More transparency and availability for industrial plants

»In times of growing cost pressure, investment decisions are more and more dependent on the total costs during the entire lifecycle of a plant or machine. Plant operators face the problem of guaranteeing maximum productivity with the lowest possible maintenance costs. Industrial plants and factories with optimized work routines and processes not only produce more: They also spend less on operating resources, energy and maintenance.«

Asset and Plant Optimization Services

Optimized plants produce more and require less material, maintenance, consumables and energy.

Our approach is to combine the expertise of reliability professionals, engineering talents and software experts with high end industrial products and IT technologies to maximize the benefit on the industrial shop floor and its mission critical equipment.

This service provides real time advice, transparency of information and instant implementation capabilities for more productivity.

 

Asset and Plant Optimization Services by Siemens combine the comprehensive plant and process expertise with the reliability of high-end industrial products and IT technologies. This generates the maximum benefit for industrial production and its mission-critical equipment.

The services include customer consultation, generation of transparent information, and immediate implementation as functions for increased productivity. The reliability health-check provides the customers with an initial overview of the current status of their production plant and proposals for improving productivity.

A failure mode and effects analysis (FMEA) is performed for an in-depth analysis of the actual plant condition. This involves, among other things, the evaluation of critical plant components and a calculation of the expected residual life of a production facility (or individual components). Based in this data, optimal measures for extending the lifetime of the plant - such as upgrades and migrations - are selected from the plant lifetime extension services portfolio, customized to the customers’ needs.

Plant Lifetime extension portfolio

  • Monitoring of critical machines:
    The availability of the entire plant can be improved by monitoring critical components like motors and gears. Additionally to individual components, the production process is also evaluated by compressing and analyzing the collected data. An alarm is triggered in the event of changes to important parameters or imminent failure of a component. Analysis of the plant data also allows the planning and coordination of preventive maintenance measures.

  • Discrete manufacturing monitor:
    An important objective of the discrete manufacturing monitor is to reduce machine downtimes. By assessing the condition of machines and plants, it is possible to detect trends early on, and measures can be planned and implemented in good time. Siemens can provide a comprehensive platform solution for all functions, from collecting and aggregating data through preliminary analysis and trending to the actual visualization.

  • Monitoring of infrastructure:
    The network is the central nervous system of the automation system. Therefore it is especially important to monitor the bus end-to-end - vertically and horizontally - from installation throughout the productive phase. This includes recording the network and device status, any changes that occur, and overloading. Alarms and incidents can be forwarded to higher-level systems. In addition, the services also offer the option of validating field bus systems, verification during acceptance, and maintenance of the bus systems.

  • Monitoring of processes, mathematical analytics:
    Operators of industrial plants need to comply with a constant stream of new and increasingly stringent immersion control guidelines. Siemens services assist them in checking and calibrating the used precision measuring equipment. The measurement and analysis methods are employed, for example, to monitor leaks and optimize the energy balance. The services can be used as a process monitoring tool in a wide range of applications. For example, monitoring cranes to find the most advantageous gripping and positioning of containers when loading and unloading ships.

  • Shop floor industrial security:
    Implementing and maintaining a secure plant infrastructure also helps the customers to increase the reliability of their production operation. The risk of an attack is reduced by, e.g., hardening the automation components. In the case of remote access, secure connections with powerful encryption, VPN, and firewalls protect the IT of the plant.

The collected data during data integration and analytics can easily be integrated in existing process control and ERP systems. This supports the optimization of maintenance processes. With uptime and performance management, Siemens offers its end customers a holistic approach. A comprehensive service agreement enables Siemens deployment quickly and efficiently in the event of failure. The entire package is tailored to each customer’s specific needs.

 

Siemens provides a wide range of solutions for process and factory automation. Focusing on relevant components brings clear advantages for the plant operator:

  • Increased plant availability and productivity

  • Reduced risk of failure and subsequent costs

  • Optimized spare–part management

  • In time information about condition–related maintenance measures

  • More effective planning of resources

  • The customers can concentrate on their core business

By exploiting all avenues of asset and plant optimization, the costs accruing for machines and production plants and the total cost of ownership can be minimized.