E4 e automotive_partmanufacturing_v10

Siemens Corporate Design PowerPoint-Templates

High-productivity part manufacturing for automotive suppliers

Essentials for ExcellenceRealize innovation.Unrestricted Siemens AG 2016

LOGOEXUnrestricted Siemens AG 2016Page #Author / Department

20XX-XX-XXWelcome everyone. My name is ------ and I want to thank you for taking the time to join our webinar about essentials for excellence in part manufacturing, focusing on the needs of automotive suppliers.

[ Briefly give your introduction. Establish your credibility to present these materials. This might be done by the webinar host introducing the speakers of the session. ]

In todays presentation, we will discuss some of the top automotive industry challenges and how Siemens offers effective solutions to achieve both your business and manufacturing goals.

So lets get started

Notes 1

Whats In the Number?30,000


20XX-XX-XXLet me ask you to make a simple guess. Whats in this number?

[Pause for 2 seconds]

Notes 2

Whats In the Number?


20XX-XX-XXOn average, a single car has about 30,000 parts, including every part down to the smallest bolt. Typically 70-90% of the automotive parts are manufactured by suppliers. The percentage depends on the OEMs and model segment.

The automotive supply chain that is made of smaller and larger companies is the backbone of auto manufacturing.

Today, there are thousands of suppliers worldwide, each with the knowledge, technical expertise, and scale to produce certain components and contribute to the making of a vehicle. Notes 3

Whats In the Number?


20XX-XX-XXFor example, auto part makers can manufacture engine and powertrain components, molds to make the plastic components, stamping dies for body parts and many more components.

Increasingly, we find that the automotive parts are made of different materials and require sophisticated manufacturing processes to produce them.

Today, we will look at a range of advanced digital part manufacturing solutions that can help improve your productivity.Notes 4

Cost Pressure

86% of auto suppliers report intense cost pressures from the OEMs4-6 % Planned annual spending cuts by OEMs


20XX-XX-XXFirst, lets take a quick look at some of the challenges facing the automotive industry and how it may affect your manufacturing priorities.

As an auto supplier, you are probably facing increasing cost-pressures from the OEMs and upstream suppliers.

Automakers are on average planning to reduce spending by 4-6% annually.

In a recent BCG report, an overwhelming majority of respondents86 percent of the supplierssaid that they are under increased cost pressure from their automotive customers.

While larger Tier 1 suppliers have managed to deal with both the push to globalize production and cost pressures for some time.

Research has found that smaller suppliers are less adept at navigating the constraints.

We all know the nature of the supply business entails that there will be constant cost pressures.

The question is how to deal with it?

Data Source: The Boston Consulting Group (BCG)Notes 5

Compressed Development Time

Suppliers haveto respond to OEM requirements faster than ever before


20XX-XX-XXWe all are familiar with this trend

Vehicle development time is shrinking constantly. A typical vehicle program that used to take 9 years just a decade ago now takes around 4 years.

And, the trend to shrink program time will continue. As per a recent report from Volvo, they want to reduce the vehicle program time to 20 months by 2020.

Therefore, the pressure is on the suppliers to respond to OEMs design requirements faster while showing the ability to meet the production targets.

Notes 6

Focus on Quality

Auto suppliers are held accountable for missing quality targets


20XX-XX-XXAutomotive quality is a big issue nowadays and we frequently hear about it in the news media.

2014 marked a record year for automotive recalls. Around 800 recalls totaling close to 64 million vehicles were recalled.

Therefore, quality is an important concern among the auto executives.

One of the reasons for higher recalls in automotive in recent years is due to the standardization of components across multiple models. This result in significantly greater volume of cars affected because of a faulty part. Standardization of parts requires that quality and safety standards are maintained and sustained worldwide. Recalls can assume global proportions.

Nowadays, smaller suppliers are increasingly vulnerable. Many of the downstream suppliers may not able to bear the financial burden of a large scale recall.

Therefore, having a clear visibility to various quality parameters of a product is paramount. Notes 7

Part Manufacturing

Manufacturing engineeringShop floor production


20XX-XX-XXTo address these trends we have seen so far cost-pressures, compressed program time and quality requirements automotive suppliers need a highly-efficient manufacturing process.

