Stay competitive as a Digital Enterprise

The Siemens Electronics Factory in Erlangen, Germany is a model for modern manufacturing. Powered by core technologies such as Digital Twins, Artificial Intelligence, IT/OT convergence, and the Industrial Metaverse, the factory embodies a sustainable Digital Enterprise ready for the future.

Optimizing performance through digital transformation

Discover how the Electronics Factory Erlangen is reducing its energy consumption and time to market while also improving quality and achieving its sustainability goals.

Our Electronics Factory Erlangen, the manufacturing hub for SINAMICS drives, serves as "customer zero" by testing our solutions in a real-world environment before they reach the market. To compete globally and manage high-variance production, the factory transformed into a sustainable Digital Enterprise aiming for net-zero emissions by 2030, having already halved its carbon footprint in two years.

This success is driven by the Siemens Xcelerator platform and the convergence of IT and OT, which enables the use of AI and the comprehensive Digital Twin throughout the entire product lifecycle.

Industrial AI and low-code platforms optimize factory processes through accessible shop floor data and digital twins.

Shop floor data is made accessible to all employees via low-code platforms and AI to continuously optimize processes. Furthermore, the factory has used the Industrial Metaverse for over a year to analyze past events and predict future performance, effectively blurring the lines between the real and digital worlds. This transformation is supported by a strong focus on upskilling the workforce and fostering a culture of experimentation.

By refining integrated software and automation solutions in-house, we ensure these technologies are battle-tested in a harsh industrial setting. Consequently, customers gain access to proven digital solutions that boost their own competitiveness and sustainability, while the factory continues to share best practices across our global network to maximize value.

Productivity up, emissions down

Be inspired by the measurable success of the Electronics Factory Erlangen.

-40% Shorter time to market

The comprehensive Digital Twin, IT/OT convergence, data analytics and Industrial AI are crucial for the factory to bring its products to customers around the world faster.

+60% Higher quality

The Electronics Factory has developed AI applications and implemented them on the shop floor. This enabled to improve process and product quality while also boosting efficiency.

+50% Higher production output

IT/OT convergence is the foundation of comprehensive data use to optimize production. Analyzing production data leads to new insights that help increase the productivity of machines and lines.

Core technologies

Explore the core technologies used by the factory

How to collect, understand and use data companywide

IT/OT convergence

IT/OT convergence enables to merge automation technology with modern IT technologies such as cloud computing and edge computing. The challenge is to do this for both legacy equipment and modern machines. The factory uses a low-code application that is deployed on one of our Industrial Edge devices to establish the data connection. The machine data is then processed and used to optimize production as part of operational management. They also use a citizen analytics approach that empowers all employees to use operational data for new insights.

How to get faster and more confident by simulating everything

Digital Twin

The factory has developed Digital Twins specifically for, but not limited to, production. All Digital Twins have in common that they are a replica of the real system and that operators can test on them without having to intervene in the real system. A specific example is the simulation of the material flow on the shop floor. Here, Automated Guided Vehicles (AGV) transport materials to the production lines. Finding optimal routes and cycle times depends on sophisticated simulation tools like Tecnomatix Plant Simulation and Process Simulate. As a result, material circulation was reduced by around 40%.

How to understand the past and how to predict the future

Industrial Metaverse

Since the factory is already using core technologies like Digital Twins, IIoT, Artificial Intelligence, augmented and virtual reality, it’s only logical that they combine these technologies to create the first steps towards the Industrial Metaverse. It is currently being used to optimize and speed up planning, for example for production expansion. And it’s being used to identify deviations in operations so that production can be continuously optimized. Another key benefit of the Industrial Metaverse is the ability to collaborate across geographic boundaries to solve challenges such as system productivity and process efficiency.

How to free skilled workers from tedious, repetitive tasks

Industrial Artificial Intelligence

The factory uses Industrial AI, among other things, in the production of SINAMICS products to ensure higher quality and to increase production efficiency. AI technology frees skilled workers from repetitive, undemanding work by using more intelligent automation technology that can perform very complex tasks using, for example, low-cost sensor technology. It also makes it easier for humans and robots to work together, taking advantage of the best of both worlds. To train the AI for bin picking, the factory is using the Digital Twins of a robot, the bin, and the parts with realistic simulation. This is much faster and more efficient than programming robots for each part or using prefabricated inlays that contain the different parts.

Less emissions from product to production to the entire site

Sustainability

The factory is committed to a carbon-free future by 2030. This dual-pronged strategy prioritizes drastic energy reduction while ensuring all power – whether generated on-site or purchased – is 100% renewable. We leverage advanced data analytics to maximize efficiency and optimize our clean energy usage.

Beyond operations, sustainability is baked into our product DNA. Every component is engineered for refurbishment, reuse, and recycling. A prime example is the SINAMICS drive family; these units are compact, material-efficient, and designed for a circular lifecycle. By prioritizing robust eco-design, we help our global customers shrink their carbon footprints while maintaining peak industrial performance.

We want to make a sustainable impact. It motivates me to see the energy of our employees and to experience new technologies that will create a sustainable workplace for our children and grandchildren.

Stephan Schlauß, Global Head of Manufacturing Motion Control, Siemens AG

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Key technologies for becoming a Digital Enterprise

Take a deep dive into the key technologies that helped the Electronics Factory Erlangen achieve its KPIs and become a sustainable Digital Enterprise.

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