, such as the ISO ation was that Siemens, the global leader
TS 16949 for automotive suppliers, and in automation technology, provides backup
must be completely documented and trace- service covering system maintenance and
able, as this is a prerequisite for ISO certifi- development,” explained Hans-Jürgen Pos-
cation. tler, project manager at Xavo.
The size and complexity of the module pro-
Standard system instead of duction was a particular challenge. Several
different processes run simultaneously
individual solutions around the clock, and up to 40 users have
parallel access to the system. User guidance
To optimize production, Johnson Matthey must support widely different tasks.
already had an MES in place, but in October The transparency of the processes must
2007 the company decided to replace it always be guaranteed, even when users
with a new, platform based system. are on the move with PDAs in the plant.
The company required an MES platform that Additionally, an enormous volume of data
would be highly configurable, increase – generated by the complete traceability
operational safety and productivity, and of all components – needs to be managed.
guarantee absolute traceability. Moreover, devices and systems with differ-
Johnson Matthey’s chief concern was high ent file formats must be integrated for the
stability during use, together with high individual processing steps.
Integrated and open for process. This includes management of Positive results
pallets and frames as well as complete,
extensions seamless tracing. The modules are identi- The new MES has significantly increased
fied by means of a data matrix code that transparency in production and has also
Conversion to the new MES was per- is applied during extrusion. been well received by employees.
formed in stages, with the implementa-
tion phases oriented to the material Data handling is extremely simple: once The decisive factor is the improved clar-
flow through production. In the first the pallets are driven into the furnace, a ity that has been achieved without cum-
phase (weighing, mixing, and knead- laser captures the label and the assign- bersome logging activities.
ing), the technology engineers needed ment is coded.
to optimize the composition of the As a result, the established team of
materials in such a manner that the re- Should the module code become unread- Johnson Matthey and Xavo is already
quired specifications were achieved. able for any reason, the system reliably planning the implementation of SIMATIC
prevents the assignment of a replace- IT in production planning as well.
The process for this was modeled using ment code, and the component must be
the SIMATIC IT Production Suite. rejected. This is a significant contribution
The Product Definition Manager took on to improved operational safety.
the task of recipe management with its
complex calculations of recipe param- The interface to the robots has also
eters. The conversion was automatically already been implemented for the con-
documented, without the requirement clusion of production phases in sawing,
for manual logging of offset versions. measuring, sorting, and packaging.
The second and third phases included
straining, extruding, and calcination. In the final control stage, the system is
also impressive in its display of the re-
The SIMATIC IT Material Manager main- markable data volumes it can process: 25
tains the product characteristics and measurement values relevant to quality
administers the batches and individual are captured and processed within one
components throughout the entire second, on a per module basis.
Innovation on the automotive
Pininfarina: MES solution with SIMATIC IT
As a global leader in automotive techno- Volvo C70, Alfa Romeo Brera and Spider,
logies, Pininfarina is always looking for Ford Focus Coupé-Cabriolet and Mitsubishi
ways of improving their production capa- Colt CZC. Among its resume of custom-
bilities. Leveraging their manufacturing ers are: Ferrari, Maserati, Peugeot-Citroën,
expertise to improve their processes, Renault, Jaguar, Honda, Daewoo, Hyundai,
Pininfarina looked to Siemens for an in- AviChina, Brilliance, Chery and JAC.
formation system to support their process The company has some 3.600 employees
improvements with increased operator and operates in Italy, France, Germany,
productivity. The solution had to deliver Sweden, Morocco and China.
to operators timely, accurate information Pininfarina Extra, the company’s design
about the production process allowing group, has been going for 20 years with
them to respond quickly to production customers including: Gancia, Jacuzzi,
events. The scope of this project included Lavazza, Motorola, Snaidero and 3M.
enhancements to the control systems
that were then integrated into the MES The business challenge
resulting in more complete information
for the operators, more robust and ac- Pininfarina needed an information system
curate production data and more rapid that would allow them to comply with car
response to process upsets and problems. builders requirements while minimizing
The SIMATIC IT-based solution is a user- the impact on operators, allowing them
friendly environment that supports the to focus on building products.
operators daily work processes through The solution needed to deliver the right
all phases of production from body-in- information at the right time without the
white and paint through final trim and distraction of other information.
inspection. And where possible the solution should
offload repetitive tasks such as data
The customer collection by capturing it directly from
the process through the automation
With a rich heritage of innovation and layer.
design dating back to 1930, Pininfarina is They also recognized the value of newer
a leading automotive services company. technologies such as radio frequency
Pininfarina has deep domain expertise in identification (RFID) to improve the
concept and design, product and process accuracy of information and reduce the
engineering, and niche vehicle manufactur- effort associated with data collection and
ing and leverages this knowledge to provide wanted the option of integrating these
creative solutions for OEMs. technologies into the solution.
Its recent project portfolio includes the
The solution •Automation interfaces control system product behavior to prevent critical sce-
integration to collect parameters from narios from arising. When installed on
The solution, designated CAP system production equipment, and to control SIMATIC IT Servers, software agents will
(Controllo Avanzamento Produzione individual production steps. analyze hardware related events, the
that can be translated into Manufactu- operating system and applications.
ring Work-In-Process Management) and The CAP system leverages automated Should predefined thresholds be excee-
implemented by Atos Origin Italia, is data collection to provide order compli- ded or potential problems detected, the-
based on SIMATIC IT, and has been desi- ance and genealogy records for each ve- se agents will send appropriate alarms
gned to provide Manufacturing Executi- hicle and part produced. ISO regulations to Siemens MES headquarters.
on System (MES) functionality, such as: require these types of documents, which As soon as they are received the alarms
are created manually and must be will be displayed automatically and can
•Production Order Management which maintained for a minimum of 10 years. then be acted upon. Siemens technical
includes creation and dispatching of As part of this solution, the control sy- personnel are able to prevent, detect
production orders based on demand stems were significantly upgraded to le- and solve most SIMATIC IT environment
from the ERP system and tracking the verage barcode readers and RFID devices issues based on incoming messages and
information and order attributes de- to increase the speed and accuracy of alarms.
fined from the ERP system. data capture. The infrastructure upgrade
also included new, web-based, graphical These are just a few of the many bene-
•Work-in-process tracking covering the user interfaces providing users with a fits provided by system monitoring with
tracking of production orders and comfortable, user-friendly work environ- SIMATIC IT Intelligent Agents:
production inventory by recording the ment for capturing user input. • Prolonged plant usage
events, movement and progress of The open architecture of the solution al- • Optimal application of available
production orders through the process. lows the system to be managed and con- resources
This includes providing visibility of the trolled centrally at their headquarters lo- • Reduced scrap
location and real-time status of all pro- cation while supporting operators across • Maximized output of better quality
duction orders. all three production facilities. This makes • Streamlined preventive maintenance
system management more cost effective measures
•Quality and conformance data collec- and responsive. • Improved productivity and profitability
tion where all relevant inspection and
dispositioning information are cap- Intelligent Agents from SIMATIC IT
tured and associated with the specific Rapid response for best results
production orders and serial numbers Thanks to the Agent Based Diagnosis
being produced. Service, part of the Siemens Maintenance
The system captures any errors or comprehensive program, the
non-conformance issues to insure that SIMATIC IT Technical support team is
any necessary rework has been prefor- capable of continuously monitoring
med and all issues have been resolved. Pininfarina’s production system and
At a glance
• streamlining and error-proofing
• intuitive operator environment for
capturing MES data
• fully-integrating machine control
with production order management
• SIMATIC IT Production Suite
• SIMATIC IT Historian
• SIMATIC IT Report Manager
• SIMATIC IT Client Application Builder
The pay-off Operators have embraced the user-friend- Key Benefits:
ly application which has streamlined pro- • automated order management and
The main goals of the project were duction while significantly reducing erro- production control
to improve the overall production neous data and production downtime. • real time WIP tracking and quality
throughput by increasing the speed and data monitoring
accuracy of data captured during the Siemens and Atos-Origin were selected • automatic anticipation of rework
manufacturing process and synchroniz- based on their capabilities and reputation • automatic collection of production
ing production activities with business of delivering on expectations.
• automated traceability for car body
priorities from the ERP system.
Pininfarina feels they chose wisely as the
The system was commissioned in system continues to deliver on those ex-
September of 2005 and has not only pectations each day.
fulfilled the requirements defined by
the business but has helped operators
focus on building quality products and
improving the manufacturing process
instead of manually documenting the
When operators are faced with deci-
sions, the system provides real-time
information, delivered in the proper
context and presented at the appropri-
ate level of detail.
Standing out through Traceability
Siemens Cornellá: MES solution with SIMATIC IT
In an effort to optimize both plant control The business challenge
systems and business processes, Siemens
Cornellá decided to fill the gap between The management at the Cornellá plant
the shop floor and the ERP system with saw room for improvement in the manu-
SIMATIC IT MES. facturing area, both with regard to quality
This communication platform optimizes and efficiency of plant control and business
the efficiency and quality of production processes as well as capabilities in terms of
data acquisition, which not only contri- traceability.
butes to the plant’s efficiency, but also
makes Siemens Cornellá the only vendor Additionally they wanted to introduce a
of traction motors for railway systems to higher level of information technology to
offer this level of traceability to its custo- the plant floor.
The implementation of systems to fulfill
The customer such requirements fitted with the strategy
to strengthen the competitive position
The Siemens factory in Cornellá belongs of Siemens Cornellá as well as that of its
to the Siemens Industry Sector and is customers.
active in the division DRIVES Technology,
more particularly in the business unit It was important to automate data flows
LARGE DRIVES. in order to be able to have quick and reliable
This business unit counts about 20 factories access to the large quantities of information
worldwide, employs 9000 people and that are needed for business.
generates a yearly revenue approximating
5 billion euros. A system was needed for automated acquisi-
Siemens is the worldwide market leader tion and aggregation of data from produc-
in the industrial drives segment and the tion control systems for statistical analysis
European number two manufacturer of and trending in order to increase plant avail-
drives for railway tractions. ability and support quality assurance.
The factory in Cornellá de Llobregat (near The system had to offer easy integration
Barcelona) accounts for a yearly sales with the ERP system (SAP R/3), and allow
volume of approximately 60 million euro. for acquisition and archiving of large vol-
For the next fiscal year the expected umes of machine data for statistical purpos-
growth is in the range of 40%. es, offering similar access to information
The Cornellá plant covers 30.000 m2. to people on the plant floor as to white col-
Here, 320 people are responsible for the lar employees.
yearly manufacture of nearly 1,700 traction
motors and converters for railway Furthermore it was of major importance
systems. From metal sheet cutting, over that the system be easy to use for less IT
production of coils, parts machining, up literate people, such as operators on the
to the assembly and final tests. plant floor.