In simple terms, the part manufacturing process starts with a digital 3D model of the part that needs to be manufactured.

This part model is used as input for the manufacturing engineering. By using digital manufacturing software you can create a copy (or a digital twin) of the complete machining process, including the machined part, fixtures, even the entire machine tool. The digital twin helps you define, test and validate the best machining process well before the production starts.

Detailed work instructions and shop documentation are then transferred to the shop floor.

The production team can use the complete work package to ramp up production and drive the equipment on the shop floor.

This presentation will mostly focus on part (or component) manufacturing and ways on how to digitalize the process. Notes 8

Automotive Supplier Opportunities

Standardize processes Produce high quality partsIncrease throughput Be more competitiveAccelerate job delivery Overcome inefficient processes


20XX-XX-XXThere are significant opportunities for auto suppliers to streamline and optimize their part manufacturing processes.

First, inefficient or partially automated steps in your work processes can adversely affect your productivity. For example, when manufacturers try to fit disparate software applications, it can result in a process that requires multiple data conversion. And this leads to inefficiencies.

Second, to be competitive in todays environment, manufacturers need to increase their throughput. If your CAM software doesnt provide a complete set of CNC programming capabilities, or when it lacks application-specific functionality, it can reduce both your programming and machining efficiency.

Finally, a standardized manufacturing process ensures consistent production quality.

Notes 9

Siemens Advantages

Standardize processes Produce high quality partsIncrease throughput Be more competitiveAccelerate job delivery Overcome inefficient processes

Synchronize the manufacturing process Drive the process with a single modelStreamline information flow Achieve production targetsMaximize efficiency of machining Program any job


20XX-XX-XXTo be competitive in todays challenging environment, automotive suppliers are asking the following questions:

How do you accelerate job delivery? You can synchronize the entire manufacturing process by leveraging a single model from design to manufacturing. How do you increase your throughput? You need to be able efficiently tackle any job, regardless of its complexity. How do you standardize manufacturing processes to produce high quality parts? By streamlining the information flow across your operation, you can improve your productivity.

Lets look at how Siemens can help you address these challenges Notes 10

Maximize efficiency of machining Program any job

Siemens SolutionsSynchronize the manufacturing process Drive the process with a single modelStreamline information flow Achieve production targets


20XX-XX-XXSiemens PLM provides an integrated manufacturing software solution that supports the entire manufacturing process from CAD/CAM all the way to the CNC controller on the shop floor.

Lets look at how our software can help you synchronize the entire manufacturing process

Notes 11

Synchronize the ProcessMore effective collaborationWork with any CAD data

Job preparation with proven know howUse industry-standard CAD software

Model driven processFor concurrent and collaborative manufacturing


20XX-XX-XXTo collaborate effectively with OEMs and other automotive suppliers, NX lets you work with any CAD data. This gives you the necessary flexibility to use part models designed in any CAD system.

Often, the 3D CAD model needs to be prepared for optimized machining. Using the powerful CAD capabilities in NX, you can cap holes, close narrow slots and edit the fillets. Also, using NX CAD you can quickly implement the latest design changes while keeping associativity. The digital part model moves seamlessly between applications without data translation, all in a single product.

Next, we will take a closer look at how our model driven process can enable concurrent workflow Notes 12

Model-Driven Process

Part model


20XX-XX-XXFor that, lets look at a typical mold manufacturing example. Many of the automotive suppliers manufacture injection molds that are used to produce a wide range of plastic parts in a vehicle, such as this radiator fan shroud.

It all starts with the 3D part model that needs to be molded.

Now lets see how this part model can drive the entire manufacturing process to machine the entire mold assembly

Notes 13

Model-Driven ProcessPreparationProgrammingProduction

INTEGRATED SYSTEM

Mold preparation /Fixture designMold programmingShop documentationElectrode preparationElectrode programmingCNC / inspection programs

Shop floor

Mold design


20XX-XX-XX

Using the automated NX mold design capabilities, you can design the core and cavity, along with all the other mold components. The mold design is the input to the manufacturing process.

