AkzoNobel’s Ashington plant can now turn the production wheel of 3,500 paint varieties in only 2 weeks. As well as meeting the ever-increasing needs of their customers, the automation technology has helped AkzoNobel reach their sustainability goals and manage the minefield of safety legislation. Through looking closely at their challenges, we have helped them realise their unique vision, so that the moment raw materials come on site, to the finished product leaving, every process is automated with Siemens SIMATIC PCS 7. We have created a unique solution that helps answer their business needs today, prepare them for the unknown threats of tomorrow, and make their automation ambitions a reality.
I feel like we’ve advanced 20 or 30 years ahead…Jeff Hope, Head of Manufacturing, AkzoNobel, Ashington.
The complexity of this project was that AkzoNobel were looking at the scalability of their production facility. The joy of the Siemens solutions is that there’s no “one size fits all”. We can accommodate not only these large plants, but also cost-effectively address the small-scale ones as well. We also have a range of tools that will help us easily migrate legacy control systems into the Siemens SIMATIC PCS 7 platform, enabling existing plants to be efficiently modernised.
To learn more about the results at Ashington, the technology at the heart of it, and how this can be scaled to suit brownfield plants, register your interest in an upcoming webinar, co-hosted by Siemens and AkzoNobel.
How companies can make the most of the opportunities presented by digitalizationIn order to enable companies to make the most out of digitalization, Siemens developed the Digital Enterprise – a holistic portfolio of software and automation solutions. It supports discrete and process industries to become faster, more flexible, and more efficient.
Digitalization of the entire value chain
The Digital Enterprise enables companies of every sector to integrate and digitalize their business processes with the highest possible flexibility regarding pace of transformation. Siemens’ holistic approach comprises offerings for product design, process and plant design, engineering and commissioning, operations and services.
Suppliers and intralogistics are integrated, based on a consistent collaboration platform. Companies can start with digitalization at any step of their value chain, for greenfield and brownfield plants, and based on standardized and open interfaces.
Our comprehensive concept of the Digital Twin consists of three forms: the Digital Twin of the product, the Digital Twin of production, and the Digital Twin of performance of both product and production. Thanks to our comprehensive domain expertise and optimized tools, Siemens is the only company that offers this holistic approach.
There is tremendous value gained from performing "what if" scenarios and predicting future performance with the Digital Twin. The ultimate goal of the Digital Twin in process industries is in the closed-loop connection between the virtual and real production enabled by the right digital infrastructure. Through this connection, the performance twin of real production leads to optimization scenarios in virtual production. After a successful simulation and implementation of these scenarios, the cycle begins again.
The Digital Twin for greenfield plants
The virtual production is created during the phase of process and plant design. Siemens provides you with a holistic toolset to design, simulate and engineer a process plant. Based on collaboration platforms like COMOS, and with full data integration from design to engineering and commissioning, we automatically create a Digital Twin of the plant including automation ready to be used in real production with minimal effort – saving engineering cost and reducing time to production.
In the real world, Siemens process control systems and manufacturing operations management (MOM) make sure that production runs reliably but helps also to collect the relevant data to generate a performance twin. This performance twin, generated out of real production systems and enriched with IoT data, optimizes production and the maintenance of critical assets.
All of these and the simulation of optimization scenarios or future plant designs support our customers to deliver an optimal plant output and to integrate their supply chains optimally.
The Digital Twin for brownfield plants
In existing plants, the hardware, software and processes are already existing – sometimes for decades.
But still it is possible to create a huge benefit out of the Digital Twin by using it for improvement of the existing processes and assets. Based on technologies like context capture and digital import of documents, the Digital Twin of an existing plant is created in a cost-efficient way, for example by using Digital Twin Cloud Services PlantSight.
With this Digital Twin, information silos in the plant are broken down and modernization and maintenance activities are based on the as-is-documentation and relevant operations data of the plant. This leads to substantially reduced search times and mistakes. With integrated workflows, the once created Digital Twin is up to date over the remaining lifetime of the plant – the connection between the virtual and real production is closed.
Jerseys made of corn
Cathay Industrial Biotech Ltd.
In the digital factory of Cathay Industrial Biotech Ltd., biochemical processes have replaced traditional petrochemical methods. The use of renewable materials like corn was industrialized with the help of our products and services.
This way it became possible to deliver better products than the petrochemical industry at competitive production cost on a large scale that’s similar to oil-based production.
Everything from a single sourceOur integrated range of hardware, software, and services can help turn your digital plant into reality. Benefit from being able to make smaller and smaller batches economically, from the smart planning of maintenance activities, and from minimizing downtimes – always considering industrial standards like Module Type Package (MTP), NAMUR Open Architecture (NOA) or OPC Unified Architecture (UA).
Cutting-edge technologies – the future of industry
MindSphere, the cloud-based, open IoT operating system
MindSphere enables industrial companies of various sizes worldwide to link their machines and physical infrastructure to the cloud and the Internet of Things. It uniquely simplifies the challenges of many industries, regarding connectivity, data analysis and prediction or the development of own applications and new business models and therefore it supports every company of its digital transformation journey.
Strategies for the digital transformation
- Where should you start your digital transformation journey and what are the resulting benefits?
- What are the most important steps and how can they be implemented?
- We are looking forward to develop an individual digitalization roadmap together with you.
Flexible plant construction
- Modular production concepts can make a shorter time-to-market and greater flexibility in the process industry a reality.
- Machine/plant builder supply autonomous working fully automated digitalized modules: new business modules as service supplier.
- The individual modules are combined to form a complete solution by using the industrial standard Module Type Package (MTP).
Enable your digital future with Digital Enterprise Finance
- Digitalization is accelerating as industry players demonstrate the substantial efficiency and competitive advantages that digital transformation offers.
- Digital Enterprise Finance from Siemens helps you realize your digital future.
- Specialist finance solutions for process industry.
Chemical Industry 4.0 - A Formula for Investment
A study of the UK chemical industry’s digital transformation and the building blocks of reliable return on investment from Industry 4.0
Reach for operational excellenceOur industry-specific suites of applications and digital services make it easy to leverage the hidden potential in your engineering-, process-, diagnostic- and event-data to ensure uptime, improve processes and manage operations. The following suites illustrate what’s possible.
Digital Enterprise for your industry
Perhaps you have data, but it is locked away in data silos, or you have very limited data and you just want to know where to start. Our experts explain.