Analysis of Engineering- Workflows as Basis for …...Page 3 03/2011 Löwen - CT T PRO ENG ©...
Transcript of Analysis of Engineering- Workflows as Basis for …...Page 3 03/2011 Löwen - CT T PRO ENG ©...
Copyright © Siemens AG 2011. All rights reserved.
ProjectEngineeringSiemens Corporate Technology
http://www.siemens.com/innovation/de/ueber_funde/corp_technology/research_technology/index.htm
Analysis of Engineering- Workflows as Basis for Optimal
Use of Engineering-Tools
8. Symposium Informationstechnologien
für Entwicklung
und Produktion
in der
Verfahrenstechnik 2.-3. März
2011, Frankfurt am Main
Dr. Ulrich Lö[email protected].: +49 (9131) 7-32948
Dr. Thomas [email protected].: +49 (9131) 7-33794
Page 2 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
“Engineers should never be the designers of their own tools.”
“Why we introduce a new tool? Because we need to reduce our NCCs!”
“Automating
chaos just gives faster chaos”
“This tool is like a Porsche…
-
but if the customer has an acre, he cannot put the power on the pavement”
Tools cannot be considered in an isolated way?
Tools cannot be considered in an isolated way?
“After 5 years of rollout we came to the conclusion that the tool is ineffective and too complicated.
Sounds familiar?
“Excessive customization of tool led to nontransparent functionalities. Different projects were linked to incompatible data bases. Users were overstrained.” “We spent 20% of our time
searching errors created by others!”
Customized to death?
Customized to death?
Workflow & interfaces
understood & defined?Workflow & interfaces
understood & defined?
Page 3 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Siemens Corporate Technology Networking the Integrated Technology Company
Chief Technology Officer (CTO)
Review innovation strategiesDrive technology based synergiesSecure innovation powerTechnology assessmentsGovernance and guidance
Customers
Corporate Intellectual Property and Functions (CT I)
Intellectual Property services & strategyStandardization, environmental affairsGlobal information research
Corporate Research and Technologies (CT T)
Global Technology FieldsPictures of the FutureAccelerators
Corporate Technology (CT)
Reg
ions
Sectors / Divisions
Industry Energy Healthcare
Chief Technology Office (CT O)
Direct support of CTO
Siemens IT Solutions and Services (SIS)
Siemens Financial Services (SFS)
Corporate DevelopmentCenter (CT DC)
Software-development partner for sectors
CT missionStrengthen enterprise premium
and contribute to
safeguard the technological future
of the company
CT value propositionEnable Siemens to be a trendsetter in any industry
served
Page 4 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Introduction of Engineering Tools – Phases and Objectives
Scopingand
Focusing
Phase
Objectives
MigrationConcept
Viability
Know “how”Evaluation / benchmarking of toolsBusiness plan
Decide “how”Implementation conceptMigration roadmap
Know “what”Your process and products/data in scopeAffected parties and stakeholders
Life-
cycleSupply
chain
Disci-
plinesProducts
People
Trans-parency
andVision
Understand and evaluate “what”Your current workflows for all relevant process and applicationsTargets of workflow improvements and boundary conditionsQualification and quantification of benefitsConsolidated tooling vision and requirements
Focus of today‘s presentation
Page 5 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Over 30 productivity factors for industrial plant business (challenges) covering the whole life-cycle
Over 240 productivity relevant industrial software aspects
Over 1000 Best Practices for industrial software
Co
mp
reh
ensi
ve
Info
rmat
ion
M
od
el
Proj
ect-
Span
nin
gRe
use
Proj
ect-
Spec
ific
Reus
e
Know-H
ow
Reuse
Bulk
Processi
ng
FlexibleInterfacingSecurity
Data H
andling
Access to Process
& System Data
Adaptabili
ty to
Comm
.-Sys.
Data
Compac
tnes
sDat
a
Cond
ition
ingAcc
ess Secu
ritySafe
ty
Lea
din
g M
od
. Pri
n.