The upper half of the diagram describes the process to define the process to machine the mold. Using the CAD design tools, you can quickly prepare the mold for machining and design the fixtures. The next step is to define the machining for the mold by using the CNC programming capabilities in NX CAM. It lets you achieve high-speed machining and high quality machined surface.

A complete set of shop documentation can be easily generated. You can transfer CNC programs, tool lists, setup sheets, and drawings, directly to the machine tools on the shop floor.

At the same time while you were defining the manufacturing process for the mold, your team can work on the electrode machining, using the same unified NX system, and working on the same data (as shown in the lower half of the diagram) they can design, prepare and program electrodes that are part of the mold assembly. Besides CNC programs, NX lets you create inspection paths to drive CMM machines. The output of the electrode programming step including CNC and inspection programs is transferred to the production to drive the manufacturing equipment.

The model driven process ensures:Associativity to the supplied design data,Concurrent workflow, and Accuracy and reliability

Many mold manufacturers around the world leverage the NX integrated platform to maximize their overall productivity

Notes 14

The integrated NX CAD/CAM system enabled us to slash our overall lead time by 30 percent

Yvon LaplantePresidentVerbom Inc.


20XX-XX-XXFor example, Canada-based Verbom Inc. achieved significant benefits by having an integrated CAD/CAM environment.

Verbom designs and manufactures tools and dies. The automotive industry accounts for 80 percent of their business. To stay competitive, they automated the entire design through manufacturing process using NX.

Leveraging the integrated CAD/CAM capabilities in NX, Verbom is able to quickly react to the frequent design changes. And, the advanced CNC programming capabilities in NX CAM enables the manufacturing department to increase the machining capacity by 15%.

Yvon Laplante, President of Verbom said the following: The integrated NX CAD/CAM system enabled us to slash our overall lead time by 30 percent.

This is a significant efficiency gain.Notes 15

Siemens Solutions



20XX-XX-XXNext, well look at how you can maximize the machining productivity by using advanced CAM system.Notes 16

Maximize Efficiency of Machining

Intelligent tool paths For efficient machining Process automation For programming productivity

Knowledge based machining For reuse of proven methods


20XX-XX-XXTo increase the manufacturing efficiency, you need advanced CAM capabilities.

The intelligent tool paths ensure efficient machining and increased machine tool performance. For example, NX CAM lets you automatically tilt the tool, so you can use the right tool to reach challenging areas and improve the surface finish.

Advanced feature-based machining automates the NC programming. NX automatically identifies machining features and applies operations. This capability is ideal for programming parts with many features, such as pockets, slots and complex holes. With feature-based machining, you can reduce programming time by as much as 90%.

With NX, you dont need to start every job from scratch. Machining data library and process templates enable you to re-use proven data and processes. This knowledge-driven programming can improve your productivity and ensures repeatability. Notes 17

Intelligent Tool PathsHigh speed machiningQuickly remove material to reduce the machining cycle.

Superior surface finishCreate smooth toolpaths to produce high quality parts.

Full control of machiningPrecisely control cutting strategies to reduce risk.

Flexible machining with 5-axis operationsMachine complete parts in one setup.


20XX-XX-XXLets take a deeper look into our advanced capabilities for NC programming.

High speed machining for hard materials can significantly reduce machining cycles. The high-speed roughing in NX CAM maintains high metal removal rates while managing tool loads.

Superior surface finish can be critical for mold-makers. The smooth flowing cutting strategies that follow the shape of the mold geometry can result in fine finishes at high feed rates.

Having a full control of the machining process enables manufacturers to reduce risk and improve quality. The Cut Region Control provides a new level of control and ease of use in planning machining strategies for complex molds. You can preview, change, and re-order the regions and the associated operations before generating tool paths.

To increase the throughput, machine shops increasingly use multi-axis machining, including 5-axis machining. It lets manufacturers minimize the number of setups, which results in shorter lead times, increased tool life and improved surface finish. Notes 18

Program Any Job

Mill turn 5 axis millingHole makingFeature based machiningOn machine probingShop floor documentsPost processingMachine tool simulation

Turbo machinery millingTurning3 axis milling

2.5 axis milling

Wire EDM 2 & 4 axisHSM methodsTool libraries


20XX-XX-XXNX CAM is a complete system for CNC programming, postprocessing and machine tool simulation.

