Realizing visions every day in every industry.

totally integrated

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... higher manufacturing speeds, tighter integration between machines, 24/7 operations

and more. While cost pressures are forcing you to increase your productivity and reduce

life cycle costs, you must continuously optimize processes in order to achieve sustained

improvements in competitiveness. You need Totally Integrated Automation (TIA).

You are reaching for …

Higher productivity

Whether you’re interested in boostingthe performance of an individual machineor optimizing your entire plant, TotallyIntegrated Automation, the foundation foryour individual automation solutions, pro-vides all the technologies from the sensorsup to the complete process control system,including the MES solution for connectingto the corporate management level. Scalableand expandable for all applications andacross the entire production workflow fromincoming materials to outgoing finishedproducts. Totally Integrated Automationoffers you unique ways of increasing yourproductivity. All the components andengineering tools are designed to supportyour process throughout its Production LifeCycle and reduce your total life cycle costs.

Reduced time-to-market

With Totally Integrated Automation, youengineer your system in one integrateddevelopment environment. You not onlyhave a more intuitive overview of your com-plete project, but the same look and feel isused by all development tools for each ofthe system components including operatorinterfaces, controllers, drives, I/O and com-munication devices. TIA provides for thistight integration. You will design, configure,program and test your system quicker anddeliver products sooner with this uniqueapproach.

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Production Life Cycle

Design andEngineering

Installation andCommissioning Operation Maint

Inbound Logistics

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Increased interoperability andreduced complexity

The concept of interoperability is designedinto every product early in its requirementdefinition. This minimizes the engineeringeffort required when designing, program-ming, and debugging your system andguarantees that all the components inter-act seamlessly and transparently with eachother. You achieve significant reductionsin engineering costs. For example, whenusing SIMATIC components, you reducethe number of software tools required todevelop and configure your system. AllSIMATIC engineering tools access a singledatabase that encompasses the entireproject, eliminating redundant data entryand minimizing potential sources of error.

Increased investment security

Secure your investment across its entirelife cycle. From discrete automation toprocess control, only Totally IntegratedAutomation allows you to break newground in your individual automationsolution while investing in a shared de-velopment environment. There’s no needto invest in different development environ-ments and maintain separate engineeringtoolsets. You win by leveraging our productand technology developments. In addition,by using a single, continuously improvedtechnology platform, the knowledge baseyou create can be maintained and secured.

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For every industry

Whether you’re in a process industry,a discrete industry, or somethingin between, Totally IntegratedAutomation forms a unique founda-tion for customized automation solu-tions in all industries.

Production workflow

Totally Integrated Automation is thefoundation for the control of yourentire production line – from incom-ing materials to outgoing productsand will make a significant contri-bution to the optimization of yourproduction systems.

Production life cycle

Totally Integrated Automation usesintegrated engineering, program-ming, communications, and diagnos-tics to secure your investment fromconception through maintenance.Your system benefits throughoutits life and your intellectual invest-ments are secured through mod-ernization.

Totally Integrated Automation combines your objectives with

Siemens products and technologies. Siemens is the only supplier to

offer an integrated foundation for implementing customized auto-

mation solutions, in all industries.

Totally Integrated Automation provides interoperability and trans-

parency to the entire manufacturing enterprise. This level of inte-

gration guarantees seamless data flow – from every field device to

every controller up to your business systems.

… Totally Integrated Automationenabling improved competitive-ness for all industries

You benefit from the seamless interoperability and transparency of Totally Integrated Automation during the

entire life cycle of your plant. All components and engineering tools are designed to provide you with the support

you need during every stage of your system’s life cycle.