Ass
oci
ati o
ns
bet
wee
n In
fo. A
sset
sH
iera
rch
ical
Str
uct
uri
ng
Enri
chm
ent
of
Eng
inee
rin
g D
ata
Stan
dar
ds
Cu
sto
miz
atio
nG
lob
al R
euse
Mo
del
Inst
anti
atio
nG
ran
ula
rity
Hie
rarc
hy
wit
hin
RU
A
Con
tain
ed In
fo. i
n R
UA
Def
init
ion
of
Glo
bal R
UA
Retr
ieva
l of
RUA
in G
loba
l Rep
osit
ory
Cros
s-Pr
ojec
t Li
brar
y
Proj
ect-
Spec
ific
Reu
se M
odel
Inst
anti
atio
n
Gra
nula
rity
Hie
rarc
hy w
ithi
n RU
A
Cont
aine
d In
form
atio
n
Def
initi
ons
of R
UA
with
in P
roje
ct
Retr
ieva
l of R
UA
with
in P
roje
ct-S
peci
fic L
ib.
Proj
ect-S
peci
fic L
ibra
ry
Conf
igur
atio
n Re
use
Auto
mat
ion o
f Pro
cess
Ste
ps
Stan
dards a
nd Nor
ms
Inte
llect
ual Pro
perty M
anagement
Know-h
ow P
rote
ctio
n
Access
ible
Data
Effects
of Modifi
catio
n
Semantic Level o
f Data
Consist. a
fter M
DC
Selection of U
nits to
be Modifie
d
Level of A
utomation
Data Consistency Checks after M
DC
Diagnostics
Documentation
ExtensionFunctionality
Import
Org
anizatio
n /
Plann
ing
Valid
ation
Realtime Control
Reliability
Alarm
Man
agem
ent
Plan
nin
g /
Op
tim
izat
ion
Inte
gra
tio
n
Secu
rity
Dia
gnos
tics
Standardized Criteria Catalogue for Evaluation of Workflows and Tools
Proven know-how base and criteria matrix for
evaluation of workflows and tools
Page 6 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Classified Best Practices as Basis for Objective and Precise Evaluation of Workflows & Tools
View Concept
Service Know-How Reuse
Technical ViewsKPI-ControllingExt. Tool Integr.Hierarch. Struct.Consistency
CustomizationAdaptability
Business Know-H.
Techn. Know-H.
Ident. Inform.
Reporting
Decision Support
Engineering Challenges
Operation Challenges
Service Challenges
ModernizationChallenges
Com
preh
ensi
ve
Info
rmat
ion
Mod
el
Proj
ect-
Span
ning
Reu
se
Proj
ect-
Spec
ific
Reus
e
Know-H
ow
Reuse
Bulk
Processing
ViewIntegration
Activation
Diagnostics
Supervision & Control
Knowledge-Reuse
FlexibleInterfacingSecurity
CommissioningChallenges
Configuration Management
Consistent Plant Documenation
CollaborativeWork
LifecycleIntegration
Data Processing
Data H
andlin
g
Data Consistency
Checks
Level of Automat.
Of Data Analysis
Semantic Level of
Data Consistency
Effects of
User Inputs
Access t
o Process
& System Data
Adaptability to
Comm.-Sys.
Data
Compactnes
s
Data
Condi
tioni
ng
Workfl. Know-H.
Lea
ding
Mod
. Pri
n.A
ssoc
i ati o
ns b
etw
een
I nfo
. Ass
ets
Hie
rarc
hica
l Str
uctu
ring
Enri
chm
ent o
f Eng
inee
ring
Dat
aSt
anda
rds
Cus
tom
izat
ion
Glo
bal R
euse
Mod
elIn
stan
tiatio
nG
ranu
lari
tyH
iera
rchy
with
in R
UA
Con
tain
ed In
fo. i
n R
UA
Def
initi
on o
f Glo
bal R
UA
Retri
eval
of R
UA
in G
loba
l Rep
osito
ry
Cros
s-Pr
ojec
t Lib
rary
Proj
ect-S
peci
fic R
euse
Mod
el
Inst
antia
tion
Gra
nula
rity
Hie
rarc
hy w
ithin
RU
A
Cont
aine
d In
form
atio
n
Def
initi
ons o
f RUA w
ithin
Pro
ject
Retrie
val o
f RUA w
ithin
Pro
ject-
Spec
ific L
ib.