The wide range of advanced programming functionality, from simple 2-axis milling to complex 5-axis machining and multi-function machines capabilities, gives you the flexibility to program any job on any machine tool using a single CAM system.

To ensure high quality products, NX also provides an integrated solution for quality inspectionNotes 19

NX CMM - A Complete Solution for Quality

Automated programmingHigh-speed inspection methodsValidate CMM machine movesRead CMM data into NXAnalyze / visualize resultsMonitor process changesInspection programmingResults analysis


20XX-XX-XXThe NX CMM software can automatically create complete inspection programs using the PMI (or Product Manufacturing Information) data attached to the part model. Programming in the context of the CMM machine, ensures optimized and safe inspection paths. You can output validated and production-ready programs to drive a wide range of CMM machines.

The inspection results from the CMM machine can be sent from production back to engineering for analysis in NX. This closed-loop solution enables you to compare as-designed with as-built-results, so you can monitor how process changes are impacting quality.

Notes 20

Using NX, weve moved into the domain of world-class CNC machining.

Ben WhitneyPresidentArmo Tool


20XX-XX-XXArmo Tool manufactures precision stamping dies and complex tooling. Most of Armo Tools business is in the automotive space.

Armo leverages the automation that NX CAM provides. They rely on Feature Based Machining to recognize and program automatically model features. Also, the advanced capabilities let the NC programmers confidently program the most complex jobs, such as multiple part tombstone configurations.

The automated process helped Armo to increase their overall productivity by 40 percent.

For most auto suppliers, embracing new technologies that can give them the necessary competitive edge is the key to success

Notes 21

New, Innovative TechnologiesRobotics Machining

DeburringPolishing and finishingTrimmingIncreased flexibilityBetter repeatabilityHigher accuracy

Complete workcellsMulti-purpose robotsProven technologyExpanded applicationProductivity improvementsAutomated processes


20XX-XX-XXFor example, the use of robots is expanding rapidly in machining operations.

Beyond the familiar tasks of lifting, positioning and welding, robots are being fitted with tool holding heads, so you can perform machining operations, including deburr, grind, cut, trim, polish, and finish.

You can improve your productivity by taking advantage of these continuous technology advances. The robotic machining lets you increase your flexibility to machine larger parts in a single setup and improve repeatability and accuracy by relying on the robots precision motions.

Siemens PLM Software has integrated its proven robotic Tecnomatix technology with the advanced CNC programming capabilities of NX CAM to provide a complete solution for Robotic Machining. Leveraging this sophisticated technology, you can automate complete manufacturing processes on the shop floor. The reduced machining cycles, and improved quality can help you increase your overall production efficiency.

Notes 22

Blank holder side panelPulleyChassis componentKinematics component BlankholderBlankholderHolder gas-filled absorber

Closure clampChassis componentDamper intakeLuggage rack holder

Seat adjustmentHKL hingeBrake line holder

Hose holder

Heat protection blank steering gearCourtesy: N. Skrynecki A transformative technologyNew, Innovative TechnologiesAdditive Manufacturing

Courtesy: FIT Production


20XX-XX-XX3D printing, also known as additive manufacturing, is a transformative technology that build parts by adding material, rather than subtracting like the conventional machining.

Its been rapidly adopted by many industries, because it frees manufacturers from the limitations of conventional machining. Additive manufacturing enables production of parts that you couldnt do before. Increased use of new materials, including various metals only accelerates the adoption of this technology. For some parts, such as castings you can reduce the production cycle from several months to a couple of weeks.

The performance improvements of the manufacture parts can be as significant. For example, a cylinder head produced using additive manufacturing can be 2 times lighter and can have 10 times larger cooling surface.

Also, automakers use additive manufacturing for functional prototypes.

To address some of the limitation of the additive manufacturing, such as the rough surface finish and multiple setups/machines needed to machine a part, a new technology has been recently introduced

Notes 23

New, Innovative TechnologiesHybrid Manufacturing = Additive + CNC Machining Leverage a single environmentMachine production-quality parts

Reduce production costsCompetitive pricing

Speed up time to marketAt time and place of your choice eliminate inventory

Improve performanceBetter products


20XX-XX-XXHybrid manufacturing combines additive and CNC machining into a single environment. With this technology, you can manufacture production-ready metal components on a single machine.

