Two pioneering projects for Siemens Energy
io supported Siemens Energy as implementation partner in two pioneering projects – the global rollout of SAP Digital Manufacturing in Querétaro, Mexico and the digital transformation of the VI Factory in Berlin, Germany.
Rollout of a global digitalization strategy
Digitalization and automation of the VI Factory in Berlin
Global standardization of the MES: Successful rollout of SAP Digital Manufacturing
Digitalization of production calls for powerful and standardized IT systems. Siemens Energy faced the challenge of harmonizing the disparate system landscape in over 80 production plants. As part of the ONE-MES global transformation program, a standardized, yet future-focused manufacturing execution system (MES) was implemented – as the technological basis for a globally scalable, digital manufacturing strategy. The plant in Querétaro – one of the five global flagship plants – was selected as the site for the implementation of a new, configurable MES template. io was responsible for the overall planning and operational implementation of this ground-breaking project.
Selecting the cloud MES solution and its implementation
Siemens Energy opted for SAP Digital Manufacturing as a cloud-based MES solution to enable a sustainable and resilient production architecture in line with Industry 4.0. A globally usable MES template was developed and successfully rolled out at the flagship plant in Querétaro in close cooperation with the local key users.
The collaborative implementation approach enabled the precise adaptation of the solution to the site’s specific requirements, promoting a high level of acceptance of the new solution among the users. Implementation was deliberately designed to adhere closely to SAP standards with a view to fully exploiting the benefits of cloud technology – such as update stability, scalability and integration capability. In addition to developing the template, the system was carefully tailored to the plant-specific requirements, tested intensively and managed by io right up to go-live. io also played a key role on site during the subsequent hypercare phase to identify any potential for further optimization at an early stage.
Key Facts
Client
Siemens Energy is a global leader in the energy sector with a focus on sustainable, digital solutions along the entire energy value chain. With over 90,000 employees in more than 90 countries, Siemens Energy consistently pursues the goal of transforming the energy world through technological innovation.
The challenge
- Standardizing a historically grown, disparate system landscape in over 80 plants
- Developing a globally scalable MES template
- Ensuring local acceptance and adaptability at the flagship plant in Querétaro (Mexico)
The solution
- Implementing SAP Digital Manufacturing as a cloud-based MES
- Developing and introducing a configurable MES template at the flagship plant
- Implementation in close cooperation with local key users to promote system acceptance
- Focus on SAP standard to ensure scalability, stability and future-proofing
Added value through the new MES approach
The introduction of SAP Digital Manufacturing at Siemens Energy led to paperless production with digitalized work instructions, checklists and automated feedback – paving the way for the Smart Factory of the future. Furthermore, the data-driven control and continuous improvement of production processes significantly improved transparency along the entire value chain.
The high level of acceptance among the users underlines the success of the flexible, configurable template approach, which serves as a scalable blueprint for global roll-out.
From the digitalization roadmap to SAP DM implementation in Siemens Energy’s VI Factory
Digital transformation is unleashing complex challenges for companies around the world– especially in manufacturing. As an experienced partner, io provides clients with holistic support – from the initial analysis of the current situation through to the operational implementation of future-proof IT and process landscapes. With over 65 years of experience in industrial planning and more than 25 years of SAP implementation expertise, io supported Siemens Energy in reshaping the VI Factory in Berlin to meet future needs – creating a seamless blend of IT, manufacturing floor design, and automation to maximize synergies.
Strategic digitalization in the VI Factory
io and Siemens Energy started their cooperation in 2023 with the aim of systematically driving forward digitalization and automation at the VI Factory in Berlin. The production facility primarily manufactures vacuum switch tubes, which are part of Siemens Energy’s sustainable Blue portfolio. This includes high-voltage switching products that rely on sustainable vacuum technology and offer a technological alternative to SF₆-based high-voltage switching products.
The project started off with the development of a comprehensive digitalization and automation roadmap. Prioritized use cases were identified and evaluated based on a detailed analysis of processes and IT tools, backed up with well-founded cost-benefit analyses. This analysis resulted in a clear implementation recommendation for Siemens Energy – including a future-ready outline of the IT architecture at the Berlin site.
Implementation of SAP Digital Manufacturing
Less than a year later, the roadmap became reality, resulting in the new SAP Digital Manufacturing MES system.
Key Facts
The challenge
- Developing a long-term digitalization and automation strategy
- Transforming a technologically sophisticated production site (vacuum switch tube production)
- Integrating IT, shop floor processes and machine connectivity within a very limited timeframe
The solution
- Creating a well-founded digitalization roadmap with clearly prioritized use cases
- Implementing SAP Digital Manufacturing based on the global template
- Integrating the specialist departments via an interactive learning journey
- Using agile project methods (SAP Activate) and a staggered go-live concept for stable implementation
- Realizing initial machine connectivity use cases to increase transparency
The go-ahead was given with a well-founded planning phase:
Requirements were identified, stakeholders engaged and a viable implementation strategy was defined.
The system design was based on an in-depth analysis of the actual production processes.
A vital success factor was the early involvement of key users through an interactive learning journey. Practical training and courses ensured that the specialist departments became familiar with the new system at an early stage and were actively involved in its design. This not only strengthened acceptance, but also enabled collaborative implementation.
The use of predefined SAP-based template processes significantly shortened implementation times and reduced customization to a reasonable level.
Alternative process variants were evaluated in advance and seamlessly integrated to fit the overall system.
Successful go-live and sustainable optimization
The project’s final phase focused on the detailed configuration of the system, supported by iterative test cycles to ensure process stability. Particular attention was given to the integration of machines and systems for the implementation of machine connectivity use cases.
A staggered go-live approach was selected for the production launch:
The production areas were migrated one at a time, reducing risks and ensuring a stable ramp-up. During the subsequent hypercare phase, the system was closely monitored to address any issues and stabilize ongoing operations.
Success factors for efficient implementation
- Template approach and best possible standard compliance: The SAP standards-based implementation enabled a faster and cost-efficient rollout.
- Interactive learning journey: Early involvement of key users ensured the development of expertise and high user acceptance.
- Hybrid methodology with SAP ACTIVATE: The combination of classic and agile project methods enabled flexibility and structured implementation.
- Parallel production starts: Launching multiple production processes at the same time enabled successful and smooth implementation of complex project scenarios.