The solution The SIMATIC IT solution was offered by butes to efficiency and traceability.
the Spanish SIMATIC IT Solution Partner Data on materials as well as updated
Several factors pointed to SIMATIC IT du- Specialist MESURE who could offer a material master data are transferred
ring the selection of a MES system. broad expertise in the MES area. from SAP to SIMATIC IT at regular inter-
Siemens is the market leader in the field vals.
of industrial automation and the solu- The project was implemented in a stepby-
tion offered covered all of the require- step approach. Eventually each of 5 All material movements during pro-
ments and specifications. areas related to the different manufactu- duction are registered by SIMATIC IT
ring methods (production of rotors, of Material Manager. When using a critical
All physical components in the wireless coils, of stators/armatures, assembly and material the system allows its in-line
network covering the plant were Sie- final testing, and parts machining) are registration.
mens too, as well as the controllers of to be covered by functionality for plant
the machine tools. management, quality assurance, material Operators receive production orders
traceability, and maintenance. from the system which gives them a re-
This only facilitated the integration with al-time view on pending jobs. They can
the SIMATIC IT MES (Manufacturing This way one area can serve as a pilot also register their activities as they are
Execution System). and the experience thus gathered can be carried out at their work station and up-
applied during the functionality “roll-out” date the order status using ‘Panel PC’s’.
Siemens is the only automation vendor to other areas.
to cover such a broad area with its offer. The system also makes manufacturing
Having one single vendor for all systems SIMATIC IT provides a standard platform instructions, construction plans, regu-
improves communication and respon- for integration between the control layer lations and guidelines available at the
siveness in case of incidents or system and the ERP level. This capacity of mutual working stations in their most recent
extensions or roll-outs. information exchange strongly contri- status.
The MES system enforces the execution This allows immediate feedback to SAP To secure maximum system and plant
of standard quality procedures by ma- for the creation of a maintenance order availability Siemens Cornellá opted for
king available a quality protocol for and the notification of the maintenance the Intelligent Agent principle in terms
each part to the operators. The quality department in case of machine or system of maintenance. The Intelligent Agents
measures are scheduled in the produc- failures. enable predictive maintenance.
tion model and through Autocontrol the
operator knows which quality assurance This can be done in real time from the They allow the SIMATIC IT support de-
parameters to check. working station rather than from a termi- partment to monitor the plant applica-
nal located in the offices. tion and alert Siemens Cornellá in case
This can be registered in the system at of imminent system failure and thus
the working station ensuring not only Any initial reluctance of people in the prevent downtime of systems and pro-
that the necessary checks are done but plant to adopt the novelty of working duction lines.
also speeding up decision making by the with IT systems was surmounted by the
operator. methodical project approach, the fact
that end users of all affected depart-
Data on the quality measures, times and ments were involved from the start, parti-
the operator who carried them out are cularly the people on the plant floor.
stored in the system for both internal
and external quality control. The user friendly web-based interface
offered by SIMATIC IT, supporting the
SIMATIC IT serves as a central informati- use of barcodes and touch panels, also
on exchange platform and also enables contributed to a smooth adoption of the
realtime communication on events. system by the users.
The pay-off What’s next? At a glance
All the manual processes, including The first of 5 project phases, being the Company:
quality processes are now automated. production of rotors has been up and Siemens Cornellá:
The communications platform between running since April 2007. www.siemens.com
SAP and production covers order man-
agement, material management and Additionally Quality assurance and mate- Industry: Discrete manufacturing
guarantees availability of up to date rial traceability have been activated in the
master data. manufacturing of casings and coils.
Right now the system is activated in the
Generally improvements can be seen last two sections, assembly and final
in compliance with delivery dates, the probes and parts machining.
through put times, and final product • introduce IT to the shop floor
quality. The increased efficiency in data This project will be presented as a best • large volume production data
capturing has resulted in serious im- practice to the 20 other plants worldwide acquisition
provements in the availability and reli- in the SIEMENS Drive Technologies - • interoperability
ability of production and quality data. Large Drives division to highlight the • traceability
The system enforces sequential handling potential.
of working steps and identification of Solution:
used materials. This has helped increase • SIMATIC IT Production Suite
plant efficiency and traceability. • SIMATIC IT Report Manager
When the project is finalized Siemens Key Benefits:
Cornellá will be the only vendor of trac- • fully automated production and
tion motors for railways to offer its cus- quality processes
tomers full and automated traceability • improved quality and throughput
of critical components. • reliable data for tracking and
The implementation of SIMATIC IT MES
has also positively influenced the per-
ception of the Siemens Cornellá plant by
the Siemens headquarters.
Just like a part of the family
Whirlpool: MES solution with SIMATIC IT
As a global player in the market for home The business challenge
appliances, it is essential to Whirlpool to
optimize the efficiency of their plants and Step 1
to be able to promptly react to changes in Whirlpool wanted to integrate the business
the manufacturing cycle. level with plant operations, in particular
concerning orders, material master data in-
As a solution, they decided for SIMATIC IT. cluding BoM (Bill of Materials), and produc-
The result was increased software stan- tion performances feedback.
dardization throughout the plants.
The existing MRP is exporting to and im-
The customer porting from MES these messages using
the Business to Manufacturing Markup Lan-
Whirlpool Corporation is the world‘s leading guage format.
manufacturer and marketer of major home
appliances, with 2006 annual sales of ap- During production execution, the require-
proximately $18 billion, more than 73,000 ment is to monitor the WIP (Work In Prog-
employees, and more than 70 manufactur- ress) of materials and orders. Additionally,
ing and technology research centers around Whirlpool wanted to apply the “Lean Manu-
the world. facturing” concept to its manufacturing
The company markets Whirlpool, Maytag,
KitchenAid, Jenn-Air, Amana, Brastemp, For this reason, they wanted to implement
Bauknecht, and other major brand names an order dispatching strategy in order to
to consumers in nearly every country properly handle the different.
around the world.
Step 2 (future implementation)
Quality management is a strong initiative
for the project. In order to monitor produc-
tion defects in an efficient way, every indi-
vidual item is monitored along the produc-
tion cycle by acquiring measures from field
devices (such as testing stations) to certify
In particular, quality assembly measures
(such as torques, stress, and others) are ac-
quired in order to calculate drifting curves
to prevent quality drops.
The solution The pay-off
At a glance
Up to now Whirlpool rolled out the solu- Leveraging the SIMATIC IT production
tion with SIMATIC IT in five plants across modeling capability, from the IT point Company:
Europe: Trento (Italy), Siena (Italy), of view the result was increasing the Whirlpool Corporation
Wroclaw (Poland), Poprad (Slovakia), software standardization throughout the http://www.whirlpoolcorp.com
and Napoli (Italy). Whirlpool is using plants by using a common library.
COPICS as European MRP (Material Re- The SIMATIC IT Cross-Industry Libraries Industry: Home appliances
quirements Planning) system but the contain basic functions for a range of
migration to SAP/R3 is already planned. functionalities needed to develop an MES
• integration of the business level
with plant operations
The existing MRP exports its orders and
• monitoring of materials and
material information in B2MML format The possibility of building a manufactu- orders for efficient quality
(XML files) that SIMATIC IT automatically ring system that uses this wide range of management
receives and dispatches it to the rele- technological bricks is one of the reasons • applying “Lean Manufacturing”
vant SIMATIC IT components for the use that allowed Whirlpool to implement the concepts to the manufacturing
in production execution. Production per- system in a very short time. lifecycle
formances are fed back in XML files at a • detailed production scheduling
very high rate from SIMATIC IT to MRP. Thanks to this infrastructure, also the
Particular care is placed in dispatching migration to SAP R/3 will be “bumpless”. Solution:
the right materials to the various equip- Due to the B2MML interface and to the • SIMATIC IT Production Suite
ments (workstations) where they have interoperability capability, MES and MRP • SIMATIC IT Report Manager
to be worked. This is aligned with a glo- are coupled and the migration on the ERP
bal strategy of Whirlpool to implement level will fully rely on this integration. Key benefits:
Lean Manufacturing concepts. Around This is also very supportive of the rollout • increased software
standardization throughout the
this concept, the strategy of handling of the application that is guaranteed by
the “pace maker” is defined. the SIMATIC IT approach.
• feeding back performances at a
high rate to the ERP
This strategy requires to find out the In fact, Whirlpool is not only planning
pace maker that is the production area additional rollouts but also additional im-
with the longer lead time and the right plementations in the existing installation.
product complexity, and to relate to this Whirlpool welcomed the performance
point the execution production plan and guaranteed by SIMATIC IT, as the require-
the material flow. ment for feeding back performances at a
Reporting and GUI (Graphical User Inter- high rate to the MRP was a crucial point.
faces) are native features of the entire And SIMATIC IT effectively addressed this
MES system makes solar cell
production more efficient
When the REC Group in Norway decided to expand and develop one of their factories for
the production of solar cell components, ÅF was contracted to implement the manufactu-
ring execution system (MES). This was done for the entire production scheme, from order
to delivery. By introducing the best available technique, ÅF could help its client to reach a
higher quality of product, a greater degree of capacity utilization and production as well as
improved energy efficiency.
Solar energy ÅF integrates the new system
The sun has always been an important REC produces wafers, a type of thin silicon
source of energy for humankind. plate used for solar cells. As this is a grow-
ing market, REC decided to expand one of
Solar energy has heated houses and dried their factories with a new production line,
food for preservation. In the future solar as well as upgrading their original produc-
energy is likely to play an important role in tion system. Production had so far mainly
meeting increasing energy demands. been manual, and the machines were old
and in need of an upgrade.
The development of solar power has been A Manufacturing Execution System (MES)
tremendous over the last few years, and the platform was needed, and for this REC chose
world market for solar cells has grown with The Siemens SIMATIC IT. ÅF was chosen to
about 40 percent each year. be responsible for integrating the system.
ÅF - leading the way in technical
The ÅF Group is a leader in technical
consulting, with experience founded
on more than a century of experience.
We offer highly qualified services
and solution for energy and the
environment, industrial processes,
infrastructure projects, development of
products and IT systems.
ÅF Group currently employs around
4700 people. Our base is in Europe, but
our business and clients extend right
across the globe. What make us unique
are our co-workers and the technical
consulting industry’s greatest bank of
It’s all summed up in our corporate
motto: “ÅF - innovation by experience.”
For further information please see
Monitoring wafer quality The solution
The production of wafers is performed The solution is based on the SIMATIC ÅF is also the Green Advisor to four
National Olympic Committees
in several different stages, and there are IT Production Suite. It handles product
quality control tests throughout this pro- genealogy, tracking and tracing as well
cess in order to maintain a high quality as orders. A major part of the plant
of product. equipment has been integrated with
the SIMATIC IT system using different
The production process can briefly be techniques. Lab equipment and about 70
described as follows: silicon is heated in crystal growing furnaces are integrated
an oven and grown into a long silicon with an XML interface. Two large shaping
ingot. lines are integrated with a database inter-
face. Finally lots of other equipment and
This is sliced up into wafers using a high lines are integrated using OPC.
precision wire saw. Each wafer is tested
and given a quality certificate. With the Apart from web forms in the SIMATIC IT
monitoring system installed by ÅF, the web portal, rich Windows clients that
history of each wafer can be traced, and directly interact with SIMATIC IT have
any divergence from the expected qual- been developed. These clients handle
ity can be tracked down and analyzed. more complex user operations.