You can build up complex geometries using additive manufacturing and then machine them for tight tolerances using subtractive manufacturing. This revolutionary technology can enable you to manufacture new classes of parts and consolidate many setups into one.

Reduced costs, shorter time to market and improved performance are some of the key advantages of this technology.

NX CAM provides a complete solution to program both the additive and subtractive operations, all in one system.

Notes 24

Siemens Solutions



20XX-XX-XXLastly, lets see how the uninterrupted flow of manufacturing information across your company can help you improve your overall productivity.

Notizen 25

Streamline Information FlowSingle source of dataFor reuse of proven data and processes

Shop floor connectivityFor efficient collaboration between manufacturing teams

Complete part manufacturing solutionFor a digitalized process


20XX-XX-XXVery often, manufacturers try to achieve production targets by relying on a disconnected workflow with bits of valuable information and knowhow residing across the company. This disconnect can be particularly obvious when connecting engineering and production. The flow of manufacturing information between the people and technology can be disrupted and it can involve paper trail and manual processes.

We will now look at how the manufacturing information can be organized in a single source of data. And how you can efficiently transfer this data to the shop floor.

So lets explore how our scalable solution can help you digitalize the part manufacturing process.

Notes 26

Single Source of Data

Data and Process ManagementTooling and fixture designCAMPart model preparationProcess planningCMM inspection programmingTool and resource library


20XX-XX-XXThe CAD-CAM-CNC process chain supports the core machining solution, which meets the requirements of many manufacturers. There are also companies that need additional applications and equipment to complete their part manufacturing process.

For improved collaboration, Siemens provides Teamcenter for data and process management. It enables the manufacturing team to work together using a single source of information.

Connecting NX CAD, CAM, and CMM to Teamcenter establishes a basis for an extended part manufacturing solution. All types of manufacturing data, from 3D part models to setup sheets, tool lists and CNC programs can be fully managed.

To define the process sequence for manufacturing parts, you can use Part Planner, a Teamcenter application. It lets you standardize the process and re-use proven processes.

The Manufacturing Resource Library, gives you a central access point to cutting tools, fixtures and other resources for your entire company. Tooling data, based on standardized tool vendors catalogs can be assembled and organized for your specific manufacturing operation. The integrated solution, lets you access classified cutting tools from NX CAM, so you can easily find the right tool for the machining process.

Notes 27

Shop Floor Connectivity

Tooling and fixture designCAMPart model preparationProcess planningCMM inspection programmingData and Process ManagementTool and resource library


20XX-XX-XXAll the production data (such as process plans, CNC programs, tool lists, setup sheets, and inspection programs) generated by the digital manufacturing software and managed in Teamcenter now needs to be transferred to the shop floor.

In many cases this is done inefficiently by taking paper drawings, memory sticks and spreadsheet printouts to the point of production.

Siemens provides an efficient way to bridge the gap between engineering and production

Notes 28

Part Manufacturing Solution

CNCDNCShop floor program validationTool managementShop floor data accessCMM inspection executionTooling and fixture designCAMPart model preparationProcess planningCMM inspection programmingData and Process ManagementPlanningProductionTool and resource library


20XX-XX-XXBy extending PLM to the shop floor you can deliver manufacturing data from Teamcenter directly to the shop floor, with no local data storage, thus eliminating duplicate data.

The production staff can access current and released CNC programs, drawings, 3D models and other data managed in Teamcenter making sure that the correct manufacturing data is used in production.

Also, shop floor applications can be connected to Teamcenter. For example, tool data management lets you ensure that tools are properly prepared and available for scheduled jobs.

The machine-specific CNC programs can be delivered directly to machine tools. And to ensure high-quality parts, you can drive the inspection machines using the CMM inspection execution application.

This diagram represents a view of our complete solution for digitalized part manufacturing - from planning to production.

This integrated solution provides some unique and powerful advantages, including:Integrated manufacturing software applications and equipment,Centralized data and process management, andEffective connection to production

Notes 29

The combination of NX CAD, NX CAM, and the SINUMERIK controller from Siemens helps us stay ahead of our competition.

