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Siemens AG Automation and Drives

www.siemens.com/automation

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Totally Integrated Automation enabling improved competitiveness in every industry

Totally Integrated Automation connects your vision with Siemens technology, products and services.

... higher manufacturing speeds, tighter integration between machines, For every industry safer production environments, 24/7 operations and more. At the same time cost pressures are forcing you to reinvent how you engineer and operate. With Totally Integrated Automation (TIA) the solution platform for all industries you will reach farther, faster and with less effort. From continuous and batch processes to discrete manufacturing and everything in between, TIA provides a single architecture for automating all industries.

Process
Food & Beverages Pharmaceuticals

Discrete
Cement & Glas

Metal/Mining

Pulp & Paper

Automotive

Production workflow Totally Integrated Automation is an integrated platform for the entire manufacturing facility from inbound logistics via the process and manufacturing engineering stages all the way to outbound logistics.

Production Workflow
Inbound Logistics Process

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Reduced time-to-market You engineer your system in one integrated development environment with TIA. Operator interfaces, controllers, I/Os, drives, communications are configured and programmed as part of an overall project. Not only do you have a more intuitive and clear overview of the complete project but also when you drill into each component, the engineering and configuration has the same look and feel. TIA gives you the benefit of very tight integration. With this unique approach, you will design, configure, program and test your system faster and deliver products sooner. Secured investment You want the flexibility to rethink how your machine, factory or process is automated without sacrificing your investment. Totally Integrated Automation takes an application view, not an installation view. It helps you manage your intellectual property and does not let the necessities for continuous improvement manage you. It is this approach which makes TIA an optimal architecture for not only digital I/O intensive discrete part manufacturing but also CPU and analog I/O intensive process applications. More and more production systems are an integrated, interconnected hybrid of batch/continuous processes and discrete manufacturing. TIA purposely enables both in one platform, without rewriting applications, without changing hardware and without learning multiple engineering environments. Increased productivity Even with everything you are reaching for, you have to do it with fewer resources. Using Totally Integrated Automation you will achieve more with less. Designed into every TIA component are unrivaled levels of integration and Siemens experience from years of working with applications like yours around the world. Combine that with a depth and breadth of products, from controllers to process automation systems, from sensors to MES solutions, from the lowest level of production right up to the systems used by management to drive your business, and you have an automation platform that understands your needs and fulfills them. You will be more productive with Totally Integrated Automation because we designed in solutions to many of your needs and when you engineer a system there is less you have to do.

Discrete

Outbound Logistics

Production life cycle With TIA, from its system-view engineering environment and common, open communications to its sophisticated diagnostics, you will get more from every stage of your production life cycle.

Production Life Cycle

Design and Engineering

Installation and Commissioning

Operation

Maintenance

Modernization and Upgrade

Electronics

Chemicals

Oil & Gas

Refinery

Energy

Water

Using Totally Integrated Automation, you will optimize your entire production life cycle

The components and engineering tools are designed in such a way as to provide you with optimal support in every phase of your systems life cycle. This allows you to secure and even increase the value of your investments.

Installation and commissioning You want to reduce the time it takes to get your system up and running in order to start profiting sooner from your production. You dont want any surprises. If you are thorough it will pay off down the road yet you need to get it done quickly. Thanks to the common engineering environment in Totally Integrated Automation, you can access all components of your automation system across all of your networks from one central point. Another example of how TIA speeds up start-ups is Component based Automation our concept for modularizing plants. Complete sections of a plant can be developed in parallel and started up in advance. When the sections arrive on site, they have been fully tested and all that remains to be done is to optimize the interfaces. And shorter start-up time also means quicker time-tomarket. Operation As an operations manager, you need to improve productivity. Not only can you optimize individual processes, but to have a major impact on productivity you have to coordinate across not only multiple production processes but with business processes as well. With Totally Integrated Automation, you can model plants and production processes. Our MES applications provide you with all the necessary tools in the production process such as archiving, quality assurance, product data definition and materials management. They are integrated into a framework and communicate quickly, securely and efficiently within the company and outside the company. In addition, they minimize downtimes by informing you immediately about the status of your plant no matter where you are. Alarms and fault messages are automatically routed to the visualization systems. Not only do you save programming effort, but also improve the visibility of your operations.

