Staying ahead of the game by keeping up with the latest trends.
Digital Enterprise for process industries
Companies from the chemical industry can now produce batches smaller and much faster than ever before, thanks to Siemens technology. So their customers now get exactly the product they want, when they want it.
Independent research, November 15, 2018
Chemical Industry 4.0 - A Formula for Investment
A study of the UK chemical industry’s digital transformation and the building blocks of reliable return on investment from Industry 4.0
The digital transformation as a success factor
The opportunities offered by a successful digital transformation are tremendous, as is spectacularly demonstrated by a Siemens customer from down under. DuluxGroup, Australia’s largest producer of paints relied on consistent, end-to-end digitalization of all processes for its new production plant and can now provide customers exactly those ranges of paint colors they want, when they want it. With this, even the latest trends can be picked up.
Siemens has worked with the multinational paint group to develop state-of-the-art end-to-end digitalization that has made production 8 times faster. Dulux Australia can now offer customized color ranges processing batches 1/50th of their former size.
Virtually eliminating manual interventions enables repeatability and pin-point accuracy of the actual production of highest quality products with minimal raw waste.
At Dulux Merrifield plant, this has also led to a 25 percent reduction in energy consumption over what it was designed for.
The Merrifield plant is both a blend-and-tint (BAT) plant for small batches and a mass production plant for high volume paints.
Comprehensive tests and virtual commissioning of automation applications, and realistic training
environments are made possible with the simulation platform Simit, even before startup. This reduced the time from testing to fully automated paint production by greater than 50 percent.
Digitalization is opening up brand-new opportunities for companies of all sizes to increase their efficiency, flexibility, and product quality and to customize their processes to an unprecedented degree. It’s clear that those who can quickly and successfully implement a digital transformation throughout their entire plant lifecycle will have a definite competitive edge. As a partner to the process industries, Siemens supports its customers on their path to digitalization.
We wanted to make sure our new factory would be future-proofed to respond quickly to the latest trends, create new business opportunities and remain at the leading edge of paint manufacturing.
Benefits throughout the entire plant lifecycle
Real added value thanks to the digital plant
Regardless of whether you want to produce ever-smaller batch sizes with maximum efficiency, intelligently plan maintenance and repair measures, or systematically minimize downtime, the digital plant is the key. It’s a vision that you can realize with our integrated hardware, software, and services program.
New prospects throughout every phase of the plant lifecycle
Our portfolio offers everything you need to efficiently record and intelligently leverage the huge quantity of data that processes generate. This is a basic prerequisite for creating a digital twin that you’ll use to map and optimize your entire plant lifecycle.
A common data platform enables all the disciplines involved in a plant project to generate a shared data model. This allows most of the processes that are usually performed sequentially to be executed in parallel, saving valuable time and expenses and at the same time increasing engineering quality.
The digital twin also allows the plant to be simulated prior to the critical commissioning phase, which ensures a reliable implementation. Other benefits of the digital twin – which can also be generated for an existing plant – include the fast and efficient performance of training and modernization measures.
The transition from Integrated Engineering to Integrated Operations is an important step on the path to Industrie 4.0 for our customers in the process industries. We provide integrated solutions throughout the entire plant lifecycle and are the first to offer a continuous data model.
Direct model of the current state
The operating phase is another area where you can greatly benefit from the digital twin. For example, you can significantly increase the reliability and availability of your plant by continuously monitoring your mechanical assets. Knowing about the current condition of your assets also allows you to intelligently manage maintenance and repair measures and reduce unscheduled downtime to a minimum.
Changes to the plant created by maintenance activities or a component replacement are directly incorporated in the digital twin. All the documents and plans affected are also automatically updated so that the latest plant documentation is available at all times.