Pascal LachanceMechanical EngineerMoules Mirplex Inc.


20XX-XX-XXMirplex Molds Inc. is a mold manufacturer with more than 25 years of experience. They chose NX because of the integrated CAD and CAM.

With NX, Mirplex implemented a concurrent workflow. While the tool designer is finishing the mold, the CNC programmer can start the programming work in NX CAM. This is possible, in spite of the fact that many design changes are still coming in from the customer; because of how easily the NX geometry can be changed.

The results are impressive. They reduced the overall development cycle by 35 percent. After design changes, Mirplex can update complete machining processes 50% faster. Notes 30

Integrated solution - Demonstration


20XX-XX-XX[below is the script for the video, which is 3:10 minutes long]

Mold Design (30 sec)NX automates the mold design process. The flow analysis simulates how material will flow inside the mold. You can create the parting surface with minimum input.The core and cavity are automatically created by using the parting surface and part geometry.You can define the rest of the mold components using the library of standard parts. To validate the mold design you can simulate the mold movements in NX. Finally, you can quickly create a complete drawing with a filled-out title block. Mold NC programming (55 sec)You can now define the CNC operations to efficiently machine the mold.The advanced roughing methods in NX CAM are designed for high speed machining of hard materials.You can re-use proven data stored in the machining database.The fully automated rest milling identifies uncut material from previous operations. You can automatically convert 3-axis to 5-axis toolpath, so you can safely use shorter tools to machine challenging geometry.NX CAM recognizes and programs many feature types by using feature-based machining. This technology can reduce your programming time by up to 90% . The G-code-driven machine tool simulation displays the motion driven from the NC code, so you can validate the operations.You can generate machine-specific CNC program by using the integrated postprocessor. Complete sets of shop documents, such as tool list and setup sheets, are easily created with NX CAM.

Electrodes NC and inspection programming (53 sec)To machine and inspect the electrodes, you can use the CAM and CMM modules in NX.The advanced NC programming capabilities let you create efficient toolpaths to rapidly remove material by using roughing and rest milling methods. For challenging electrode geometries, the 5-axis capabilities enable you to machine parts in a single setups.NX CMM lets you work directly in the NX 3D environment. The inspection programming can be automated by using the PMI information, such as tolerances and surface finish data attached to the solid.NX provides inspection program verification and full machine simulation. By selecting the appropriate postprocessor, you can create machine-specific inspection programs.Design change (51 sec)A design change is an everyday challenge for manufacturers. How fast you can incorporate the design changes can affect the efficiency of your entire manufacturing process.In this example, the designer uses Synchronous Technology to quickly change the thickness of the tab on the molded fan shroud. To visualize the design changes, NX can display comparison of the original and the revised part model.The part edits propagates to the mold cavity, which is automatically updated to reflect the new size of the tab.Using the Wave link capability in the Electrode Design module, you can update the manufacturing surface of the electrode.The design change propagates to the toolpaths for the electrode. NX automatically regenerates the machining process and updates the NC code, inspection program and all the other shop documents.The latest revision of the work package can be sent to the shop floor, so the updated version of the mold components can be machined.

Notes 31

Summary


20XX-XX-XXAs you could see, our software provides a complete solution to digitalize your part manufacturing.

With our integrated system, you can create a digital twin of your part model, resources and machining processes. You can define and prove your manufacturing process in a digital environment that can reduce production costs on the shop floor and improve quality.

Our technology helps you establish the digital thread connecting people, equipment and systems that lets you synchronize the entire manufacturing process, so you can consistently achieve your production and business goals. Notes 32

Thank YouJohn DoeJob titleGroup / Region / Department XY Street 12312345 CityPhone: +49 123 45 67 89Fax: +49 123 45 67 89Mobile: +49 123 45 67 89 0E-mail:[email protected]

siemens.com


20XX-XX-XXPlease contact us to continue the conversation. We would like to discuss your specific manufacturing needs and see how we can help you improve your efficiency.

My name and this is my contact information. Please feel free to contact me.

Thank you for your time.

E4 e automotive_partmanufacturing_v10

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