Increasing performance through
visibility on the shop floor
The customer There are so many factors that contribute
to manufacturing operations, therefore it
Volkswagen, as leaders in the automotive is a difficult task finding the bottlenecks,
industry, need no introduction. small inefficiencies and identifying minor
Volkswagen of South Africa, established in maintenance trends. The only way these
1946, is a wholly owned subsidiary of Volk- inefficiencies can be ironed out completely
swagen AG in Germany. is by monitoring and recording each compo-
Volkswagen of South Africa is located in nent of the operation automatically, in order
Uitenhage, an industrial town some 35 km to analyze production trends and identify
from Port Elizabeth in the Eastern Cape. areas of inefficiency. This increased visibility
For generations, Volkswagen of South Africa of shop floor operations allows these opera-
has led the pack in the key areas of transfor- tions to be tweaked to produce the best pos-
mation. Setting key targets and measuring sible performance.
their success, that is how they achieved
such a proud record as a responsible corpo- However in a manufacturing environment
rate citizen. and especially within a production line,
where there are hundreds of machines,
The business challenge workstations and operators, not knowing
why the plant performance isn’t living up to
Due to inherent intricacies of a logistically design is not an uncommon scenario.
intensive production line, Volkswagen re-
quired visibility of plant floor operations in Increased visibility was expected to shed
order to analyse trends in the production light on key pain points such as operator tar-
process and identify areas of inefficiency. diness, constant minor stoppages, unneces-
Such visibility enables improvements to- sarily lengthy cycle and equipment switcho-
wards the best possible performance, and ver times and less than optimal intermediate
keep it sustainable. product buffering.
The solution a standard, configured solution which is recorded data to be contextualized and
open and expandable, yet customizable presented on the office level by means
To address this Volkswagen of South to meet specific user requirements. of pre-defined and ad-hoc reporting.
Africa turned to Business Connexion Real time information such as current These reports provide multiple aspects
Industrial Solutions, a provider of high throughput performance, running status of the operation. Downtime reports
availability industrial IT systems for and problem stations are identified and identify problem areas by showing
manufacturing environments. The assi- visualized in real time to operators, team equipments with the most downtimes,
gnment was to provide a Manufacturing leaders and maintenance staff through and which types of downtimes occur
Information System to increase visibility 46” LCD Andon displays. Andon pull more frequently, therefore enabling op-
of their production operations on the cords are available to allow operators to timization of maintenance.
new 2010 Polo body shop floor. quickly alert team leaders of quality or
operational problems, aiding in quick Equipment downtimes are logged au-
To integrate control and HMI devices resolution on the fly, therefore increasing tomatically with an automatic machine
across different areas of the shop floor the direct run rate. state and reason, and where the down-
enables centralized data collection to time reason cannot be automatically
provide real time production informa- All control and HMI devices are con- determined from the equipment, the
tion across the shop floor, and aggre- nected centrally via a fibre ring, allowing operators are notified of downtime in-
gated, contextualized reporting to the view of all shop floor areas via SCADA stances on the SCADA terminals, which
office management level. This was terminals in each area. they can then declare by means of a fin-
achieved using Siemens SIMATIC IT, Si- ger touch screen interface, eliminating
matic WinCC and Simatic S7, resulting in Centralized data acquisition enables all unknown downtime causes.
Cycle time reports show which areas reworked units can be verified against
are not performing as quickly as they the recorded amounts.
should, possibly starving following are-
as. Buffer reports show if buffer areas Gantt views of historical equipment sta-
are always able to supply parts when tuses can be used to view multiple equip-
they are required. ments in parallel to identify and improve
Key performance indicators can be eva-
luated throughout the shift, or the day, Such operational dependencies also
in order to identify performance dips in include operators, and therefore ope-
certain shifts. rator bad habits can be identified and
corrected to be more efficient. An ad-hoc
Availability of equipment can be deter- reporting option allows more custom re-
mined and compared, to identify bot- port queries and data contextualizations.
tlenecks. The amount of inspected and
The pay-off At a glance Solution:
• SIMATIC IT Historian & OEE on top of
This increased information and visibility Company: Simatic WinCC and Simatic S7
has given VWSA increased insight and Volkswagen of South Africa
understanding of operational intricacies Key Benefits:
which can be used to optimize processes Industry: Automotive Manufacturing • Increased optimization agility
to be more fluid and increase through- • Increased operations visibility
put. Partner: Business Connexion Industrial • Identification of recurring
Similarly, the general performance indi- • Real-time identification of
Requirements: production problems
cators available are an easy way to see
• Cross-area availability of shop floor • Key Performance Indicators for
if these optimization efforts increase
data general performance assessment
performance, and if the improved per- • Standard, configured solution, yet
formance is sustained. open and customizable
• Data available to management
level via deployable web interfac
SIMATIC IT for Life Sciences:
Operational Excellence at and across plant level
Manufacturing Execution Systems (MES) are becoming ever more critical in manufacturing oper-
ations. The life science industries are currently facing many challenges, ranging from increased
competition, cost pressures and regulatory compliance to patient safety and reducing time-to-
market. Today, being able to produce better and faster is critical and achieving operational ex-
cellence is the required strategy for modern life science manufacturers.
Efficient manufacturing is about consolidating and optimizing available manufacturing re-
sources, including equipment, people, processes and products at and across plant level. Manu-
facturing Execution System (MES) with embedded Manufacturing Intelligence, addresses these
requirements. MES encompasses real-time production execution and data availability, delivering
production and quality information that supports optimization of production activities from
order creation to finished goods. Seamlessly integrated with automation and business systems,
MES helps you manage your entire plant operations on a global scale.
SIMATIC IT for Life Sciences
Out-of-the-box and pre-validated,
Siemens has been active in the pharma- SIMATIC IT for Life Sciences offers a wide
ceutical industry for many years. The range of MES functionality together with
mission of the Siemens MES Centre of a sound validation package, enabling
Excellence for Life Sciences is to provide advanced interoperability and reduced
pharmaceutical and life science com- complexity.
panies with the right MES software and
services to help them achieve opera- SIMATIC IT for Life Sciences guarantees
tional excellence. full compliance with GxP and FDA proce-
dures and ensures fast deployment, low
SIMATIC IT for Life Sciences is a modular, TCO and high ROI.
flexible and scalable MES platform that
meets the ISA-95 standard. SIMATIC IT for Life Sciences optimizes
manufacturing processes, enforces
SIMATIC IT for Life Sciences bridges the quality and regulatory compliance and
gap between R&D and manufacturing, shortens time-to-production and time-to-
and integrates and optimizes develop- market.
ment, quality and manufacturing pro-
cesses to ensure optimal manufacturing With SIMATIC IT, improve factory produc-
and market responsiveness. tivity and quality at a lower cost.
Baxter - Full electronic Batch Record & Release with XFP
Baxter implemented an MES system to tion of manual errors in production, speci-
be sure to manufacture products right fically in mixing, printing and packing. The
the first time. Baxter Healthcare relied on Irish plant of Castlebar operates with over
XFP-MES for Medication delivery and Re- 1,000 employees. As the manufacturing
nal divisions. The solution deployed inclu- process is primarily manual, the process is
des Weighing & Dispensing, Material Ma- always prone to human error.
nagement, electronic Work Instructions
and Electronic Batch Record & Release. Enhanced flexibility
All European Baxter MD & Renal plants
The customer plan for increased growth in products with
numerous different product codes in each
With approximately 46,500 employees product type. This can involve complex pro-
worldwide, Baxter applies its expertise in duction processes. One of the key objectives
medical devices, pharmaceuticals and bio- was to deploy a flexible system that could
technology to make a meaningful difference enable rapid change of the production sche-
in patients‘ lives. Baxter International Inc. dule. In addition, Baxter needed the flexibi-
operates in three main businesses: BioSci- lity to change its batch record workflow as
ence, Medication Delivery (MD) and Renal. the manufacturing process changed.
This case study focuses solely on the MD Full quality compliance
and Renal divisions. Baxter MD is a leading The electronic batch system must gua-
manufacturer of intravenous (IV) solutions rantee full compliance with internal stan-
and administration sets, premixed drugs dards, industry standards and customer
and drug reconstitution systems, pre-filled requirements. As an example of an internal
vials and syringes for injectable drugs, elec- standard, the system should highlight any
tronic infusion pumps in addition to other specific product code requirements such as
products used to deliver fluids and drugs to unique sampling and inform the operators
patients. to take the right amounts of samples at the
The business challenge
Accelerated batch release
Back in 2003, Baxter Medication Delivery Previously, three days lead time was needed
and Renal Divisions in Europe were eager to to pre-print the blank paper-based batch
implement an electronic batch system with documentation. The large amount of paper-
the principal objectives of cost reduction, work completed by manufacturing for each
increased quality compliance, enhanced fle- batch led to a significant time in secondary
xibility and acceleration of batch release. batch review and also in returning paper-
work for correction.
Error prevention and cost reduction
The main goal was to avoid solution and This added additional unproductive time to
product discard, via the automatic preven- the release cycle of the batch.
The solution accurate in all systems. Material con-
sumption and reconciliation, dispense,
The European divisions of Baxter MD & inventory adjustment, flow management
Renal selected the XFP-MES solution to and batch information are pieces of in-
manage all production operations. formation that are constantly updated in
XFP, the ERP and LIMS systems.
The implementation of XFP includes ma-
terial flow and inventory management, At the time of writing, the XFP-MES
weighing, counting and dispensing, di- Solution is deployed at the following
rected manufacturing, daily equipment Baxter manufacturing facilities: Ireland,
checks, mixing, printing, filling, steri- Belgium and Italy.
lizing, electronic batch records (eBR),
batch testing and reviews, packaging The next sites to be deployed are in Spain
and labelling operations and finally data and Canada. Ireland served as a pilot site
warehousing. and Belgium has become the MES excel-
All data is stored in a central repository
available for use and review, enabling
Baxter to perform trend analysis such
as laboratory trends, scrap analysis and
measure manufacturing output and
At Baxter MD & Renal Europe, XFP inte-
grates with the ERP and LIMS systems
making sure that information is always
At a glance
• Require a multi-language MES
system for pan-European deploy-
• Convert paper-based system into
electronic batch files
• Enhance quality and regulatory
• A Right First Time (RFT) ratio higher
• Reduced Production Schedule to
30mins prior to target time
• Reduced Batch Release Cycle Time
from days to hours
• Reduced headcount by $110k per
• Saved $250K for reduced discards
The pay-off duction in headcount has been achieved • Improved compliance to Manufactu-
due to the continuous checking and ring Procedures
The implementation of a full electronic interrogation of data. All samples are • Cut investigations to hours instead
batch record solution has shown good tracked on the system preventing of days
returns. The e-batch system guides samples from being mislaid.
operators through the complete pro-
cess, acting as an electronic router with Thanks to the traceability, electronic
controlled task execution and automatic signature and security features, the
calculations while recording all actions. system helps ensure total quality com-
Human error risks have been significant- pliance with any industry regulations, in-
ly minimized, quality has increased. cluding FDA. Finally, the new system has
led to the reduction of batch release time
Examples of added control in the fol- and of course cost.
lowing areas had led to increased error
reduction: All data is gathered in one batch report,
• All samples are tracked on the system which is accessible at any time. Reviews
preventing samples from being are only done on exceptions, which
mislaid. translate into significant time and cost
• Scanning of WIP into line cleared savings. Over 6,500 batches and 9,500
manufacturing areas/departments. mixes have been released electronically
• Automated checks of Batch Number & in the Castlebar site.
