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The Economic Impact of Digitalization on Electronics Manufacturing
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enabled innovation, created and sus- tained employment, and promoted global competitiveness. A survey from the Boston Con -
sulting Group on Industry 4.0 in Germany and the United States showed that expectations are high: two-thirds of survey participants on both sides of the Atlantic said they expect clear productivity and cost benefits, and more than 40 percent anticipate higher sales.
Tools for Smart Manufacturing
Smart manufacturing for
electronics is now supported by a number of vendors who offer commercial software and hard- ware products, as well as serv- ices. These tools provide much needed functionality for elec- tronics manufacturing to estab- lish an Industry 4.0 operation. Digitalization of manufac-
turing processes for electronics eliminates physical prototypes, disconnected systems, paper- based and manual work instruc - tions, and silos of information for a continuous, integrated flow from design and planning to production. The difference between this
Digitalization can benefit any size manufacturer across nearly every industry.
design respins, while improving overall product quality. An example in electronics devel-
approach, which generates and dis- tributes accurate, validated product and process models across the com- pany, and current piecemeal digitali- zation strategies, is demonstrated at every stage of product development. Key differences and benefits of
a smart manufacturing methodology include: more reliable and manufac- turable designs; better collaboration among design, engineering and man- ufacturing; less data redundancy; fewer shop floor planning mistakes; less error-prone manual data entry; optimized inventory and JIT materi- als; enforced manufacturing best practices; accurate and up-to- date work instructions; plug- and-play data collection and KPI monitoring; fast time to root-cause identification; and a transition toward higher prod- uct mix without loss of factory performance. Digitalizing the entire
product development process, from design to production, con- nects all the steps in between with a digital thread. This smart manufacturing strategy for electronics ensures that the design can be made, the manu- facturing plan is up to date and synchronized and that the pro- duction system is optimized and performing as planned. This information delivers signif-
opment is PCB design for manufactur- ing (DFM) analyses, which are per- formed early and regularly, rather than waiting until the design is com- plete. Each time an analysis is per- formed, the overall design im proves. The greater the degree of shift, the greater the benefit. More responsive manufacturing. With a digital thread linking product design and manufacturing, planning can be performed earlier in develop- ment. By the time the design is com- plete, manufacturing can quickly fol- low. This opens the door to product customization and personalization. Smarter decision-making. More informed decisions are made possible
demands frequent innovation. Left-Shifting Digitalization Left-shifting refers to perform-
ing tasks that would normal occur later in the design process at an ear- lier stage. Applying a left-shift digi- talization methodology allows users to verify and remedy potential issues before production, reducing costly
Siemens’ Amberg facility combines the real and virtual worlds: products
communicate with machines and all production processes are optimally integrated and controlled by IT.
icant competitive advantages over conventional, partially digitalized approaches, including faster time-to- market and more frequent NPIs. Also, product development activities that used to take weeks are now done in hours, when connected by a digital thread. Simulations and analyses are performed on digital twins to ensure right-first-time production. A smart manufacturing strate-
gy can reduce time-to-market by as much as 50 percent, allowing manu- facturers to succeed in a market that
See at SMTAI, Booth 430
by better visibility into manufactur- ing and the availability of analysis tools that fully exploit manufactur- ing data. Cost control. By improving the effi- ciency of manufacturing processes and materials, at individual sites as well as the global enterprise, a smart electronics manufacturing strategy can reduce overall manufacturing costs, ultimately keeping products affordable for customers.
Proof of Concept
Siemens is a leading supplier of Continued on page 80
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