Using Totally Integrated Automation,you will optimize your entire production life cycle

Production Life Cycle

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Design and engineering

Increasing your engineering efficiency willenable you to tap into significant savings.The SIMATIC PCS 7 Distributed ControlSystem is one example of how the principlesof Totally Integrated Automation come to-gether. Not only does the PCS 7 systemuse the standard controller and visuali-zation software, but it is also configuredwith the same development environment.The same hardware platform can nowprovide you with both process and dis-

crete control. This reduces maintenance over-head, and spare parts management.There are also powerful pre-engineeredsoftware modules available for specificapplications.Through automatically generated operatorscreens and messages, you can quickly createsystems for visualizing your plant operations.

Design and Engineering

Installation andCommissioning

Installation and commissioning

You need to reduce start-up and commission-ing time and get your system up and runningas quickly as possible. Surprises can’t betolerated. Any misstep, and your projectis behind schedule.

The integrated engineering environmentin Totally Integrated Automation enablesyou access to all components of your auto-mation system across all of your networksfrom any available communications point.Component Based Automation, based uponPROFINET, the Industrial Ethernet standard,enables you to design seamless interopera-bility into your systems. Complete sectionsof a plant can be developed in parallel andtested in advance. When the sections arriveon-site, they are fully functional and can beconnected using standard Ethernet commu-nications components. This leads to signifi-cantly reduced start-up time and gets youto market more quickly.

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Operation Modernization and Upgrade

Maintenance

Using Totally Integrated Automation, you willoptimize your entire production life cycle

Operation

It’s everyone’s responsibility to improve pro-ductivity. Not only do you need to optimizeindividual processes, but you need to coor-dinate across multiple processes and coordi-nate with business systems.

Using Totally Integrated Automation, youcan model and optimize plants and pro-duction processes. Our MES applicationsprovide you with all the necessary tools inthe production process such as archiving,quality assurance, product data definition,and materials management. They are inte-grated into a framework and communicatequickly, securely, and efficiently within thecompany and outside the company. In addi-tion, they minimize downtime by informingyou immediately about the status of yourplant no matter where you are.

Alarms and fault messages are automaticallyrouted to the visualization systems or totrigger activity in other plant or businesssystems. Not only do you save programmingeffort, you also improve the visibility andefficiency of your operations.

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Maintenance

Managing a service and maintenance orga-nization is complex, and any process simpli-fication will save you time and money. WithTotally Integrated Automation, you can usethe same components throughout your op-erations, significantly reducing training foryour service personnel.

Fail-safe versions of our controllers are avail-able as are high-availability versions in redun-dant design. Hot swappable modules allowmaintenance during operation. And userparameters can be loaded over the networkat the press of a button, without additionaloverhead.

Even if the system experiences faults, thereis a wealth of fault detection and trouble-shooting tools available to you. For example,you can perform remote diagnostics of your

Production Life Cycle

Design and Engineering

Operation

Installation andCommissioning

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automation system via telephone or Internet.In many cases, service personnel don’t evenhave to be on site to eliminate faults. Theresult is an increase in your plant’s availability,while you save time and money.

Modernization and upgrade

Respond faster and more flexibly to changingmarket requirements. Totally IntegratedAutomation enables you to expand or convertyour plant without interrupting operations.Distributed I/O devices for integrating newdrives, valves, instruments or sensors can beadded or removed on the fly. This allows youto take advantage of our advances in tech-nology during your retrofit, because new TIAproduct generations are integrated easilyinto existing systems. The unique integrationof Totally Integrated Automation is a definingfeature right back at the development stageof our products and systems. This guaranteessystem compatibility and ensures that youcan continue to work with the familiar engi-neering tools.

Also, with Component Based Automation –a technology integrated within the SIMATICfamily to simplify object-oriented modulardesign – you can modernize or adapt yourproduction lines to new products particularlyquickly. Machines or production areas canbe replaced or added plug & play. New ma-chines can be integrated into the existingplant networks easily on-site, without chang-ing the control program and without affect-ing already tested functions.