Proj
ect-S
pecif
ic Li
brar
y
Config
urati
on R
euse
Aut
omati
on of
Pro
cess
Step
s
Standard
s and
Nor
ms
Intel
lectual
Propert
y Man
agem
ent
Know-how
Protectio
n
Accessi
ble Data
Effects
of Modifi
cation
Semantic
Level of D
ata Consist. a
fter M
DC
Selection of U
nits to be M
odified
Level of Automation
Data Consistency Checks after M
DC
Integration of Views within Tool
Integration with Tools of other Domains
Hierarchical Structure in Views
Semantic level of Data Consistency
Data Consistency Checks
Distribution of Views
Customization of View Integration
4 Generic Support
3 Explicit, High Level
2 Explicit, Low Level
1 Implicit Support
0 No Support
Classification ModelClassified Best Practices
Page 7 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Overall
evaluation report
Individual evaluation results
Bac
k of
fice
anal
yses Analyze workshop results
Re-Modeling of engineering workflow
Align results and incorporate feedback
Consolidate individual resultsPrepare final report
Analyzing Workflows –
Project Concept
•
List of weighted requirements
ErectionInstallationCommissioning
…
…
Hydraulics/ Fluids
Civil Engineering
Automation
Electrical Engineering
Piping & Instrumentation
OperationServicing
ManufacturingPurchasingDetailed Engineering
Basic Engineering
Plant design/ Technological Design
Tendering ErectionInstallationCommissioning
…
…
Hydraulics/ Fluids
Civil Engineering
Automation
Electrical Engineering
Piping & Instrumentation
OperationServicing
ManufacturingPurchasingDetailed Engineering
Basic Engineering
Plant design/ Technological Design
Tendering
PEP
Eng
inee
ring
Task
s
Plant Engineering Phases
Fields of activityown BS / FS
BoP
Fields of activityown BS / FS
Captured Workflow•
Main tasks•
Typical work results•
Current tools
•
Fields of plant engineering activities
Wor
ksho
ps
2. 2a. Modeling and analysis of current Engineering
Workshop Series
(two-day workshop)
1. Identify fields of activity for plant engineering
3. Identify and weight requirements for workflow
optimization and tool support
Page 8 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Customer Preparation of Workshop
Please provide the following resources, persons and information for a successful workshop and significant results
Experts for engineeringhave to fulfill the following profiles:
Engineering/Technology headsTechnical project managersGroup Managers Engineering/TechnologyEngineers/Technologists (engineering tool users) from all relevant fields of work / disciplines
Basic information for workflowGathering of engineering-workflow should be referenced to a representative plant project
Identification of suitable project in advanceIncorporation of involved project participants / departments / teams in the workshop
Do defined workflows already exist? E.g. process instructions, project plans, task descriptions for departments / roles / groupsExisting documentation for these workflows to be provided in advance to the workshop
Participants Information to be prepared
Meeting room with one 5m free wall for graphically workflow modeling (pin board)Beamer, flip chart
Infrastructure
Page 9 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
1a. Identify Fields of Activity for Plant Engineering
Positioning towards functional tasks and project phasesConcept Design
Basic Engineerin
gDetail
Engineering Instal-lation Commis-
sioningService /
Maintenance
Product Design & Engineering
Process Engineering
Plant & Assembly Layout
Manufacturing Engineering
Automation Control
Electrical & Instrumentation
Civil Engineering
Mechanical Engineering
…
Concept Design
Basic Engin.
Detail Engin.
Instal-
lation
Commis-
sioning
Service / Maintenance
Why we need this categorizationUnderstanding engineering contextPreparation of workflow modelingUnderstand the interrelations of different tasks, sub-workflows & tool featuresBasis for identification of customer/use cases specific tool setupsBasis for positioning of tools in customer’s workflows driven by the technical tasksUnderstand the respective area of influence of cross-functional features (project-related)
Page 10 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
1b. Scoping of the Workshop Regarding Importance of Requirements and Topics
Category Requirements Importance1 Data handling and
integrationSingle source” principle for data of different engineering disciplines or project phases (roundtrip engineering) Assurance of data actuality & consistency of modifications Clear and transparent structuring of project data
2 Standardization / Design of Modules for project-spanning reuse
Global standardization and reuse conceptConsistent specification & supply of reusable modulesLibrary management and project support
3 Reuse in Customer Projects
Usage of libraries of devices / modules / assembly for re-use across different projectsQuality/Efficiency of provided modules in projectsCreation of reusable templates (master copies) in projects
4 Collaborative engineering
Simultaneous engineering, multi-site engineeringAccess rights and user managementCollaboration with suppliers (equipment and engineering)