Maintenance Managing a service and maintenance organization is complex, and any process simplification will save you time and money. This includes reducing training requirements, stocking fewer spare parts, managing fewer service calls, improving safety and reducing downtime. With Totally Integrated Automation, you can use the same controllers throughout your operations, significantly reducing training for your service personnel and the number of spare parts required in inventory. Fail-safe versions of our controllers offer safer systems for operators and maintenance personnel. Fault-tolerant versions eliminate unplanned system outages. Hot-swappable I/O and system modules allow maintenance during operation. And user parameters can be loaded over the network at the press of a button, without additional overhead. Even if the system does go down, there is a wealth of fault detection and troubleshooting tools available to you. For example, you can perform remote diagnostics of your automation system via telephone or Internet. In many cases, service personnel dont even have to be on site to eliminate faults. The result is an increase in your plants availability, while you save time and money.

Modernization and upgrade You want to respond faster and more flexibly to changing market requirements. Or you just want to get more out of your existing operations by taking advantage of new technology without starting all over. Totally Integrated Automation enables you to expand or convert your plant without interrupting operation. Distributed I/O devices for integrating new drives, valves, instruments or sensors can be added or removed on the fly. This allows you to take advantage of our advances in technology during your retrofit, because new TIA product generations are integrated easily into existing systems. We are rigorous about system compatibility and ensure that you can continue to work with familiar engineering tools and components. Also, with Component based Automation a technology integrated within the SIMATIC family to simplify objectoriented modular design you can modernize or adapt your production lines to new products particularly quickly. Machines or production areas can be replaced or added plug & play. New machines can be integrated into the existing plant networks extremely easily on site, without changing the control program and without affecting already tested functions.

Design and engineering Engineers want to push the performance limits of the machines and processes they design while maintaining a transparent view of their overall project. Management wants more from engineering with less cost. In Totally Integrated Automation engineers and management find the most comprehensive and effective solution platform for manufacturing and process engineering. For example, not only does our process control system use standard controllers and visualization software, it is also configured with the same development environment. This reduces engineering time, maintenance overhead, and spare parts management. There are also powerful preengineered software modules available for specific applications. In addition, you can deploy user programs without change across a variety of networks. All you have to do is reconfigure the network itself. Through automatically generated operator screens and messages, you can quickly create plant visualization systems. From the configuration data, the process control system derives operating and signaling behavior on its own for controller, motors and valves.

Design and Engineering

Operation

Modernization and Upgrade

Installation and Commissioning

Maintenance

Production Life Cycle

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Using Totally Integrated Automation, you will optimize your entire production workflow

Enterprise Resource Planning (ERP)

Manufacturing Execution Systems (MES)

MES Solutions

Totally Integrated Automation

Control
Process Control, PLC, Human Machine Interface, Motion Control, Numeric Control Sensor Technology, Machine Vision, Drive Systems, Safety Integrated

Industrial Communications (PROFIBUS, Industrial Ethernet/PROFInet, AS-Interface)

Inbound Logistics

Process

Discrete

Outbound Logistics

Enterprise Resource Planning (ERP)

Using Totally Integrated Automation, you will secure your investment and take advantage of further innovations
Your companys intellectual capital is more valuable than ever in todays highly competitive business environment. Strategic decisions surrounding the future of automation technology become a key factor in sustaining your competitive edge. By building your systems using Totally Integrated Automation you preserve the investments youve made in capital and intellectual property by guaranteeing compatibility across different generations of products. The decisions you make today will impact your company for decades. While securing your investment, TIA continually delivers innovative technology, keeping you ahead of your competition. Totally Integrated Automation allows you to invest in your future today.
SIMATIC NET Industrial Communication SINAUT Telecontrol System