Modernization and Upgrade

Maintenance

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With Totally IntegratedAutomation you canoptimize your entireproduction workflow

TotallyIntegratedAutomation

Controllers, Distributed I/O,Human Machine Interface

Motion Control, Computer Numeric Control

Industrial Controls and Switching Devices

Inbound Logistics Process

Enterprise ResourcePlanning (ERP)

Operations Level

ManagementLevel

Control and Field Level

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Industrial Communication (PROFIBUS,PROFINET/Industrial Ethernet, AS-Interface)

Sensor Systems, Drive Systems,Safety Integrated

Outbound LogisticsDiscrete

Process Control, SCADA System, Industrial Software

Industrial Software

Manufacturing Execution Systems (MES)

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Your company’s intellectual capital is more valuable than ever in today’s

highly competitive business environment. Strategic decisions surrounding the

future of automation technology become a key factor in sustaining your competitive

edge. By using Totally Integrated Automation, you preserve the investments

you’ve made in capital and intellectual property by guaranteeing compatibility

across different generations of products and different types of applications.

The interoperability of Totally Integrated Automation ensures the highest level

of system compatibility in our current and future products and systems.

You will benefit from Totally Integrated Automation now and throughout

the life of your system.

With Totally Integrated Automation, youcan secure your current investment whilestill taking advantage of further innovations

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TotallyIntegratedAutomation

Control Level

Operations Level

Field Level

Management Level

ERP – Enterprise Resource Planning

MES – Manufacturing Execution Systems

Ethernet

EthernetSIMATIC IT

SIMOTIONMotion Control System

SIMATIC PCS 7Process Control (DCS)

SINUMERIKComputer Numeric Control

• Maintenance• Modernization and Upgrade

Industrial Software for

• Design and Engineering• Installation and Commissioning• Operation

SIMATIC NETIndustrialCommunication

PROFIBUS PA

SIMATIC SensorsProcess Instrumentation

HART

AS-Interface

Industrial Ethernet

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Safety IntegratedSIMATIC HMIHuman Machine Interface

SIMATIC ControllersModular / Embedded / PC-based

TotallyIntegratedPower

SIRIUS Industrial ControlsSENTRON Switching DevicesSIMOCODE proMotor Management System

SIMATIC WinCCSCADA-System

AS-Interface

PROFIBUS

PROFINET

Industrial Ethernet

SIMATIC Distributed I/O SINAMICS Drive Systems

GAMMA instabus

KNX/EIB

SIMATIC: Totally IntegratedAutomation in practiceSIMATIC, the most installed automation platform in the world, is based upon the

principles of Totally Integrated Automation: seamless interoperability and trans-

parency. Three core design elements, common data management, common

communications, and common engineering environment, allow SIMATIC users to

achieve the benefits of Totally Integrated Automation.

You can create a highly integrated manu-facturing facility by optimizing informationflow. With SIMATIC, all the hardware andsoftware components speak the samelanguage. For this reason, it is extremelyeasy to configure data flow, even acrossdifferent physical networks and all systemssuch as SIMATIC, SIMOTION and drivesystems.

PROFIBUS and PROFINET/Industrial Ether-net, for example, are treated identically.Changing from one to the other requires

only that the communications processoris changed – without modifying the userprogram and without additional engi-neering overhead. The integrated com-munications system, from the corporatemanagement level to the field level, isbased on internationally recognized stan-dards like PROFINET/Industrial Ethernet,PROFIBUS and AS-Interface. And it sup-ports global information flow with Internettechnologies.

Common communications

You can reduce your programming over-head through the use of a commonengineering system. Within the SIMATICfamily all of the engineering tools, fromdiagnostics to configuration, are integratedwithin a project manager. The hardwarecomponents and the communication sys-tem are centrally configured, and all soft-ware tools are coordinated to work witheach other. All of this supports you duringthe complete engineering process for theentire life of your systems.