5 Version and Change Management
Creation of versions and managing of variantsReleasing of project dataSystematic Change Management
6 …
2
3
4
1
4Example
Page 11 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
2a. Modeling and Analysis of Current Engineering
Strengthens and clarifies common picture, scope and terminologyBasis for identification / discussion of strengths & weaknesses Problems with dependencies and with the use of tools become evidentCommon elaboration / depicting requirements and optimized scenarios
Example
Systematic, interactive modeling of tool spanning engineering workflow
Scope of supply, areas of workTasks, activities and related effortsUsed engineering tools und data managementTask sequence, data flow, technical & logical dependencies
Task sequence/ Data flow
Activity•
Responsible•
Int. /external•
Used tool(s)•
Efforts / Repeats
Result•
Results type•
Responsible•
Data Format •
State/Maturity•
…
Page 12 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
2b. Identification and Weighting of Requirements for Workflow Optimization and Tool Support
Helps to structure and prioritize current issues and requirementsBased on measurable weights and proven best practices
Customizable catalogue of requirementsEngineering2
workflow/tool requirements categories Data handling and integrationStandardization / design of modules for project-spanning reuseReuse in projects (intra & cross-project)Collaborative engineeringMgmt. of project configurations / releasesQuality ManagementStandardization / automation of tasks & resultsConsistent plant/ project documentationMass data processingInterfaces to tools of other domainsUser interface of tools / systems
Engineering fields of workRequirements EngineeringProcess EngineeringPlant/Factory Layout DesignManufacturing EngineeringPlanning of Piping & InstrumentationElectrical & Power Supply EngineeringAutomation Control EngineeringMotion Control EngineeringCivil Eng. / Steel Structures / Auxiliaries Mechanical EngineeringCost Calculation / ContractSafety & Security Engineering
Identification / weighting of requirements/topics regarding workflow optimization and tool support
Identification of relevant requirement topics1
Assessment of maturity of current tool support and target support
Page 13 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
1,5
1,5
2,8
1,4
3,1
2,5
2,5
2,8
2,7
1,8
1,5
0,6
0,4
1,0
3,4
3,2
3,0
2,8
3,3
3,5
3,2
3,2
3,1
2,6
2,8
3,0
2,0
2,0
Assurance of data actuality & consistency of modifications
Creation of reusable templates (master copies) within project4. Collaborative engineering
Simultaneous engineering, Multi-site
Systematic Change ManagementCreation of versions and managing of variants5. Version and Change Management
Collaboration with suppliersAccess rights and user management
„Single Source“ principle for data in whole project1. Data handling and integration
2. Development modules for global reuseClear and transparent structuring of project data
Quality/Efficiency of provided modules in projectsUsage of libraries / modules across different projects
3. Reuse in customer projectsLibrary management and project support
Consistent specification & supply of reusable modulesGlobal standardization and reuse concept
2b. Identification and Weighting of Requirements: Results to be used for Common Prioritization
Current Level of Tool support1
Target Level of Tool support2
Example
1 = low / indirectly, using workarounds
2 = excplicit
basic support
3 = extensive support
4 = universal, customizable
0 = none
1,2
Average of individual values from workshop participants
Page 14 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Example: Suitability Analysis for Comos in Engineering in Metals & Mining
Page 5 July 3rd, 2009 for internal use only / © Siemens VAI 2009MT-Standardization
D R A F T
V00.11_2009-07-03
Suitability profile of Comos® for MT xx
• Fulfillment of identified major tool requirements by Comos® is on very high level
• High degree of fulfillment for all prioritized plant engineering fields of work
• In summary: high suitability of Comos®
Relevance2 of tool requirements and fulfillment3 by Comos® Relevance2 of plant engineering fields of work and fulfillment3 by Comos®
Overall suitability1 = “high”
1 average fulfillment for fields of work weighted with average fulfillment of tool requirements;rating levels: high, medium, low
2 average of individual values from workshop participants; for tool requirements only clusters shown3 appraisal of analysis team4 individual fulfillment values weighted with respective relevance
scale: 0 = no/ none, 1 = low, 2 = medium, 3 = high, 4 = very high
0
1
2
3
4Data handling and integration
Consistent plant/ projectdocumentation
Management of projectconfigurations
Project specific reuse
Cross-project reuse
Know-how reuse
Mass data processing
Interfaces to tools of otherdomains
Collaborative engineering
User interface
Relevance of Requirement Fulfillment by Comos
0
1
2
3
4Cost calculation
Plant Layout Design