Expiry for product labelling.
• Batch review by exception/deviation The Right The First Time ratio is above
only. 99%. Cost savings account for more than
$250K per annum. Efficient paperless
It is now possible to manage more volu- manufacturing has become the new mot-
me with less resource and better quality. to of Baxter MD and Renal sites across
Less storage space is required and a re- Europe.
Production plant at Fresenius
Medical Care modernised with IT
and automation solutions
Bad Homburg Ober-Erlenbach/Germany. As well as supplying the software products
The Siemens Industry Automation divi- and associated hardware, including the rel-
sion is modernising the business IT and evant field devices, Siemens also provided
process control technology of the pro- planning, engineering and installation
duction plant for dialysis concentrates services.
at Fresenius Medical Care GmbH in Bad
Homburg Ober-Erlenbach. The online connection to the ERP system
and automation level enables fast and se-
SIMATIC IT, the Manufacturing Execution cure data exchange. Thanks to the resulting
Systems (MES) software, acts as a link flexibility, it is possible for production to
between SAP and the PCS7 process con- adapt and react easily in the area of order
trol system, optimising plant capacity uti- management.
lisation and increasing flexibility.
Plant-specific, configurable order scheduling
SIMATIC IT supports integrated data flow and activation makes it possible to achieve a
for all necessary information into and out of high level of capacity utilisation of physical
production. System support is provided at resources and to minimise idle time.
every stage of the production process and
creates a tight integration of the different It can also help make considerable savings
system levels. by moving some automated subsidiary plant
maintenance processes to idle periods.
This considerably reduces the amount of ef-
fort and the error rate associated with the The operator user interface is tailored to the
previous, paper-based production process. plant, and offers secure, near real-time data
Electronic data capture makes the manufac- capture. Sophisticated input checks prevent
turing path traceable and transparent. input errors and inform the user directly.
Detailed planning and automatic activation Comprehensive standard analytical func-
of orders and batches are standard, along tions provide options for detailed data
with total product genealogy and produc- analysis and analysis of the finished pro-
tion analysis. ducts for further process optimisation.
Client: British Energy
Industry: Nuclear Power Generation
Brief: Monitor the inventory of controlled nuclear materials and generate reports for the
EU regulatory authority
Application Area: Track and Trace
Architecture: Siemens SIMATIC IT
Statistics: Rolled out to all UK nuclear power stations
“DAI have successfully delivered a well executed project which has deployed a high quality
system across our plants. We are delighted with the effectiveness of the implementation
and are already seeing its benefits.”
British Energy Project Manager
The customer The business challenge
British Energy - part of EDF Energy, operates The existing system used for tracking nucle-
8 UK nuclear power stations. All these pow- ar material, FORCE, had been in place since
er stations have been operational for many 1992. As such it was based on technology
years and some of the systems within them that could not easily be adapted to meet the
have been in place for a long time. new requirements. However the old system
was very well suited to the user’s existing
Within the nuclear industry, compliance needs and had proven to be accurate and
with regulatory requirements is essential. reliable over many years.
As such, when the international legislation The challenge was to provide a new system,
that provides the regulatory framework based on current, well supported technol-
was revised, requiring electronic reports ogy that would continue to meet ongoing
that track the movement of nuclear materi- operational needs while also addressing the
als throughout the business, British Energy new requirements and providing the flex-
needed to develop an accurate, reliable and ibility to adapt to changing future regulatory
efficient way to comply with the modified demands.
All this to be done while maintaining high
levels of safety, reliability and integrity.
The solution tion), Status (Good to Go, Cooling etc), The system was procured from DAI, a sy-
Dismantling and Disposal. stem solutions provider with long term
British Energy decided to commission experience in both the energy sector
the design and implementation of a Where necessary is has automated links and Track and Trace systems.
new state of the art nuclear materials to other existing IT systems allowing
accountancy system to replace the exi- direct import of specific tracked parame- NuMAS was based around the Siemens
sting one. ters and thus reducing duplicated entry SIMATIC IT system framework providing
and potential data inconsistency across a system that is entirely configurable
The new system, NuMAS (Nuclear Ma- systems. and is suitable for Track & Trace and
terials Accountancy System), is a con- reporting throughout the Energy Sec-
figurable Track and Trace application NuMAS is an auditable system that tracks tor, both for operational and regulatory
which allows British Energy to monitor movements of nuclear material at each compliance requirements.
its inventory of controlled materials, station via a centrally based enterprise ar-
and meet its regulatory commitments chitecture. It has the flexibility to be used NuMAS was delivered by DAI in a se-
to report on the balance, movement in an individual station or fleet context, ries of releases that led from prototype
and transformation of these materials to and has the capacity to generate the prin- through pilot to final build. The initial
the appropriate European Commission cipal regulatory reports embedded direct- phase defined and developed a generic
authority. ly into the main user interface. prototype containing the full range of
functionality that would be required
At its core NuMAS tracks and reports on In addition this thin client graphical “drag across all stations in the fleet.
both nuclear fuel and other controlled and drop” user interface, and additional
components throughout their full life- custom report writing tool provide a mar- This phase involved input from a cu-
cycle, including Receipt, Movement, ked improvement in flexibility and ope- stomer stakeholder group consisting of
Assembly, Nuclear Composition, Para- rator experience when compared to the users, engineering, IT security and ma-
meters (Decay Heat, Isotopic Composi- previous system. nagement. Throughout development,
DAI provided regular demonstrations of systems operating in parallel for a period,
prototype progress, and sought feed- to allow full comparative evaluation of DAI
back to ensure that the final prototype NuMAS in operational mode, prior to
met the expectations of the full stake- completing the switchover and decom- DAI is a systems company with a proven
holder group. missioning the previous system. track record for delivering reliable
solutions for major projects. We focus
on operational-level applications,
After rigorous testing the prototype sy- The project ran on-schedule and on-bud- integrating with ERP and existing
stem was then configured into specific get, and was proposed for nomination to commercial systems. Our creative use of
station solutions and rolled out station the BCS IT Project of the Year awards by commercially available technologies has
by station over a number of months, British Energy. led to our reputation for providing cost
effective, adaptable solutions that meet
with each station solution consisting
the end customer’s business needs.
of the same base product and look and
feel, but with station specific characte- For four decades we have quietly,
ristics and requirements captured and The benefits consistently and effectively worked
delivered in full. behind the scenes to help implement
major projects that improve the
NuMAS has provided British Energy with operational efficiency of global
This provided individual stations with a new logistics solution that has a more companies across both the manufacturing
the system they wanted, but gave the sophisticated tracking process and grea- and supply chain parts of their businesses,
fleet a system commonality that would ter levels of IT support than its predeces- Formal Quality Assurance processes have
been systematically applied across DAI’s
deliver simplified maintenance and ma- sor. At the same time it has maintained
business for over 25 years, up to the
nagement. Full legacy data migration the high levels of integrity and accuracy levels need to satisfy both the Nuclear and
from the predecessor FORCE systems on needed to ensure continued regulatory Pharmaceutical industries.
each station was a constituent part of compliance and has replaced a system
each station’s rollout. that was closely tailored to the business DAI’s application support service provides
guaranteed ongoing responsibility and
in a way that rapidly allowed the new
response throughout the operational
This was followed by a phased changeo- system to gain a high degree of user ac- lifespan of a system. Following training
ver from FORCE to NuMAS, with the two ceptance. and commissioning, we provide ‘early life’
assistance on customer sites. Ongoing
stewardship of systems is provided
through Service Level Agreements
providing levels of cover up to 24x7x365.
Industrial plant equipment typically lives
longer than the IT systems that manage it.
This leads to a requirement to refurbish
or replace the IT systems, in order to
extend the overall operating lifespan.
DAI has developed specialist skills in
retrofitting systems into live operational
environments, while maximizing system
availability, across a range of industries.
York House, 4 Wolsey Business Park,
Tolpits Lane, Watford,
WD18 9BL, United Kingdom
For further information: www.dai.co.uk
SIMATIC IT UNILAB helps SLN (Société Le Nickel) in New
Caledonia refocus on Core Activities
Modern, productive laboratories are sub- areas: the sampling workshop, the Fluo-
ject to considerable demands. rescence-X laboratory and the Wet Process
To offer optimum service to internal and laboratory. The laboratory carries out all
external customers, they need to distin- analyses, from geology to finished products
guish themselves in terms of traceability, (ferronickel and matte) via ongoing control
quality assurance and connectivity. of the manufacturing process, not forgetting
With the implementation of its LIMS, SI-
MATIC IT Unilab, Siemens Industrial IT has Around 300 analyses per day are carried
fully computerized the operations of the out, amounting to some 10,000 samples a
Doniambo laboratory at Société Le Nickel month. Most of these analyses are carried
(SLN). out in the Fluorescence-X laboratory.
The Business The need for modernization
Société Le Nickel is a subsidiary of the In the early 1980s, the Fluorescence-X labo-
French group Eramet, founded in 1880. ratory was fitted with an IT system: the cen-
With over 120 years of history in New Cale- tralizer. This in-house Cobol-based software
donia, Société Le Nickel has a wealth of made it possible to manage all the analyses
experience in the field of mining exploration carried out in this laboratory automatically,
and metallurgy. from scheduling certain samples to sending
the results to various customers.
The company has five mining centers and
a number of subcontracted sites. The ore is However, this system quickly showed its
extracted there and then shipped by ore car- limits: restricted coding and hardware which
riers to the factory in Doniambo where fer- had become obsolete, making maintenance
ronickel is produced (which is used to make increasingly complex.
stainless steel). This structure currently
allows the company to aim at long-term pro- The laboratory’s managers therefore wanted
duction of 72,000 tonnes of nickel per year. to introduce a more comprehensive sys-
With approximately 2400 employees SLN is tem which would also integrate all of the
regarded as the leading private employer in analyses carried out in the various areas and
New Caledonia. make use of the most up-to-date methods.
To process the ongoing flow of samples for The demand stems from the need to meet
analysis, SLN uses 30 employees in three the specific requirements of a modern,
Implementation in the Wet Process lab is
already a success, users are discovering
the benefits of the new system in full. In
the next stage, the SLN project team in-
tends to extend the LIMS to more of the
laboratory’s customers (the factory and
mining centers) so that they can fully
manage their samples.