From modular engineering to modular automation – for increased flexibility
In view of the trend toward increasingly individualized customer requirements, products must be produced in smaller and smaller batches and as quickly and economically as possible. In this environment, modular production is growing in importance. It makes it possible to quickly and easily adapt the plant configuration to constantly changing requirements. Process plants are built from modules with their own automation/intelligence that can easily be added to or rearranged. Using the MTP (module type package) interface, all the modules can be efficiently interconnected via a higher-level control system. Siemens not only supports this in automation with the Simatic PCS 7 process control system and the TIA Portal, it also enables modular engineering throughout the entire plant lifecycle using the COMOS engineering tool and the Simit simulation software.
NAMUR Open Architecture (NOA)
Digital benefits thanks to the “second data channel” – fast, easy, and reliable
Intelligent processing of huge volumes of data from production facilities in the process industries is playing a crucial role in the digitalization of industry. The challenge is to access these existing and often unused volumes of data (“big data”) without affecting the data itself and without compromising on system security and availability. The NAMUR Open Architecture (NOA) describes the requirements for connectivity via the second data channel and in the future will define standardized data structures according to the “NOA information model.” Our range of products includes components that support NOA. They can be used to create a second data channel that permits a direct connection from the field to the apps and to the MindSphere cloud solution.
Thanks to NOA, new monitoring and observation (M+O) functions no longer need to be measured against the stringent demands of core automation. In the future, automation solutions with significantly lower availability requirements can be used.
Strategies for the successful digital transformation of your company
For industrial companies worldwide that wants to remain competitive, digitalization isn’t a question: It’s a must. But where should you begin your digital journey, and what are the costs? Let us help you design your digital transformation. We created Digitalization Consulting for customers like you in the process industries. Find out about our range of digital options for your entire value chain. We’re happy to help.
Smart apps for maximum data transparency
State-of-the-art automation technology can generate vast quantities of data from production processes. But sophisticated evaluation tools are needed to turn this data into transparent information that will allow your company to exploit the full potential of digitalization. The following apps illustrate what’s possible.
Companies on the way to becoming digital enterprises
See for yourself how successfully companies in the process industries benefit from our integrated hardware, software, and services program.
Efficiency sets the tone
The DuluxGroup is Australia largest producer of paints.
When building their new production plant, Dulux relied on state-of-the-art manufacturing technology and consistent, end-to-end digitalization of all processes.
This enables efficient manufacturing of paints in any quantity, whether in batch sizes of one or in mass production.
Personalization is a top trend in medical technology.
Biotechnology company BioNTech is specialized in the development of personalized cancer vaccines.
BioNTech chose Siemens as its strategic partner for GMP production.
Factory of the future
The Solvay/Butachimie chemical factory in Chalampé, France, is one of the world’s largest facilities specializing in the manufacture of polyamide 6.6 and its intermedi-ary products.
Investments in future-proofing their facilities resulted in the changeover of all pro-duction facilities to SIMATIC PCS 7.
To simplify the migration and further optimization, the real plants were tested before their actual commissioning – as a sort of “virtual twin” – using SIMIT simulation software.
Completely integrated digital solution package consisting of electrical and telecommuni-cations technology, instrumentation, and process control for Norway’s Ivar Aasen oil plat-form in the North Sea.
With the COMOS and COMOS Walkinside software solutions, technicians receive accu-rate 3D mapping information on every component of the plant – without ever having to set foot on the platform.
Digital solutions convert data into real-time knowledge, enabling faster, more intelligent decisions and savings in the millions.
The Albert Friedrich AG (Fripa) paper factory uses the SIPAPER industry concept for its new PM7 toilet tissue line.
The solution is precisely tailored to the paper industry.
It includes highly efficient drive systems, automation and process management systems, intelligent energy distribution and services.
The move of the Munich Paulaner Brewery from the Nockherberg to Langwied was fully planned in advance.
Paulaner used the TECHNOMATIX simulation tool to ensure that the plant engineering went smoothly at the new brewing location.
To compare brewing scenarios and to determine the optimum setup, the brewing process was simulated.