Whether you are programming a PLC or aPC-based solution, configuring a humanmachine interface, defining communica-tion links or implementing motion controls,

all the tools work seamlessly together. OurPLC and PC-based systems use the sameengineering tools as our process controlsystem. And when you create control andvisualization components for one platform,they are seamlessly available across allplatforms.

This modular concept makes applyingotherwise complex technologies mucheasier. Software libraries we supply cansimplify the implementation and integra-tion of MES components. Our MES com-ponents are coordinated by SIMATIC ITFramework and are easily integrated withplant floor and back-office/front-officesystems.

Common engineering environment

Through SIMATIC’s common data man-agement, you reduce time-consuming,redundant data entry tasks and eliminatefaults caused by incorrectly entered data.All software tools share the same inte-grated data. This eliminates redundantdata entries, and thus, potential sourcesof error.

Huge savings in time result. You only haveto create symbolic references in one place,so those defined in any tool are understood

by all the other tools within the integratedengineering environment. And thanks tobuilt-in multiuser capability, data consis-tency is guaranteed even when severalpeople are working simultaneously on oneproject. In addition, defined parametersare passed on in the engineering systemacross network boundaries to the fieldlevel including sensors, actuators anddrives – even via the Internet.

Core elements of SIMATICCommon data management

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When BMW was looking to start the new production lines of the 5 seriesand 7 series automobiles, they needed a way to reduce system downtimeto stay ahead in a very competitive marketplace. By deciding to useIEC 61131-compliant programming languages, they were assured thatcontrol logic was quickly understood and extremely easy to analyze bytheir engineers, especially during troubleshooting. And by choosingSIMATIC Industrial Software, BMW was able to optimize their engineeringand maintenance processes for additional downtime reduction by rely-ing on an integrated systems approach to diagnostics that automaticallygenerates and displays fault messages on the user’s operator panels.SIMATIC’s open standards, powerful diagnostics and an integrated engi-neering environment improve plant availability today to over 99%.

SIMATIC Software

“Only precise diagnostics enable plantavailability approaching 100%.”

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Totally Integrated Automation at work

With five takeoff and landing runways totalling over 14 miles, Boston’sLogan Airport is one of the busiest airports on the east coast of the UnitedStates. To ensure runway safety, Logan, which was built in 1923, had toupdate the automation system for its runway lighting. Bids were to focusprimarily on reliability, user-friendliness and extensive diagnostic optionsso that problems could be resolved more quickly. These are precisely theadvantages offered by the high-performance SIMATIC S7-400 family fromSiemens. Redundancy on a large scale helps maintain the high availabilityand reliability of the S7-400. The new facility in Boston has since madea significant contribution to air safety in this metropolitan city.

SIMATIC Controllers

“Safety, the linchpin of unrivaled reliabilityand availability, takes top priority where therunway lighting at airports is concerned.”

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Cost-effective implementation of international standards is essential for evensmall-scale manufacturing. So when Novartis needed to modernize a pharma-ceutical pilot plant, SIMATIC PCS 7 was the system of choice. Since activepharmaceutical ingredients are manufactured in the plant which are also to besold in the USA, FDA-compliance is required – even for production lines outsidethe US. SIMATIC PCS 7 automated the entire process and guaranteed seamlesscollection and documentation of all relevant information.

SIMATIC PCS 7 – Process Control System

“In the pharmaceutical industry, seamlessdocumentation of all data, even in the caseof small batches, is indispensable tovalidation.”

Cost-effective, easy to implement safety for personnel, machinery, andplant was critical for one of the largest processors of crude oil in the world.Shell used Safety Integrated to implement a refinery-wide modernization.The system was brought up to the very latest standards of safety, in somecases even exceeding levels required by law. Twenty-five percent of thedistributed inputs and outputs are now automated with Siemens fail-safetechnology. Safety Integrated provides a very cost-effective solution byincorporating the principles of Totally Integrated Automation.

Safety Integrated

“Safe, efficient automation of criticalprocesses is easy and cost-effective withTotally Integrated Automation.”