Ethernet

Manufacturing Execution Systems (MES)

Ethernet

Production Order Management

Material Management

Production Operations Recording

Equipment Management

Pro

SI

Control

Industrial

Industrial Ethernet

Ethernet

Safety Integrated

SIMATIC Software

Wireless Communication/ MOBIC

PROCESS FIELD BUS

PROFIBUS

SIMATIC Controller/ Automation System AS-Interface Actuator-Sensor Interface Level ECOFAST IP 65 Decentral Automation System

PROF

Plant Information Management

Product Specification Management System

Threefold integration is the foundation for the most complete and tightly integrated automation platform
Common data management Through Totally Integrated Automations efficient data management, you reduce time-consuming, redundant data entry tasks and eliminate faults caused by incorrectly entered data. All software tools share the same integrated database. This means that data is only entered once, yet it is available and used throughout the system. You only have to create symbolic references in one place, so those defined in Common communications You can create a highly transparent manufacturing facility by optimizing information flow. With Totally Integrated Automation, all the hardware and software components speak the same language. For this reason, it is extremely easy to configure data flow, even across different physical networks. PROFIBUS and Industrial Ethernet, for example, are treated identically. Changing from one to the other requires only that the communications processor be Common engineering You can reduce your programming overhead through the use of a common integrated engineering system. Within Totally Integrated Automation, all of the engineering tools, from diagnostics to configuration, are integrated within a project manager. The hardware components and the communication system are centrally configured, and all software tools are coordinated to work with each other. All of this supports you during the complete engineering process for the entire life of your systems. Whether you are programming a PLC or a PC-based solution, configuring a humanmachine interface, defining communication links or implementing motion controls, all the tools work seamlessly together. Our process control system uses the same engineering tools as our PLC and PC-based systems. And when you create control and visualization components for one platform, they are seamlessly available across all platforms. This modular concept makes applying complex technologies much easier. Software libraries we supply, for example, can simplify connection to MES applications. Our MES applications are integrated into a similar framework and coordinate with business processes in much the same way we integrate plant floor processes. You now have a common systems strategy, from the plant floor to business systems. changed without modifying the user program and without additional engineering overhead. The integrated communications system, from the field level to the corporate management level, is based on internationally recognized standards like AS-i, PROFIBUS, Ethernet, PROFInet and TCP/IP. And it supports global information flow with built-in Internet technologies such as E-mail and the World Wide Web. any tool such as a configuration tool, a program editor or a screen designer are understood by all the other tools within the integrated engineering environment. And thanks to built-in multi-user capability, data consistency is guaranteed even when several people are working simultaneously on one project. You save not only time, but headaches as well.

oduction Modeler

MATIC IT FRAMEWORK
Detailed Production Scheduling Laboratory Information Management System

SIMOTION Motion Control System

SENTRON Circuit Breakers

SIMATIC PCS 7 Process Control System

SIMATIC HMI Human Machine Interface

Field Instrumentation / Analytics

HART
SIMOCODE-DP Motor Protection and Control

SINUMERIK Numeric Control SIMODRIVE

Drive Systems

IBUS PA

SIMATIC Distributed I / O

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SIMATIC NET Industrial Communications SIMATIC Software

Only precise diagnostics enable plant availability approaching 100 %.

When BMW was looking to start production of its new 5- and 7-series automobiles, they needed a way to reduce system downtime to stay ahead in todays competitive marketplace. By choosing IEC 61131compliant programming languages, they were assured that control logic was quickly understood and extremely easy to analyze by their engineers, especially during troubleshooting. And by choosing SIMATIC Industrial Software, BMW was able to optimize their engineering and maintenance processes for additional downtime reduction by relying on an integrated systems diagnostics approach that automatically generated and displayed fault messages on the users operator panels from SIMATIC HMI. The result: TIAs open standards, powerful diagnostics and an integrated engineering environment improved plant availability today to over 90 %.

