Digitalizing Wire and Cable Industry OEMs for Industry4.0
Case in Point: Digitalizing Wire and Cable Industry OEMs for Industry4.0
At a glance
Focus: Digitalizing Wire and Cable Industry OEMs for Industry4.0.
Challenge: Currently relevant data in the required format is not available to the end users in wire and cable industry at one place for decision making and strategy
Approach: For this customer, Siemens team co -created a digitalization roadmap and proposed our cloud-based solution to this OEM and its’ end customers for viewing and analyzing the accumulated data
Impact: Future possibility of ‘Pay as you Use’ business model where OEMs can rent machine to end users and charge as per throughput
Siemens India
Siemens India manufactures steam turbines, turbo compressors, high-voltage switchgear (circuit breakers, disconnectors and gas-insulated switchgear), switchboards, remote monitoring systems (RMS), fire detectors and suppression systems, motors and generators, relays and Smart Grid systems, transformers, and advanced medical imaging equipment. The factories replicate global, best-in-class manufacturing systems and practices, with a facility to overhaul and repair gas turbines, compressor blades and rotors.
Siemens India is a leader in technology solutions for intelligent (smart), sustainable cities, smart grid, building technologies, mobility and power distribution. Siemens is involved in the Restructured Accelerated Power Development and Reforms Programme (R-APDRP) of the Government of India for installing Smart Grid solutions in many cities in India. Siemens India has signed a Memorandum of Understanding with Confederation of Indian Industry (CII) to be the Lead Industry Partner in a consortium for the conceptualization and development of Smart Cities in India.
For over six decades, Siemens India has been the preferred technology solutions provider, conceptualizing and implementing various flagship projects in Mobility, Energy Management, Power and Gas, Smart Cities, Intelligent Infrastructure, Industrial Applications, Healthcare and Smart Financing. Siemens India is also strengthening its digitalization portfolio and working on select applications in the country.
Siemens India develops skills with Corporate Citizenship initiatives like ITI upgradation, faculty development, Technical Skills Development Centre and Scholarship Programs for meritorious Engineering students. The company has signed Memorandums of Understanding with the Government of Gujarat and Steel Authority of India, and works with industry bodies, such as Automation Industry Association, Indian Machine Tool Manufacturers Association and CII, to impart technical education. Siemens also has initiatives for sustainable and integrated community development in rural areas.
Digitalizing Wire and Cable Industry OEMs for Industry4.0
This customer is a leading OEM in Wire and Cable industry and has a wide range of products in wire and cable Industry specializing in extrusion and sheathing lines required for forming the insulation on the copper and aluminum conductors. They have over 500+ extrusion line installations In India and abroad.
Business challenge
Currently relevant data in the required format is not available to the end users in wire and cable industry at one place for decision making and strategy
Currently relevant data in the required format is not available to the end users in wire and cable industry at one place for decision making and strategy formation. Big cable and wire end user can have more than 80 extruder lines in a single plant for different type of wires and each extruder line can also be used to run different recipes. Many of these Extruder lines are from different OEMs and are not interconnected. For an end user it is very difficult to compare the performance of these machines, find major downtime reasons, compare operator efficiencies, and map consumables like inks, PVC for these machines etc. This customer being a leading OEM was receiving such enquiries from lot of end users.
In cable and wire industry, production data from shop floor is required to be entered in higher level system like SAP and other ERPs periodically. Currently this is being done manually at many end users due to lack of interconnectivity between these machines.
Hard logbooks are prepared to keep track of raw material used for example oil, Inks and PVC
Wire and cable industry is a very dynamic Industry and with changing end customer requirement, the time required for bringing product to market is very short.
Lot of hit & Trial is involved in commissioning, for example key settings for maintaining tension in cable or wire line can take a lot of time and this leads to prolong stay of OEM engineer at end customer, leading to wastage of resources.
Lack of tools for safe and secure remote commissioning especially in today’s time when domestic and international travelling is limited due to the pandemic.
Industry 4.0 solution
For this customer, Siemens team co -created a digitalization roadmap and proposed our cloud-based solution to this OEM and its’ end customers for viewing and analyzing the accumulated data. Browser based application is designed by Siemens with below Features:
Machine wise OEE, Breakdown analysis
Reports will be available Shift wise/Daily/weekly
OEE Report
Worker Performance
PVC Consumption
Downtime analysis
Process downtime
Production report
Mapping of consumables like Oil, inks and PVC with output produced. For example how much PVC or ink should be used as per recipe running and how much is consumed
Integration of End user’s energy management system in MindSphere (Siemens’ cloud platform) to map the power consumed per unit output produced.
MindSphere will provide this OEM, running machine data for machine improvement and development
To post real-time production data from shop floor to the end user’s SAP automatically, the OEM is using Industrial Data bridge i.e IDB. All machines at the end user’s plant are integrated first and then data is brought to IDB. This OEM provides machine-wise production data to their end customers in required format, from there end customer picks data through APIs.
The OEM is using Siemens NX software for designing machine components. Integration of software for machine Simulation virtual commissioning are planned for the next stage. This will help to reduce customer’s commissioning time
This OEM is using Siemens SINEMA RC for remote commissioning and provide after commissioning support.
Key benefits
| Area | Outcome |
|---|---|
| Productivity & Throughput | Future possibility of ‘Pay as you Use’ business model where OEMs can rent machine to end users and charge as per throughput produced. |
| Downtime & Reliability | OEM can roll-out new business model and offer subscription-based services like predictive maintenance, remote connectivity services, downtime analysis. |
| Visibility & Analytics | Availability of running machine data for machine improvement and analysis purpose. |
| Operational Benefit | Industry 4.0 compliant machine with remote connectivity will give this OEM edge over its competitors. |
| Operational Benefit | OEMs can view KPIs for their global installations on a single cockpit. |
| Operational Benefit | More revenue because of the spare part business improvement. |
Technologies used
Change management and implementation
We are creating value by addressing the challenges of Indian manufacturers with an integrated Digital Enterprise approach. We formed a cross functional team cutting across verticals and ensure that all our projects are agile and customer centric. The Siemens’ team stepped in to implement the customer’s vision of digitalization and drive the transformation for Indian manufacturers by kickstarting their i4.0 journey.
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