Higher involvement of the customers
will help the laboratory return to its real
role: providing analyses.
productive laboratory: requirements in Implementation
terms of traceability, quality assurance
and connectivity (simplifying how re- To optimize the implementation itself, At a glance
sults are sent to the relevant customers/ Siemens and SLN firstly carried out a pre-
departments). liminary analysis. This procedure lasted Company:
several months, to allow the SLN project SLN (Société Le Nickel) in New
“We want to simplify operations relating team to get to know the work of the Caledonia
to the processing of samples, thus im- laboratory and to provide them with the
proving productivity and optimizing the opportunity to consider all requirements System Integrator:
way our teams work. and interpret them correctly. Siemens Industrial IT
This will improve the service we offer to The information obtained was used to IS2I www.is2ichalon.com
our customers.” says Jean-Lucien Poli- prepare a detailed specifications docu-
cisto, Head of the Laboratory Analysis ment. The SLN project team started by Requirements:
section setting up the LIMS in the Wet Process • integration of all analyses in different
laboratory. This installation was accom- areas
panied by regular visits from Siemens and • up-to-date methods
A solid partner which consid-
regular remote monitoring. After 6 to 7 • connectivity
ers speciﬁc requirements months, the software was entirely set up • traceability
and integrated in this part of the labora- • quality assurance
SLN needed a solid partner which could tory. The SLN project team is currently
offer a lasting solution. “Siemens provid- completing the rollout of the LIMS in the Solution: SIMATIC IT Unilab LIMS
ed a favorable response to our request Fluorescence-X laboratory.
while also continuing to listen to our Benefits:
requirements. The considerable motivation of the proj- • Simplified operations for processing
ect team, close involvement of all parties samples
The presentation on SIMATIC IT Unilab – (laboratory and Industrial IT staff) and • Reduction in manual inputs
which is the Siemens LIMS – caught our the way the group works together were (bar codes, bar code readers)
interest and then won us over. key factors in the progress and success of • Reduces risk of errors
this project. • Increased productivity
This solution allowed us to integrate • Increased involvement of customers in
specific requirements relating to our Due to geographical constraints a three- the analysis process
company: in terms of interfaces with way partnership was set up between • More time for core activity:
other IT systems, connections to mea- Siemens Industrial IT in Belgium, SLN the analyses
suring instruments, and specifications and IS2I – a local Siemens partner – so
which are particular to the laboratory that the solution could be deployed with
(managing certain analyses, internal greater flexibility. “This helped us to
coding of samples, and so on).” make quick progress, with complete con-
Claude Bon, Head of the Industrial IT fidence, toward finishing the deployment
section. of the LIMS”, said Claude Bon.
Value Added Services
SIMATIC IT Value Added Services
A broad concept of Customer Care
The importance of Support and Services for optimized plant
Manufacturing Execution Systems (MES) are becoming ever more critical in manufacturing oper-
ations, not least because they enable the implementation of corporate strategies based on qual-
ity, efficiency, cost containment … Which is why manufacturers typically require these systems
to be maximally available and up to date.
In order to meet the global market requirements with more demanding production and business
goals, manufacturers are stepping up investments in plant IT infrastructures.
As such, also MES installations and hence their maintenance are becoming more and more mis-
This has generated, as a side effect, an increasing importance of plant IT solutions such as MES,
but also and more particularly of their availability and reliability.
SIMATIC IT, the Siemens MES solution, provides the right answer to today’s industry challenges,
and enables a higher level of market and manufacturing responsiveness through increased
production performance, real-time cross plant and plant centric visibility and controlled brand
By completing this wide range of functionality with a renewed and extended set of services and
support, Siemens is strongly committed to customer care, for the whole product and project
life cycle, from the analysis of the economical investment to the implementation phase and the
post installation assistance.
SIMATIC IT Value Added Services (VAS) offers significant and measurable benefits to customers
through an innovative Maintenance concept, a new Partner Program and Technical Training.
A comprehensive sures often face an increase of operation- rameters could be the first step towards
Maintenance Program for al expenses: unplanned downtimes tend those economic and quality benefits.
to be more frequent and longer, require Supported by SIMATIC IT, manufacturers
your MES Installation more time for an in-depth crisis analysis, increase cost-effectiveness by planned
and ultimately they are more costly. plant monitoring at given points in time
Manufacturers often underestimate the (preventive) or continuously (predic-
importance of updating software ver- In most manufacturing operations, how- tive).
sions, taking into consideration main- ever, a blend of predictive, preventive
tenance of applications, or preventive and reactive activities would be appropri- This is accomplished through the use
actions to avoid compromising the plant ate, productive and cost efficient. of Agent Technology, which anticipates
availability. and provides warnings of performance
The renewed and extended SIMATIC IT threats and helps prevent production
The SIMATIC IT Maintenance Program Maintenance Program also includes the slow-downs or complete breakdowns.
helps customers prevent unforeseen possibility to take predictive measures, In order to maximize the benefits of
or unplanned costs for system inter- enabling double cost reductions by elimi- these value added SIMATIC IT services,
ventions, composing a maintenance nating unnecessary services and their manufacturers have at their disposal the
program based on both standard and costs, and by reducing downtime related Technical Support Service (TSS), a team
optional services, with the right balance profit loss. Identifying industry specific of highly skilled experts engineers on
between predictive, preventive and re- Key Performance Indicators and risk pa- SIMATIC IT products as well as on MES,
active measures, and based on the new-
Effectively deployed, this approach
becomes essential for the customers
when facing problem analysis and solv-
ing (RAM unavailable, memory loss,
broken networks, unreachable PCs, CPU
overloaded, memory leaks, unreadable
B2MML, old hardware, etc.).
Though reactive maintenance is ap-
propriate and effective for systems that
handle non-critical stages of manufac-
turing and in relatively straightforward
production processes, manufacturers
who rely exclusively on reactive mea-
Value Added Services
SIMATIC IT Maintenance Services
Professional Services Excellence Options
Agent-based Diagnosis Service
Central Dispatch Center Service
Update Management Service
Technical Support Services
Corrective on-site Service
Mature Product Support
• Hotline 24/7
• Technical Web Support
• Remote Support
Software Update Service
Test and Development Licenses
interaction with 3rd Parties, Base Tech- • Technical Web Support: structure, a complete diagnosis and
nology, SQL, Networks, Web, ERP. The user has access, through the Inter- troubleshooting service can be pro-
Jointly with selected partners, Siemens net, to a set of continuously updated vided by the TSS team, supported also
offers a global service and maintenance technical documentation about by means of secure remote access.
network with a unique level of skills, SIMATIC IT software.
expertise and know-how: spot-on for This includes general information, a
multi-site manufacturers, who need support database and tips, such as Hot Software Update Service (SUS):
centralized yet global support services Fixes and Release Notes, Product Docu- This service provides the new versions
providing round-the-clock monitoring, mentation and Frequently Asked Ques- of SIMATIC IT software including new
analysis and real-time solutions. tions. functions and Service Packs when re-
Siemens believes that its maintenance • Remote Support:
offering contributes significantly to the Upon specific request of the customer The updates are automatically delivered
top line performance and the bottom and after verification of the IT infra- to the customer.
line productivity of the plant.
SIMATIC IT Maintenance
The SIMATIC IT Maintenance Program
adds strategic value to its cross-industry
software products and industry specific
solutions with a high value mix of stan-
dard (Professional Services) and optional
services (Excellence Options).
Technical Support Service:
• Hotline 24/7:
Exhaustive hotline technical assis-
tance is offered for SIMATIC IT prod-
ucts as well as for interaction with 3rd
party products or applications, and IT
Excellence Options ments after a monitoring activity of the of an engineering team with project
customer’s software configuration, and specific knowledge.
Agent-based Diagnosis Service: the level of update of Product, Libraries
This service can predict potentially criti- and their applications. Central Dispatch Center Service:
cal conditions in the system (e.g. lack of A support provided for other Siemens
memory with as a result data loss) and This tool is extremely meaningful to Products (e.g: SIMATIC BATCH, SIMATIC
initiate measures in order to prevent achieve a standard alignment of the same PCS7) and for application software
them from happening, thus securing version of Product and Libraries in all implemented on top of SIMATIC IT by 3rd
the continuity of the operations or the plants involved in the project. parties.
well functioning of
the system. Agents Programmed Mainte-
are based on a non- nance:
invasive innovative With this service, the
technology. customer can plan a
certain number of days
Application Sup- of intervention for
port: system maintenance,
A complete assis- with periodic checks
tance to customer of the application soft-
specific applications, ware and related IT
built on top of the infrastructure. This will
SIMATIC IT standard products, focused Mature Product Support: avoid potential issues from occurring in
to minimize risks and maximize the per- A customer can choose for support and the future, due to e.g. consumption of
formance of the SIMATIC IT solution. maintenance on phased-out product ver- system resources.
Update Management Service: Test and Development Licenses:
This service offers the possibility to dis- Corrective on-site Service: Additional licenses with a validity of one
tribute and install updates and enhance- This service offers the on-site assistance year, to be used only for test or develop-
ment purposes and for products already
installed at the customers site.
This service can only be purchased if the
customer has a SIMATIC IT Maintenance
SIMATIC IT Partnership:
Our successful approach to
the MES market
Much of our customers’ satisfaction
is due to the exceptional professional
skills, industry experience and commit-
ment of our Partners, who use
SIMATIC IT to develop, implement and
maintain leading MES solutions.
SIMATIC IT Partners are high-level con-
sultants dedicated to helping their cus-
tomers in achieving their business goals.
Siemens is fully committed to join com-
petences with strong and experienced
partners to deliver solutions based on
SIMATIC IT that help customers to im-
prove their overall performances.
Together, the SIMATIC IT Team and the
SIMATIC IT Partner Community can grant
the key factors for a successful MES
implementation in order to respond to
any customer requirements.
Value Added Services
The SIMATIC IT Partner Program is ad-
dressed to all companies interested in
committing to achieve MES excellence
It’s a flexible proposal that can meet
the needs of partners with specific or
broad industry experience with local
or global presence, with a complex or
simple organization, with or without
MES experience. Partners are supported
by Siemens to strengthen their technical
know-how and MES positioning and to SIMATIC IT Solution Partner Specialists key factors. In order to meet customers’
enhance their future potential. are MES experts in selected industries expectation of highly qualified MES sys-
and have a dedicated team in place. tem integrators, Siemens MES improved
On the basis of the Siemens Solution the SIMATIC IT educational services offer
Partner Program structure, Siemens MES They have a specific know-how, account with a comprehensive learning program
offers two levels of SIMATIC IT partner- management skills and they want to dedicated to partners: the SIMATIC IT e-
ship according to the different strategic transform their broad MES expertise into learning courses.
requirements and objectives: MES leadership based on SIMATIC IT.
Our partner program is designed to SIMATIC IT Technical Partner
• SIMATIC IT Solution Partner protect investments and increase the Development
• SIMATIC IT Solution Partner Specialist competitive advantage of Solution Part-
ners Specialist, to help Solution Partners Being part of the SIMATIC IT partner
SIMATIC IT Solution Partners are com- wanting to grow in the MES market and program, the Technical Partner Develop-
panies with basic MES skills wanting to become Specialists. ment (TPD) offers a wide range of tech-
start with SIMATIC IT and committing The quality of our Partners is pre-eminent nical services from presales to product
to achieve an expert level of SIMATIC IT for the success of the SIMATIC IT story, consulting to support of Partner projects
technical know-how. a profound education being one of the in the best possible manner.