SIMATIC IT

Faster new plants construction is a significant contribution towards reducing time-to-market.

As a global player and market leader, SAB Miller (South African Breweries) wanted to construct the most technically advanced brewery in the shortest possible time. Consistent use of distributed automation on PROFIBUS and AS-Interface along with reductions in the cabling overhead guaranteed that the ambitious project goals with regard to installation time and costs could be achieved. Over 1,000 different field devices are networked in the brewery using PROFIBUS. This included over 400 servodrives in the packaging hall alone. Thanks to the use of intelligent field devices such as the SIMOCODE motor protection relay, maintenance personnel can call up diagnostics information from the field devices from the central control room. The result: the total time required to build the plant from the management decision to the first brewing run was only 18 months.

Only flexible production systems make it possible to get new products to market faster to allow better utilization of patent terms.
With its new multi-purpose plant, Bayer CropScience AG is wellequipped to face the stiff competition in the market for pesticides. The modular design of the plant enables extremely flexible production. A seamless electronic link between the control systems and the newly introduced SAP system was also required to achieve the integrated solution. A totally integrated production control system from process automation with SIMATIC PCS 7 right up to the MES solution with SIMATIC IT controls all processes in the plant, collects all information plant-wide and prepares it for the SAP system. The result: the most flexible production system possible, enabling optimal plant utilization and reducing time-to-market for new products.

SIMATIC Controller

At 8,000 cigarettes per minute, downtimes in the packaging areas are not acceptable.
Philip Morris, the global cigarette powerhouse, manufactures most of the worlds leading cigarette brands. This can cause headaches within their production systems, where six brand changes a day are not uncommon. They needed a high degree of system flexibility to meet the demands of the marketplace. Totally Integrated Automation provided Philip Morris with the strategy they needed. SIMATIC controllers and distributed I/O devices allowed the system to be structured, modular in design with distributed intelligence and control. Autonomous modules were coordinated over PROFIBUS and run independently of the central controller. Downtime in one area of the system did not affect other areas, increasing overall plant availability. The result: Philip Morris was able to completely eliminate total system downtime in this crucial packaging and palletizing system.

SIMATIC HMI Human Machine Interface

When you have a host of different recipes, changing from one to the other without losing time while maintaining consistently high quality is crucial to success.
Continental needed a strategy to maintain over 100 recipes used in the production of tire rubber. And since peoples lives depend on their tires, having a centralized, secure recipe management system was critical. At the same time, these recipes have to be ready at any time for use on the plant floor. Continental chose to use a process visualization system from the SIMATIC HMI spectrum. All the details of the recipes, as well as the collected quality data, are stored centrally and homogeneously in one database, secure but ready to be called up on demand. The result: Continental was able to safely and securely manage their trusted recipes while maintaining the flexibility they needed to remain competitive.

SIMOTION and Drive Systems

The highest possible levels of precision and minimum use of materials in pre-production are the be-all and end-all for competitive end products.
Dimeco, one of the leading suppliers of flexible punching and bending equipment, needed to reduce production waste generated by their equipment. And TIA provided a strategy that was just what they were looking for. Dimeco developed the first mechatronic roller feed based on SIMOTION, an advanced motion control system. SIMOTION combines complex motion control, logic and technology functions within a single controller. All engineering tasks are implemented with the integrated graphical engineering tool SCOUT. All production parameters are stored in the controller along with up to 200 machine recipes. SIMOTION, when used together with Siemens drives, guarantees continuous and reproducible manufacturing precision of 0.05 mm. The multi-axis design also enables zigzag control of the roller feed in order to interleave complex cutting patterns. The result: Dimeco was able to offer their customers a machine that greatly reduced production waste.

