Schindler Optimizes Production Runs with E-CAE Configurator for Escalators

Faster Results with E.series

Jrg Wenzel Mainz

Schindler Elevators and Escalators have been using electrical configuration tools since 1992 to cope with the ever-increasing diversity of escalator options. To maximize the configurators potential and increase productivity, the worlds market leader for escalators and moving walkways selected E3.series.

Figure 1: The longest escalator built by Schindler runs underneath the Kiel Canal in Rendsburg and has a conveyor height of 28m with a 60 kW engine rating.

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Not since first being introduced to the general public at the Worlds Fair in Paris, over 100 years ago, could we imagine life without them: escalators and moving sidewalks serve airports, train stations, department stores and numerous other locations. While the mechanical principles havent changed, much has been done in the electrical area.

Figure 2: Its impossible to imagine life without escalators. E.series is the basis for automatically selecting the electrical options for the manufacturer.

A multitude of electrical options, such as monitoring and regulating lubrication, drive and braking systems, servicing, lighting, displays and sensors, makes escalators safe, reliable and

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convenient systems nowadays. Embedded in these options are the complex rules and regulations for the different country and regional-specific standards. Adhering to these standards can be simplified dramatically by use of electrical configurators.

Figure 3: Employees worldwide can input the required options for manufacturing escalators using the online catalog.

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With the promis E-CAE System, we had already designed an electrical configurator in 1992 based on the PPL programming language (Promis Programmable Language), which by using the master schematics, could create system-dependent circuit diagrams, explained Herbert Schmied, the configurators designer and employee of Schindlers R&D Electrical Department. Due to the increasing complexity and requirements of EN 15 (European Norm 15) for escalator specifications, as well as our integration requirements for sales, inventory control and production, we could no longer modify this generation of configurator and justify the costs. That is why, in 2002, we began our search for a suitable E-CAE System that would fulfill our requirements. E3.series Tests Successfully As part of the study, Schindler decided to investigate the following E-CAE Systems: promis Engine, E.series and Eplan. The biggest concern was that the software could meet the requirements of higher flexibility, ease of use, as well as extensive programming and integration capabilities. Concretely, this meant, among other things, an easy-to-use programming interface, the possibility to create wiring, cable and terminal lists, and extensive import/export functionality, the latter referring to, in particular, the exchange of promis data with the future E-CAE System, as well as OLE Integration, especially with Excel. Additional considerations pertained to the cost/benefit ratio, integration with the in-house order processing system SEOP (SchindlerEscalatorOrderProcessing) and availability of reliable support for the E-CAE Program. At that time, on the basis of their newly developed E-CAE Suite, E3.series, CIM-Team GmbH came closest to our ideal solution. E3.series is a modern, efficient, intelligent and open system that permits direct access to object data through the bi-directional COM interface, which is used by Visual Basic and other programming languages. E.series can be fully integrated into our engineering process, the most important prerequisite for designing our configurator, stated Schmied.

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Figure 4: Sheet before configuring with E.series-based configurator

Figure 5: Sheet after configuring with E.series-based configurator The configurator has been in productive use since April of last year. By coupling the in-house order processing system SEOP with SAP and an on-line documentation system, all production data and documents are available online to all Schindler employees worldwide. Over 250 standardized electrical escalator options can be generated automatically in German, English, French, Spanish, Italian and Chinese with the help of the order processing system, SEOP, and User News - Schindler Jrg Wenzel, Mainz

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the E-configurator. The configuration for the escalators MIC-F controller, which automatically checks and configures the panel using a self-designed proofing system, is also used on the schematics. The lead time from entering the order until delivery varies between 46 weeks depending on the size of the order.

Figure 6: Schindlers E.series-based E-configurator Special Requests Can Also Be Automated Approximately 6000 escalators and moving walkways, consisting of more than 10,000 parts each, were produced in 2004 at Schindlers production sites in Vienna, the USA, Brazil and China. The share of fully standardized orders was approximately 50 % in Vienna and 90 % at the other production facilities with the remaining orders having to be manually edited. Manual editing can be further reduced based on the openness and flexibility of E.series, according to Schmieds assessment. Currently, the online-entered data is checked completely by the in-house order processing system SEOP and stored in a database. Next, the master schematics generated with E.series are copied by the configurator, automatically verified and modified according to the proofed data. Afterwards, a system-dependent schematic is created, from which additional data, such as BOMs, can be generated.

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Neutral bill of materials also exist in SAP, which are supplied with precise order parameters from the circuit diagram. Standardized options are usually no problem, but special requirements for these escalators must be manually reworked. After opening a configured project, adding and connecting the additional required parts, we must also manually rework the corresponding bill of material parameters, explained Schmied. This year we want to shift a meaningful part of the material management from SEOP to E.series. Then, if we enter special requests into the finished circuit diagram, the configurator can obtain the necessary data from E3.series and from there automatically allow for these special requests in the bill of materials. We can also automate special requests, up to a certain degree, shorten the lead time and minimize source errors. At this point, E.series has fulfilled Schindlers requirements regarding practical applications. In the future, the company plans to fully automate the creation of cable lists, taking into account the diverse cable and country specifications (PVC, halogen-free, protective covering...) as well as material calculations using the E3.series SAP interface. For training purposes, Schindler Elevators and Escalators also want to use E.series to create dynamic or "living" circuit diagrams that react to events, such as start/stop/error.

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