Siemens Gamesa Renewable Energy is prepared for the future
Flexible and efficient production line
Improved utilization of production capacity
Close cooperation and communication
Intuitive automation for the future
SGRE has aimed to enhance flexibility, increase efficiency, and expand production capacity in their generator production line. The goal has been to transition from the old pulse line to a step line. In close collaboration with BILA, SGRE has positioned itself to meet the challenges of future Industry 4.0.
The new step-line production is structured as stand production, meaning that each station performs a specific task in the process of assembling the generator. In total, there are eight different stations on the line. The difference between the step line and the pulse line is that each station can operate independently of the activities at the other stations. This eliminates the need to wait for items to be moved simultaneously along the entire line. Additionally, two extra stations have been added to the production line.
The solution has resulted in SGRE establishing a production line ready for the future. Productivity has significantly improved, flexibility has increased, and production capacity is now optimally utilized. Moreover, the installation and initiation of the BILA application open up the opportunity to continue the close collaboration on the development of SGRE's generator production.
New production line enhances flexibility
The new step-line production is structured as stand production, where each station performs a specific task in assembling the generator. There are a total of eight different stations on the line. The advantage of the step-line over the pulse line is that each station can operate independently of the others, eliminating the need to wait for items to be moved simultaneously along the entire line. Additionally, two extra stations have been added to the production line, further enhancing its flexibility.
Another significant change is in the processes related to operating the revamped production line. Emphasis has been placed on automating parts of the processes to standardise production from generator to generator, regardless of the operators at each station. This is achieved by standardising the interfaces on the HMI and making the process more intuitive and easy for operators to follow. The result is improved quality in the produced generators, higher accuracy, and reduced cycle time at two of the stations, leading to a significantly optimised production.
Furthermore, the entire system on the production line is prepared for SGRE's Smart Production. This has already resulted in a new collaboration between BILA and SGRE regarding BILA's new data collection application, enabling SGRE to gather selected data from different stations. From a commercial perspective, Matthias Arkenau, Head of Industrial Engineering at Siemens Gamesa Renewable Energy, Plant Brande, emphasises:
"With the new BILA application, SGRE can now collect data and demonstrate the production quality of different generators to our customers. This ensures that we can provide better quality and service in the future,"
Matthias Arkenau, Head of Industrial Engineering
The application also allows for the analysis and optimisation of work processes and continued development of the production line.
Finally, the working environment for operators has been improved as old systems have been replaced and updated with the latest technology. This also means that operating the system now requires minimal knowledge and experience, benefiting the entire production.
Production line operational in 14 days
A crucial requirement for establishing the new production line was that it had to occur during a two-week production stop at SGRE. BILA had only two weeks to relocate what needed to be reused from the old line and set up the new one. It has been a demanding task successfully accomplished through the close collaboration between SGRE and BILA.
"BILA has been physically present at SGRE in Brande throughout the project with our mechanical, electrical, and software employees, as well as our project managers. This was necessary to provide both parties with the right confidence and security in the project, ensuring no delays in production. The working group consisted of a select team from both organisations, ensuring continuity, close coordination, and good communication throughout the project. It was supported by weekly meetings to adhere to the tight schedule and address design requirements and guidelines," says Thomas Brinch Boll, Project Manager at BILA.
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