These services are provided by a team • Definition of a business plan with through in AS MES Training facilities in
fully dedicated to the growth of the agreed targets in collaboration with Europe (Genoa-I, Frankfurt-D) and US
MES Partners Community, able to grant Siemens Sales and the partner (Addison-IL).
to Siemens Partners presales consulting, • Monitoring of the mandatory partner
dedicated bidding assessment and tech- certification On demand, sessions can be held out of
nical tutoring. • Execution of the mandatory technical the standard calendar and at other loca-
The team consists of high skilled consul- feasibility study to minimize project tions according to trainers’ availability
tants that provide consulting services at risks and logistic constraints.
• Solution Architect can support dur- SIMATIC IT Technical Training SIMATIC IT training can also be attended
ing the definition of the Functional on the MES E-Learning platform, a Web-
Design Specification and of the Soft- based distance learning infrastructure to
ware Design Specification. Siemens organizes a complete Training learn at your own pace, through remote
• Senior Consultant can support at Courses Portfolio, to build a consistent lessons.
Technical Project Management level to learning path for our customers: from
tackle problems before they escalate, product feature descriptions to a hands- Empowering your MES staff with
mentoring critical service requests on learning experience. The SIMATIC IT SIMATIC IT Technical Training can be a
and monitoring milestone achieve- training program consists of a range of critical success factor for your manufac-
ment. training courses providing deep knowl- turing enterprise as it ensures:
• Product Consultant can support the edge of SIMATIC IT Products. To success-
project development and address spe- fully achieve this goal, the training con- • Continuous on-site presence of
cific issues in the engineering phase. sists of around 20 courses in both theory competent staff
and practice. • Efficient MES installation
Only SIMATIC IT Partners can order management
these consulting packages which remain Training classes are given by engineers, • Advanced capability to recognize of
flexible along the project development fully coordinated and linked with other potential issues
allowing refocus when and where it is teams such as Research and Develop- • Prompt problem resolution coordina-
needed. ment, System Tests, Product Consulting tion with TSS
and Industry Managers, in order to be
Additionally, the TPD is supporting the fully aligned on developments and inno-
partner program with following tasks: vations of SIMATIC IT. For more information about the
• Screening of potential partners and please visit:
evaluation of MES capabilities Training Courses are held the whole year www.siemens.com/simaticit
A Selection of SIMATIC IT Partners
AC&A is a company that belongs to Grupo Isastur and its activity is focused in Industry Automation, implementing projects in several
industrial sectors, such as environmental, energy, F&B, paper,…AC&A has experience in the full range of Simatic products and has
been one of the first companies in Spain to be certified as Siemens Solution Partner.
As SIMATIC IT partner, AC&A develops MES solutions, offering the whole cycle of a SIMATIC IT project to their customers.
Moreover, the company has a deep knowledge in different Automation Systems, which allows to integrate SIMATIC IT according to
For further information: http://www.grupoisastur.com/es/empresas/ac&a
By means of a well thought-out optimization of your industrial projects, Actemium increases the overall performances of your
production lines or machines – and thus your return. The focus is not on the network or software, but on offering you the best
solutions to optimize your production techniques, increase your efficiency and reach an optimal customer satisfaction. Actemium
distinguishes oneself by offering neutral consultancy and advice on the best solution. We guide you in selecting the best product
to fit your needs. Do you wish us to implement our solution as well? Actemium works with sector- and solution-specific ‘dedicated
teams’ of specialists. Moreover, our service team assures a flexible and reliable support.
For further information: www.actemium.be - Contact: firstname.lastname@example.org - Willem Van Overmeiren, Business Unit Manager,
T: +32 9 325 75 50
For further information: www.actemium.nl - Contact: email@example.com / For further information: www.actemium.ch -
Contact: firstname.lastname@example.org / For further information: www.actemium.de - Contact: email@example.com
+ advenco Consulting GmbH
advenco Consulting GmbH located in Giessen, Germany, is an IT company in the range of production management and optimization,
offering consulting, software and services on Manufacturing Execution Systems (MES), Advanced Planning and Scheduling (APS) and
Enterprise Manufacturing Intelligence (EMI / BI) systems.
advenco provides all services to successfully implement IT projects in the manufacturing environment. The “advenco Consulting
method” is a methodology that allows comprehensive project engineering during the complete project lifecycle. Following these
methods, projects will become more predictable and the risks (missing fundamentals, wrong economic valuations, imprecise target
definitions etc.) will decrease at the same time. The overall project success will be positively influenced.
advenco has relevant references throughout Europe, mainly in the food and beverages, chemicals and environmental industries.
For further information: www.advenco.de - Contact: firstname.lastname@example.org
+ ÅF Group
The ÅF Group is a leader in technical consulting, with experience founded on more than a century of experience.
We offer highly qualified services and solution for energy and the environment, industrial processes, infrastructure projects,
development of products and IT systems.
ÅF Group currently employs around 4700 people. Our base is in Europe, but our business and clients extend right across the globe.
What make us unique are our co-workers and the technical consulting industry’s greatest bank of experience.
It’s all summed up in our corporate motto: “ÅF - innovation by experience.”
For further information: www.afconsult.com
+ Atos Origin
Atos Origin is a leading international Information Technology (IT) services company, providing Hi-Tech Transactional Services,
Consulting, Systems Integration and Managed Services to deliver business outcomes globally. The company’s annual revenues are
EUR5.1 billion and it employs 49,000 people.
Atos Origin is the Worldwide Information Technology Partner for the Olympic Games and has a client base of international companies
across all sectors. With over 20 years of MES experience, 400+ MES solutions implemented worldwide and its proprietary method for
delivering business value, M4MES, Atos Origin is a trusted and recognized MES Partner.
For further information: www.atosorigin.com/mes - Contact: email@example.com
ASKOM, engineering company founded in 1993, is based in Gliwice, Poland. Askom is an integrator of Automation Systems and MES
systems as well as SCADA software producer. We offer consultancy services, design and “turn-key” delivery of control, monitoring
and management systems . With over 70 engineers team we have resources for development and commissioning of large projects.
References of several years of activities brought our know-how both in discrete and continuous processing, in diverse branches of
industry, including food & beverage, power plants, cokeries, paper and chemical industry. ASKOM is ISO 9001 certified and has
Siemens authorization as Solution Specialist in PCS7 and SIMATIC IT as well as Solution Partner in Automation – SIMATIC and WinCC.
Our MES activities include projects covering batch management, tracking & tracing, order management related to production
scheduling, quality management, OEE, and integration to ERP.
For further information: www.askom.com.pl - Contact: firstname.lastname@example.org
ATS is a Global Independent Solution Provider, with over 25 years experience in the manufacturing systems arena and a wealth of
experience undertaking Continuous Improvement initiatives and Manufacturing IT solution design, deployments and 24/7 support
assignments. Many world-class multinational manufacturing companies engage ATS in their improvement initiatives, Manufacturing
IT deployments and the 24/7 availability of their manufacturing operations. ATS is the world leading Manufacturing Execution
Systems specialist with global delivery capabilities.
ATS is a registered SIMATIC IT Partner Specialist in Australia, Belgium, Czech Republic, Germany, Netherlands, Spain, Turkey, UK and
ATS International B.V.
For further information: www.ats-global.com
Contact: Mike James, Group Managing Director ; email: Mike.email@example.com
+ Ardan Control Tech
Ardan Control Tech is a leading provider of Industrial IT,and control solutions, operating in versatile industrial markets: Process,
Discrete, Hybrid, Energy management, Power plants and Petrochemical facilities. Ardan expertise in the field of industrial IT
encompasses the mastery of a variety of disciplines required for floor shop solutions: MES, DCS systems, control & PLC solutions, Data
acquisition, RFID, HMI systems etc’.
As a long term partner of Siemens, Ardan masters the execution of the TIA strategy and is experienced in the integration and
deployment of the following: SIMATIC IT MES, Simatic PCS7, Simatic Batch, WinCC, Plant intelligence, Rout Control, Step7 PlC’s
and others. The company’s experience is based not only on implementing Simatic IT but also on the integration of SIT with third
party systems in multi-site, large installations and through all project stages: definition, planning, engineering, supply of hradware,
installation and programming. Thus enabling ACT to supply the customer with a comprehensive, end-to-end Industrial IT solution.
For further information: www.ardantech.com - Contact: firstname.lastname@example.org
+ Brock Solutions Inc.
Brock Solutions Inc. is an Engineering Solutions and Professional Services company specializing in global projects requiring MES
(Manufacturing Execution System) Solutions and Automation Engineering. Brock has extensive experience in various industry sectors
including: Automotive, Aerospace & Defense, Food & Beverage, Tobacco, Pharmaceutical, Printing, Transportation & Logistics, Metals
and Consumer Products.
Our expertise includes the definition, design, development, and deployment of MES solutions that interact with ERP systems and
plant floor control systems in real-time. Brock contributes to the manufacturing community by involvement in MESA (Manufacturing
Enterprise Solutions Association) International with several employees active in committees as well as Co-CEO John Southcott serving
as Chair of MESA’s International Board. Brock Solutions is an active SIMATIC IT Partner.
A Selection of SIMATIC IT Partners
+ BST Buck Systemtechnik GmbH
BST Buck Systemtechnik GmbH was founded in 1989 in Brunsbuettel near Hamburg, and very close to the big chemical industrial
areas. There BST become one of the leaders in realizing TELEPERM M, SIMATIC PCS 7 and SIMATIC Batch projects. Especially the
migration of older process control systems to SIMATIC PCS 7 contributes to the company’s growth.
Since 2003 BST became a SIMATIC IT partner. Together with our customers we created successful projects with the DIS and SAP
connector as well with the production suite, historian and UNILAB.
More than 20 specialized engineers implement the complex projects for chemical, power plants and food industries.
BST is a registered SIMATIC IT partner in Germany.
For further information: www.bst-sys.com - Contact: email@example.com
Bayer Technology Services has been providing MES solutions for more than 20 years combining factory knowledge and implementation
know-how. Early on, the Bayer experts established MES standards, thus allowing customers to get reliable solutions for reasonable
expense. The service which the 50 experts in the field of MES offer comprises consulting as well as project execution and customer
BTS develops and delivers solutions that fit the specific needs of the process industry and the individual production site.
This combination of standard software and customer specific applications creates an MES solution of great functional value at
For further information: www.bayertechnology.com
+ Business Connexion (Pty) Ltd
Business Connexion (Pty) Ltd is a leading integrator of innovative business solutions based on information and communications
technology (ICT). With over 4500 employees and a track record spanning 32 years, Business Connexion runs mission-critical ICT
systems and manages products, services and solutions for JSE listed and key public sector organisations, parastatals and medium-
sized companies. Business Connexion provides manufacturing enterprise solutions and ICT technologies that range from business
consulting, project management, ERP systems, custom application development, cloud computing and data centres. Business
Connexion, augmented by the strength of its strategic alliances with world leading ICT suppliers, provides large scale turnkey
manufacturing solutions. In addition, its world-class CRM support through its Service Management Centre reaffirms the groups’ key
focus area of providing excellent client support with the ultimate objective of growing long-term business relationships.
