單條生產線可生產 350 多種產品。
更高的效率和靈活性
- 數位化之前，該工廠採用三條獨立的生產線，生產 77 種產品。如今，憑藉著完全整合且數位化控制的生產線，該工廠可以輕鬆生產超過 350 種產品。
- 此前，三條生產線平均每 21 秒生產一件產品。儘管產品規格和種類增加，但單條生產線上每件產品的生產週期已縮短至僅 9 秒，凸顯了效率和靈活性的顯著提升。
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水平整合
在數位企業的整個價值鏈中的無縫數據流
數位化拯救印度一座擁有 50 年歷史的工廠
Siemens Xcelerator 將 Siemens 位於孟買附近卡爾瓦的 50 年歷史的低壓開關設備工廠改造成永續發展的數位化企業。
卡爾瓦工廠轉型為一座全面數位化、永續發展的工廠，完美詮釋了 Siemens Xcelerator 如何透過加速數位化轉型，為企業帶來競爭優勢，使工廠能夠以更永續的方式營運，縮短整體生產時間，並提高製造靈活性。
Siemens 位於孟買附近卡爾瓦的低壓開關設備工廠，是繼德國和中國工廠之後，全球第三座同類工廠。這家永續發展的數位化企業憑藉其貫穿整個價值鏈的端到端數位化，樹立了全球標竿。改造這座擁有數十年歷史的工廠所需的技術和工程專長，為正在開啟數位轉型之旅的企業樹立了鼓舞人心的典範。
該工廠生產的低壓開關設備產品廣泛應用於工業、機構、關鍵電力和商業等領域。這些產品滿足模組化、多樣化、可靠性、安全性、高效性和世界一流品質等關鍵標準。卡爾瓦工廠代表著一項重要的工程成就，帶來了許多實際效益，例如更高的靈活性、效率、品質和永續性。
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垂直整合
IT/OT 融合：數位企業中從廠房到頂層的數據
此次轉型是透過在整個價值鏈中引入數位化解決方案並垂直整合業務流程，徹底革新傳統流程而實現的。團隊利用 Siemens Xcelerator 產品組合（例如 NX、Teamcenter、TIA 和 MES），建構了產品、生產和效能的數位孿生模型，整合了從產品設計到生產設計、工程、執行直至服務層面的橫向流程。 IT/OT 整合也協助建構了企業級與廠房級之間極為重要的垂直整合。
該開關設備工廠將先進的生產方法與數位孿生、IT/OT 融合和 MES 等最新技術相結合，並採用永續的工業實踐，使其成為一家永續發展的數位化企業。
整個價值鏈的整合與數位化
產品設計
Siemens 軟體將設計和製造工程無縫連接，透過整合機械設計、電子元件、軟體、封裝設計和模擬等整體方法，確保驗證和最佳化。這種綜合方法使企業能夠快速適應不斷變化的市場需求，在提升產品效能的同時縮短產品上市時間。
生產計畫
快速且靈活的生產排程能夠為短期和日常營運提供明智的決策依據。利用先進的演算法，平衡需求與產能，並制定切實可行的生產計畫。這種方法能夠最大限度地提高效率，縮短生產時間，降低成本，確保營運更加順暢，並實現最佳產量。
服務
利用數位孿生技術連接並最佳化設計、系統、軟體、模擬和視覺化流程，在問題實際出現之前就將其解決。透過連接人員、自動化和簡化產品生命週期流程，並提供視覺性以支援創新產品決策，工業物聯網即服務 (IaaS) 可確保營運的完全透明。
Combining the real and digital worlds
The Siemens factory in Kalwa can now manufacture over five million devices annually. The low-voltage switchgear factory has achieved end-to-end digitalization across its value chain through Product Lifecycle Management software such as NX and Teamcenter, Totally Integrated Automation (TIA) Portal, and Manufacturing Execution System (MES). These solutions enable the design of products, tools and equipment, master data management, automation, process simulation, and product traceability.
The company recognizes this factory as a standard for considerable productivity enhancements digitalization provides, while simultaneously showcasing Siemens digital product portfolio.
The digitalized factory is proof of how adopting digitalization will help Indian industry, especially small and medium enterprises (SMEs), achieve manufacturing excellence. SMEs can utilize digitalization to address growing demands such as mastering increasing product and process complexity, reducing time to market, adapting to changing market requirements, deliver individualized products and secure continuous product improvement while remaining sustainable.
Improved sustainability
Energy efficiency at the factory is twofold. The entire site aims to be carbon-free by 2030, which means that reducing energy consumption is a top priority. Also, the energy used will be generated from on-site renewables. Data analytics plays a critical role in increasing energy efficiency and making the most of renewable energy. The factory partly uses the energy generated from the rooftop installed solar thus resulting in reduction in the energy consumption.
This holistic approach enabled by Siemens Xcelerator allows enterprises to not only operate with more agility but also more sustainably, securing long-term growth and competitiveness.
October 2024
Proven outcomes at Siemens Kalwa factory
Production capacity: 35% increase in production capacity from 1’1 to 1’5 pieces per year
Sustainability: Carbon footprint reduced by 86%
Energy consumption: Energy consumption reduced by 394MWh
Flexibility: Product variants increased from >77 in 3 lines to >350 in 1 line
Time to Market: Cycle time reduced from ~21 seconds to ~9 seconds
Quality: 22 quality parameters checks in 60 seconds to 68 checks in 9 seconds
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