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SIMATIC PCS 7 Process Control System

Using Totally Integrated Automation, you will benefit from our complete service and support

In the pharmaceutical industry, seamless documentation of all data, even in the case of small batches, is indispensable to validation.
Novartis used the SIMATIC PCS 7 process control system to modernize its pharmaceutical pilot plant for manufacturing active ingredients in small batches. Since active pharmaceutical ingredients are manufactured in the plant, which are also to be sold in the USA, FDA compliance is required even for production lines outside the US. SIMATIC PCS 7 uses internationally established standards designed for use in plants requiring validation. SIMATIC PCS 7 was used to automate the entire process and guarantee seamless collection and documentation of all relevant information. The result: SIMATIC PCS 7 made it easier to consistently implement FDA guidelines and provided significant savings at validation.

Totally Integrated Automation is at home no matter where in the world

SIMATIC Machine Vision

your plant is located or where you deliver your machinery. Our service and support is available to you and your customers everywhere. And we provide comprehensive support from planning through start-up to modernization for all of your automation solution needs.

Timely detection of defective parts prevents additional costs in the rest of the production process.
In VWs foundry, aluminum cylinder heads are manufactured for VW, Audi, Seat and Skoda. Faulty cylinder heads must be rejected for re-machining on a consistent basis. SIMATIC Machine Vision, the image processing system in TIA, ensures fully automatic visual checking. The higher-level SIMATIC controller that rejects the workpiece for re-machining, if necessary, is informed via PROFIBUS. The result: 100 % quality assurance. Only completely fault-free cylinder heads are processed reducing costs and increasing product quality.

Design and Engineering

Installation and Commissioning

Operation

Maintenance

Modernization and Upgrade

Safety Integrated

Online Support The comprehensive, generally available information system over the Internet, from product support to service & support to the support tools in the shop. Technical Support The competent consulting service for technical issues with a broad range of requirements-based services around our products and systems. Technical Consulting Assistance in the planning and design of your project: from the detailed analysis of the current situation and the definition of goals through the consulting about product and system issues all the way to the development of the automation solution. Design and Software Engineering Assistance in engineering and development with requirements-based services from configuration to the implementation of an automation project.

On-Site Service Our On-Site Service includes services for all aspects of commissioning and maintenance as a major prerequisite to ensure availability. Repairs and Spare Parts In the operating phase of a machine or automation system, we offer comprehensive repair and spare parts services that maximize your operating safety. Optimization and Modernization To increase the productivity or to save costs in your project, we assist you with high-quality optimization and modernization services.

Safe, efficient automation of critical processes is easy and cost-effective with Totally Integrated Automation.
Shell & DEA Oil, one of the largest processors of crude oil, used TIAs Safety Integrated to implement a refinery-wide modernization. The modernization brought the system up to the very latest standards of safety, in some cases even exceeding levels required by law. 25 % of the distributed inputs and outputs at Shell & DEA Oil are now automated with Siemens fail-safe technology. Siemens Safety Integrated provides a very cost-effective solution by incorporating many standard elements of TIA. For example, safety-related communication is handled over standard PROFIBUS utilizing a special safety application protocol called PROFIsafe. The result: an integrated control and safety system provides the highest level of safety for personnel, machine and plant yet is cost-effective to own and operate.

Field Instrumentation

Detailed fault messages are indispensable for early, precise fault detection.
In the most up-to-date water-based paint factory in the world at DuPont Performance Coatings, engineers are constantly searching for more efficient, safe and reliable production strategies. The SITRANS process instruments of TIA feature simple installation and outstanding communication and diagnostics capabilities. These devices have become established as standards for pressure and temperature measurement. The use of these instruments resulted in significant time savings in critical areas such as project planning, documentation and start-up. It is particularly easy to integrate the SITRANS field devices into SIMATIC PCS 7. The engineer can read the current diagnostics status of the field device at any time over PROFIBUS. In the event of a fault, operators receive a detailed message that quickly directs them straight to the cause. The result: PROFIBUS made it possible to connect field devices even in the hazardous area and where space was at a premium.

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