For further information: www.bcx.co.za
Contact: Frans.vanEeden@bcx.co.za (Frans van Eeden)
+ CIT Systems
CTI Systems is one of the leading manufacturers of customized, computer controlled equipment for automated material handling, heavy-
duty storage and surface treatment systems as well as production, painting and assembly equipment.
For more than 45 years, CTI Systems has experience with fully automated systems and more than 1000 installations worldwide.
The goal of CTI is to provide the customer with a complete, tailor-made system, engineered and manufactured with the latest technology,
installed on a turnkey basis to provide optimum economic effects. CTI Systems is an active SIMATIC IT partner in Luxemburg.
For further information: www.ctisystems.com
Cube Technologies is an international industrial solution provider to clients from all manufacturing sectors. With offices in South
Africa, Australia and Saudi Arabia, we provide technology-based solutions to clients who deal with a team of handpicked experts.
Our solutions offer full turnkey capability for process control systems (DCS or SCADA) and MES/MIS systems with complete redundancy
for small, medium and large applications. Projects have been successfully completed in the Automotive, Pharmaceuticals, Metals,
Food & Beverage, Chemicals and Petro-Chemicals Industries. Siemens software products used in these solutions included Simatic
IT OEE/DTM, Simatic PCS 7, Simatic Batch, WinCC and the Simatic IT Production Suite components. These project have increased
production, improved plant visibility to management, provided ERP interfaces for financial systems and enabled customers to
maximize their overall equipment effectiveness (OEE). Cube Technologies is your partner in totally integrated automation.
For further information: www.cubetech.co.za
DAI is a systems company with a proven track record for delivering reliable solutions for major projects.
We focus on operational-level applications, integrating with ERP and existing commercial systems. Our creative use of commercially
available technologies has led to our reputation for providing cost effective, adaptable solutions that meet the end customer’s
For four decades we have quietly, consistently and effectively worked behind the scenes to help implement major projects that
improve the operational efficiency of global companies across both the manufacturing and supply chain parts of their businesses,
Formal Quality Assurance processes have been systematically applied across DAI’s business for over 25 years, up to the levels need to
satisfy both the Nuclear and Pharmaceutical industries.
For further information: www.dai.co.uk - Contact: firstname.lastname@example.org
+ DAL ELEKTRIK OTOMASYON
Being Siemens Solution Partner for Process Control Systems since 2000, we supply Simatic IT Historian Solutions especially in Cement
Industry, integrated with Simatic PCS7. We supply turnkey electricity and automation to our clients.
The goal of Dal Elektrik Otomasyon is achieving perfect quality, occupational health and safety, respecting the enviroment.
+ Egemin Automation
Over 60 years of passion for automated industrial processes is what Egemin Automation is offering you. Core activities of this international
operating partner are consultancy, engineering, process control security and realization of solutions for process and automation
as well as a wide range of life cycle services.
Egemin Automation’s experiences are in intralogistics, food, (petro-)chemicals, tank terminals, life sciences and infrastructural objects.
Please challenge us to discuss with you how our know-how and experience can support you in the realization of your objectives.
Egemin Automation, Baarbeek 1, B-2070 Zwijndrecht
For further information: www.egeminautomation.com
+ EMTE SISTEMAS, S.A.U.
Emte Sistemas specializes in the development of control systems for industry and large infrastructures. During the past 12 years
we have undergone sustained growth, in particular in the Infrastructure and Industry Division where we have reached more than
40 M € annual turnover with 350 employees. Of these, over 120 are control software technical staff, and the rest are specialists in
complementary technologies (Instrumentation, Electrical, Facilities, etc.) which means that we can execute turnkey projects with total
guarantee. In the Industrial Sector, Emte Sistemas primarily serves the pharmaceutical, chemical, food and automotive industries,
through Process Control and Production Management automation projects, known as MES (Manufacturing Execution System).
The most common applications of a MES are: Calculation of KPIs such as OEE (Overall Equipment Effectiveness), management of
Plant Manufacturing Orders with automatic supply of consolidated data to ERP, or management of Genealogy and Traceability of
For further information: www.emtesistemas.com - Contact: email@example.com
A Selection of SIMATIC IT Partners
Engineering is a global player and Italy’s largest systems integration group and a leader in the provision of complete integrated services
throughout the software value chain: design, development, outsourcing services, products and proprietary vertical solutions, IT and
strategy consultancy, tailored to the business models of our clients in all markets. With 6,300 employees and 36 branch offices,
Engineering is present throughout Italy, has a direct commercial presence in the EU, in Ireland and Belgium, and outside the EU in Brazil
and Latin America. Thanks to the purchasing plan and the ability to open new markets, the Group has a global production capacity in over
50 countries, managing IT initiatives linked to the development of projects in the industrial and telecommunications sectors.
+ Expirivia Spa
Exprivia Spa, a company listed at the MTA, the Star segment of Borsa Italiana (XPR), is a System Integrator that approaches the different
markets with innovative solutions.
InFaber srl is Exprivia’s centre of excellence in IT Manufacturing, and supplies services and solutions for MES (Manufacturing Execution
Systems), covering the entire value chain from knowledge of the processes to the implementation and management of application
Infaber is Siemens Spa Industrial Automation Solution Partner, collaborating for several years in national and international projects for
major industries in Food, Automotive, Aerospace and Tobacco.
For further information: www.exprivia.it
Global Automation Partners (GAP), a is an engineering and consulting firm for Automation and Manufacturing IT (MIT) projects.
GAP Manufacturing IT (MIT) practice is a methodology driven IT consultancy with engineering discipline, delivering the potential of
technology via rigorous application of standard templates, modules, and solutions. Using proven, methodical, practical, scalable and
effective work practices GAP MIT delivers high value with predictable results. GAP MIT value-driven methodology incorporates the three
first principles of solution delivery; people, process, and technology. Each phase is designed to consider or manage organizational
impact (i.e. people), optimize processes according to best-practices, and apply the appropriate level of technology. Solutions support
business initiatives that range from large scale enterprise re-engineering efforts, incremental kaizen driven improvements, broad
scope business improvement initiatives such as six sigma or customer and supplier driven supply chain optimization. The process
begins with stated business objectives and ends with beneficial solutions installed and performing in the customers’ business.
Gijima has a proven track record spanning over 10 years for providing Manufacturing Execution Systems (MES) solutions that are
based on the successful combination of technological and business innovation at every stage of the value chain. This ensures
sustainable success through the standardisation of enterprise-wide production processes. It improves executive decision making and
provides our clients with improved efficiencies and up-time, increased productivity, reduced production costs, increased capacities
and on-time delivery, quality and regulatory compliance, fast, secure and flexible engineering and improved process control.
Seen in the context of our manufacturing process knowledge, extensive ICT services and strong client base, we offer our
manufacturing clients the potential to become an enterprise that is dynamically optimised to the rapidly changing manufacturing
environment. Gijima provides Consulting, Implementation, Support and Project Management services.
For further information: www.gijima.com
As a complete provider of automation solutions in the production field, we have been shaping the future of automatic production
processes in cooperation with our customers for over 30 years. This enables us to offer solutions along the entire supply chain, from the
sensor level via the level of control systems and down to the MES level for the connection to ERP systems.
In the MES area we focus on the sectors Process Industry, Food, Beverages & Pharmaceutical as well as Chemical & Plastics Industry.
The MES start of our customers arises often through Historian- and OEE-/MIS-solutions. hsh is a competent partner as well for production
scheduling, tracking & tracing (Genealogy) and workflow control.
hsh-systeme für prozess-IT gmbh, heiner-fleischmann-str. 7, d-74172 neckarsulm
For further information: www.hsh-systeme.com
+ HVL B.V.
HVL is a system integrator, headquartered in Eindhoven, NL. HVL has a market focus on food & beverage, (waste)water, chemical and
automotive markets. HVL is one of the main solution providers for both MES and industrial automation in the Netherlands.
HVL’s technical keynotes are its status as certified SIMATIC IT Specialist, certified PCS7 Specialist, its adoption of International
standards (e.g. ISA-88 for Batch and ISA-95 for MES). With 750 employees, HVL aims to provide added value for her customers by
providing solutions that help them to produce in a flexible, effective and efficient way.
For further information: www.hvl.nl
+ Hyla Soft
Hyla Soft is an international company with headquarters in Genoa (Italy), and branches in Turin (Italy), Naples (Italy), Chicago (U.S.A.),
Portsmouth (U.S.A.), Sao Paolo (Brazil), Madrid (Spain) Cleveland (Australia) and Winston (South Africa).
Hyla Soft specializes in IT solutions in the field of industrial manufacturing, through MES (Manufacturing Execution Systems) and related
Hyla Soft has been Siemens SIMATIC IT partner specialist since 2003: we cooperate with Siemens with SIMATIC IT product development,
project delivery, and support. Our experience in the manufacturing area includes production control and execution, plant intelligence,
warehouse management, RFID implementation, and Geographic Information Systems.
For further information: www.hylasoft.com
IASTECH is a Control Systems Integrator in Brazil, providing industrial automation solutions since 1990.
IASTECH develops and supplies complete solutions with Control, Supervision and Plant Management Systems.
The company marketing focus is: Pharmaceutical and Cosmetics; Chemical and Biotechnology; Food and Beverage; Water and Wastewater.
We have expertise in Batch Systems (ISA-88); GAMP methodology for Computerized System Validation; and Manufacturing Execution
The company has 49 employees, including Automation and IT professionals to develop projects with control and information systems.
For further information: www.iastech.com
A Selection of SIMATIC IT Partners
Imtech is an european technical services provider, with more than 25,000 employees active in the fields of information &
communication technology and electrical & mechanical engineering. A total solution provider throughout the full breadth and depth
of the technology spectrum. The business unit Automation Solutions combines know-how of manufacturing processes, information
technology and software packages and tools to agile solutions enabling effective production management and Operational
Imtech is a certified SIMATIC IT partner and have strong partnerships with IBM and Microsoft for their business solutions.
For further information: www.imtech.eu
+ Inﬁnity Technology Solutions
Infinity Technology Solutions SpA (ITS) employs committed engineers with expertise within Project Management, Process Modeling
and Design, Business and Manufacturing IT Systems, and Automation. We deliver solutions and consultant services within the Energy,
Construction, Process and Discrete Manufacturing, and Transportation industries.
The company was founded in 2008 and has had constant growth since. Today, ITS has offices in Genoa and Milan. Customers of ITS can
be found globally; Italy, Europe, America and Asia. Our vision is to be a trusted partner for functional, flexible and innovative business and
production systems - from idea to successful business processes of a company.
Through our breadth and quality of services, we are your total solution partner.
For further information: www.itsinfinity.com - Contact: firstname.lastname@example.org; email@example.com
Based on 30 years of experience in the manufacturing and Supply Chain domain, Logica developed a set of services named
“Manufacturing Atlas”. Manufacturing Atlas improves your Key information of the production and supply chain in manufacturing
companies and provides a full overview of the entire production chain. It starts with the development of a view providing the right
information, in the right place and at the right time. That means an industrial company can respond rapidly and promptly to changes
and thereby produce more efficiently and effectively. As part of the Manufacturing Atlas, the portal immediately translates real-time
data into operational information and practical improvements for both the shop floor and the management.