Process Engineering
Piping and instrumentationschematics
Planning of piping
Planning of fluids/ hydraulics
Electrical and Instrumenation& Control
Automation and processcontrol planning
Civil Engineering / SteelStructures / Auxiliaries
Mechanical Engineering
Relevance Fulfillment by Comos 96%Weighted
average4 of fulfillment
77%Weighted
average4 of fulfillment
Page 5 July 3rd, 2009 for internal use only / © Siemens VAI 2009MT-Standardization
D R A F T
V00.11_2009-07-03
Suitability profile of Comos® for MT xx
• Fulfillment of identified major tool requirements by Comos® is on very high level
• High degree of fulfillment for all prioritized plant engineering fields of work
• In summary: high suitability of Comos®
Relevance2 of tool requirements and fulfillment3 by Comos® Relevance2 of plant engineering fields of work and fulfillment3 by Comos®
Overall suitability1 = “high”
1 average fulfillment for fields of work weighted with average fulfillment of tool requirements;rating levels: high, medium, low
2 average of individual values from workshop participants; for tool requirements only clusters shown3 appraisal of analysis team4 individual fulfillment values weighted with respective relevance
scale: 0 = no/ none, 1 = low, 2 = medium, 3 = high, 4 = very high
0
1
2
3
4Data handling and integration
Consistent plant/ projectdocumentation
Management of projectconfigurations
Project specific reuse
Cross-project reuse
Know-how reuse
Mass data processing
Interfaces to tools of otherdomains
Collaborative engineering
User interface
Relevance of Requirement Fulfillment by Comos
0
1
2
3
4Cost calculation
Plant Layout Design
Process Engineering
Piping and instrumentationschematics
Planning of piping
Planning of fluids/ hydraulics
Electrical and Instrumenation& Control
Automation and processcontrol planning
Civil Engineering / SteelStructures / Auxiliaries
Mechanical Engineering
Relevance Fulfillment by Comos 96%Weighted
average4 of fulfillment
77%Weighted
average4 of fulfillment
CustomerSiemens Metals & Mining business unitGlobal business, multi-site set-upProjects from acquisition to handover incl.process-, mechanical-, electrical,- automation engineering
TaskAnalyze principle, technical suitability of Comos for engineering activities & workflowsIdentify requirements and develop approach for potential Comos implementation project
ResultAnalysis and modeling of engineering workflows in relevant Business SegmentsKey-findings & recommendations for productivity improvementIdentification of basic requirements for future tool support Suitability profile for ComosConcept and roadmap for Comos Implementation
Structured RequirementsOptimized Workflows
Page 15 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Selected References
Analysis & optimization of engineering tool landscape Siemens Energy -
Power Distribution -
Energy Automation (E D EA)
Validation & optimization of Comos –
PCS 7 integration strategy based on engineering workflows of external key customers
Comos suitability analysis at Siemens VAI Metals Technologies (I IS MT)
Analysis of engineering tool landscape Siemens Energy -
Fossil Power Generation -
Module & Project Engineering (E F ES)
Evaluation of engineering workflows and interface management for Siemens Energy -
Conventional Island ( E F NP)
Analysis for engineering tooling integration in Siemens Industry –
Rail Automation (I MO RA)
Page 16 03/2011 © Siemens AG 2011Löwen - CT T PRO ENG
Lessons learned
Think “lifecycle” and not “IT”Users of a single system will always preach why it does not fit … Benefit is in the whole lifecycle!
Transparency: First know „what“, then decide „how“
Changes can influence different process chains in and outside the companyUnderstand relevant processes from different point of views
Data structures should be guided by work process and not vice versa
Most important … be patient!“Engineers should never be the designers of their own tools.”
“Why we introduce a new tool? Because we need to reduce our NCCs!”
“Automating
chaos just gives faster chaos”
“This tool is like a Porsche…
-
but if the customer has an acre, he cannot put the power on the pavement”
Tools cannot be considered in an isolated way?
Tools cannot be considered in an isolated way?
“After 5 years of rollout we came to the conclusion that the tool is ineffective and too complicated.
Sounds familiar?
“Excessive customization of tool led to nontransparent functionalities. Different projects were linked to incompatible data bases. Users were overstrained.” “We spent 20% of our time
searching errors created by others!”
Customized to death?
Customized to death?
Workflow & interfaces
understood & defined?Workflow & interfaces
understood & defined?
Copyright © Siemens AG 2011. All rights reserved.
ProjectEngineeringSiemens Corporate Technology
http://www.siemens.com/innovation/de/ueber_funde/corp_technology/research_technology/index.htm
Thank you for your attention!
Dr. Ulrich Lö[email protected].: +49 (9131) 7-32948
Dr. Thomas [email protected].: +49 (9131) 7-33794