This information can be used to take immediate action, whereas the weekly summaries widely used up until now have provided only
MAVAL is one of the main System Integrators from the group of SIMATIC PCS7, SIMATIC NET and SIMATIC IT partners.
MAVAL has got expertise in Continuous Process Control and Automation, becoming specialists in the Food & Beverage Industry.
Our wide experience combining SIMATIC PCS7, SIMATIC NET and SIMATIC IT MES solutions on their entirety (from the early analysis
phase to engineering and their final commissioning) gives us the ability to play the perfect role as integrators, demonstrating unique
and global skills on every project we undertake, coordinating every resource involved, and offering a full coverage of the customers’
needs, thanks to our huge know-how and flexibility.
For further information: www.maval.es - Contact: firstname.lastname@example.org
+ Mesure Systems
Mesure Systems is dedicated to the activities of consulting, analysis, management and delivery of MES projects.
We are specialists in the implementation of Production Management and Control Systems, either in discrete manufacturing, batch
industries or primary (process) + secondary (filling & packaging) sectors. From a start-up system of KPI management to the most
complex multiplant system, fully integrated with the ERP and automation, including material management, track & trace, genealogy,
order management, quality management, maintenance, etc.
We are ready to be part of your team in continuous improvement process, focusing in increasing reliability, efficiency and profit.
For further information: www.mesure.es - Contact: email@example.com
+ M+W Process Automation
M+W Process Automation is one of the leading independent providers of complete automation solutions and offers consulting and
implementation services for all levels of business and production processes. Our main focus lies in the planning and engineering of
PLC and DCS systems and their vertical integration into higher-level PIMS and MES solutions. We provide daily, and throughout the
entire life cycle, customer support of their production facilities.
With our subsidiary teufel software (SAP Gold Partner) we can also deliver the complete range of services for the integration of
For further information: www.pa.mwgroup.net
Hardware and software engineering, installation, commissioning, calibration and qualification of electrical, instrumentation and
automation systems including SCADA, DCS and MES-System for all process industries, specially for chemical, pharmaceutical,
biotechnology and paper industries.
• MES systems for pharmaceutical and biotechnology production units
• FDA/GMP valuable process control systems for pharmaceutical and biotechnology production units.
• Modernization, migration with a minimum of shut down time as an all over solution including collection of information about the
existing processes, analysis, recording, recabling, testing and qualification.
For further information: www.penta-electric.ch - Contact: firstname.lastname@example.org
+ PRC Engineering
PRC Engineering is on of Sweden’s leading suppliers within plant engineering, process automation and Industrial IT/MES for the
pharmaceutical, food and beverage, biotech and chemical industries. Our scope covers a plants total lifecycle from conceptual design
to commissioning and qualification. Our customers are mostly based in northern Europe but our field of operation is global and
includes consultancy services and turn-key deliveries.
PRC Engineering is a solution provider to Siemens within Process Automation, SIMATIC IT and is as the only company in northern
Europe appointed solution provider Pharma.
For further information: www.prc.se - Contact: email@example.com
A Selection of SIMATIC IT Partners
PROCISA was founded in 1981, as an organization of engineering services, automation and IT solutions, in production and related
areas. PROCISA is specialized in providing high-value technical and technological solutions to the industrial market. Since its
beginnings in the sugar industry in 1981 PROCISA turned into a leading company in the food industry. In 1993, PROCISA looked for
expansion into the American market.
Nowadays, PROCISA is able to manage process control and Information Technology solutions for MES, based on SIMATIC IT products,
in several industries covering energy generation and management, iron and steel industry, mineral and sewage treatment, remote
control, material logistics, system information, production tracking, automation systems integration and integral administration of
plant processes including ERP integration.
Proxima develops solutions for the management of agro-industrial processes for 21 years. We serve about 200 customers, all of the
agribusiness sector, and have extensive experience incomplex projects, among them the management of various business units.
More than 2.2 million hectares of agricultural productive area and 60% of brazilian bioethanol and sugar production are managed by
our softwares. MESAgro - the first MES solution in the world for agribusiness, totally based in the SIMATIC IT Platform - is supporting
our customers to be more efficient and competitive in this renewable and sustainable business.
For further information: www.mesagro.com.br
Russula is an engineering company with 23 years of extensive experience in the steel industry. The company has executed over 600
automation projects for melt shops, reheating furnaces, profile, section, bar, wire and rod mills and processing and finishing lines.
Russula has its own assembly installation with the technical capacity to design and fully assemble control panels, PLC´s, Multidrive´s
and electrical cabinets.
Russula is an independent engineering company with major offices in Spain, United States, Mexico, Brazil, Argentina, India and
SIDAT Ltd. was established in 1990 in Prague and its core business is the supply of automation systems, Manufacturing Execution Systems
(MES) and technologies. SIDAT´s specialists are ready to provide support in the field of system integration, production management and
manufacturing process automation, such as HMI/SCADA and MES.
SIDAT has gradually developed the profile of a specialized company focusing on F&B, the Chemical, Pharmaceutical and Oil&Gas Industry,
Production of Building Materials, Water Treatment Plants and the Automotive Industry.
SIDAT is a Siemens certified Solution Partner and a SIMATIC IT Solution Partner Specialist.
+ Siemens Industrial IT
Siemens Industrial IT is a specialized team highly experienced in the implementation of industrial IT projects in production and
quality. We have successfully completed over 150 implementations of SIMATIC IT solutions for Laboratory Information Management
(LIMS), product specification management and MES in the process industry, particularly in metals, paper, pharma, chemicals and
food & beverage, and often on a corporate level.
Key aspects of our activities include concept development, consulting, implementation services and long-term technical support
of the solutions. In close collaboration with the local Siemens organization, Siemens Industrial IT supports from Belgium both local
customers in different European countries as well as global roll-out projects.
For further information: www.siemens.com/industrial-it - Contact: firstname.lastname@example.org
Siemens IT Solutions and Services is a European based premium player providing state-of-the-art IT solutions and delivering outsourcing
services with global reach. Through profound industry know-how and beneficial innovations, Siemens IT Solutions and Services enables
customers to transform their business processes on an ongoing basis. In December 2010, Siemens and Atos Origin announced their
intention to form a global strategic partnership. Siemens will contribute its Siemens IT Solutions and Services to Atos Origin in order
to create a European IT Champion with global reach. Siemens IT Solutions and Services employed more than 32,000 people in over 40
countries and posted annual sales of around EUR 4.2 billion in fiscal year 2010, of which more than 75 percent is generated outside of
the Siemens group. For MES business Siemens IT Solutions and Services offers a complete range of services based on SIMATIC IT - from
Consolidation & Harmonization of MES and Implementation to Application Management.
For further information: http://www.it-solutions.siemens.com/b2b/it/en/global/about-us/Pages/about-us.aspx
+ Siemens I IS
Siemens Industrial Technologies offers innovative and industry-specific IT products, solutions and services.
These include IT and MES solutions tailored for individual industries and for universal application (cross-industry).
From automation to the ERP level, we offer expert support worldwide, based on our extensive IT knowledge, our industry expertise and
our global presence based on SIMATIC IT.
+ SP Software & Automation Pty Ltd
Our company was founded in 2004 with a vision to provide the best available and robust Industrial Automation and IT solutions for
the manufacturing, utilities and process plants. Headquartered in Melbourne, Australia our areas of expertise are in: Manufacturing
Execution Systems (MES) & OEE measurements, Energy and Carbon Emission Management systems, SCADA and DCS engineering,
Control systems (PLC / DCS) programming, Computing languages and Database programming, Lean Manufacturing and Six sigma.
Coupled to our expertise in the above technology areas, we have deep industry specific knowledge in: Steel & Metallurgical plants,
Cable industry, Pharmaceuticals, Paper, Winery. We support our customers with Engineering Services that include: Preparation of
Function Description, Control system selection, Software Development and Coding, Commissioning, Training, Computer Systems
Validation. Throughout the engineering lifecycle and software development phase, we follow the V-model to validate the software
developed by us.
A Selection of SIMATIC IT Partners
TECHNORD is a family group of 300 persons specialized in Electrical Engineering: we are industrial integrator of services.
Our different business areas are Industrial Electricity Low and Medium Voltage, Electrical Cabinets, M.E.S. (Manufacturing Execution
System), Industrial Data processing, programming of PLC and supervision system and industrial and office automation networks.
TECHNORD is certified to the very highest level by the leading manufacturers on the worldwide market.
For further information: www.technord.com
+ TOPHINKE AUTOMATION & GEBÄUDETECHNIK
Employees: 47, Company founded: 1968
The company Tophinke Automation & Gebäudetechnik AG is in the following ar-eas active: MES, Industrial Automation, Electrical
Installation, Manufacturing of Electrical Cabinets, Certification and Control of Electrical Installations
Process Know-how: Food and beverage are sensible products. They require a high standard during the pro-duction and packaging.
The company Tophinke have an extensive know-how in this area to achieve the required control and quality-management.
Aseptic competence, Tools and und methods for validation, Minimizing the needed resources for achieving quality-management
Company Tophinke has an extensive competence in the following areas: Pasteurizers- and degasingsystems, Steriletanks, Blend- and
mixingplants, Productionlines of Milk, from deloading to final product, Spray drying, Fluidised bed processes, Evaporation systems,
Centrifuges, CIP Systems, Breweries, Brickmanufacturingsystems, Thermoforming, Metallprofile Manufacturing, High rack storage
areas, Woodstacking Systems.
For further information: www.tophinke.ch - Contact: email@example.com
Xavo was the first SIMATIC IT Partner in Germany. Since 2003 the company is creating successful solutions based on SIMATIC IT for
customers from all over europe. Xavo is located in Bayreuth (Headquarters), Nuremberg and Reinach (Switzerland).
About 35 higly skilled and motivated employees working at Xavo. The industry sectors Xavo is focussed on are: Food & Beverages,
Tobacco, Life Sciences, Pharamceuticals and Green Technologies. Xavo has many years of experience in both Production Suite and
For further information: www.xavo.com/plantscheduling
Everything from one source! For ZIEMANN this is not just a slogan. ZIEMANN is committed to providing complete turn-key breweries
of the highest quality using state-of-the-art technology and offering reliability without compromise. And ZIEMANN doesn’t stop in the
production area either. The full integration of complete tailor made bottling and packaging plants are familiar tasks for ZIEMANN.
From pilot plants to mega-plants: Quality and success based on more then 159 years of tradition has made ZIEMANN an innovative
global market leader and pioneer in turn-key projects for new breweries as well as for brewery expansions.
As a global teamplayer ZIEMANN works hand-in-hand with its customers and takes their visions seriously. This stands for extensive
competence, smooth interfaces, fast communication and flexible decisions. From consulting and planning up to the implementation
of the project – our highly experienced specialists will provide you with first-class service.
For further information: www.ziemann.com - Contact: firstname.lastname@example.org
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