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Improving plant utilization and reducing time-to-market for new prod-ucts are just two of the results of having a flexible production system.SIMATIC IT delivered Bayer Crop Science AG these advantages in theface of stiff competition in the pesticides market. The design of theirnew multipurpose plant enables extremely flexible production. Aseamless electronic link between the control system and their newSAP system was also required to achieve the desired solution. A totallyintegrated production control system – from process automation withSIMATIC PCS 7 right up to the MES solution with SIMATIC IT – coordi-nates and controls all processes in the plant, maintains all informationfrom the plant and coordinates it automatically with the corporateSAP system.

SIMATIC IT

“Only flexible production systemsmake it possible to get new productsto market faster.”

Sometimes the need for safety extends far outside the factory walls.Continental, one of the world’s largest tire manufacturers, has people’slives depending on the security of their tested recipes. And to main-tain the safety and security of these recipes, Continental turned toSIMATIC HMI. Continental needed a strategy to maintain over 100 reci-pes used in the production of tire rubber. And these recipes have to beready at any time for use on the plant floor. All the recipe details andthe collected quality data are stored centrally in one database, securebut ready to be called up on demand.

SIMATIC HMI – Human Machine Interface

“When you have a host of different recipes,changing from one to the other withoutlosing time while maintaining consistentlyhigh quality is crucial to success.”

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SAB Miller (South African Breweries) used SIMATIC NET to go from man-agement approval to production in a new brewery in just 18 months. Asa global player and market leader, SAB Miller wanted to construct themost technically advanced brewery in the shortest possible time. Consis-tent use of distributed automation on PROFIBUS and AS-Interface alongwith reductions in the cabling overhead guaranteed that the ambitiousproject goals with regard to installation time and costs could be achieved.Over 1,000 different field devices are networked in the brewery usingPROFIBUS. This included over 400 servodrives in the packaging hall alone.Thanks to the use of intelligent field devices such as the SIMOCODE motorprotection relay, maintenance personnel can call up diagnostics informationfrom the field devices from the central control room.

SIMATIC NET – Industrial Communications

“Faster new plant construction is asignificant contribution towards reducingtime-to-market.”

Dimeco used SIMOTION to reduce waste in their new flexible punchingand bending machines. Dimeco developed the first mechatronic rollerfeed based on the SIMOTION Motion Control System and Siemens drives.SIMOTION combines complex motion control, logic and technologyfunctions within a single controller. All engineering tasks are implementedwith the integrated graphical engineering tool SCOUT. All productionparameters are stored in the SIMOTION memory along with up to 200machine recipes. SIMOTION guarantees continuous and reproduciblemanufacturing precision of ± 0.05 mm. The multiaxis design also en-ables zigzag control of the roller feed in order to interleave complex cuttingpatterns.

SIMOTION – Motion Control System

“The highest possible levels of precision andminimum use of materials in preproductionare the be-all and end-all for competitiveend products.”

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SIMATIC Sensors

“RFID systems optimize materialflow and logistics.”

DuPont Performance Coatings uses PROFIBUS to maintain reliable instru-mentation in hazardous areas. In their state-of-the-art water-based paintfactory, DuPont Performance Coatings’ engineers are constantly searchingfor more efficient, safe, and reliable production strategies.The SITRANS process instruments feature simple installation and out-standing communication and diagnostics capabilities. These deviceshave become established standards for pressure and temperature mea-surement. The use of these instruments resulted in significant time savingsin critical areas such as project planning, documentation, and start-up.It is particularly easy to integrate the SITRANS field devices intoSIMATIC PCS 7. The engineer can read the current diagnostics status ofthe field device at any time over PROFIBUS. In the event of a fault, op-erators receive a detailed message that quickly directs them straight tothe problem.

Skoda relies on Siemens RFID systems to reliably identify vehicle bodiesin its automotive production. From vehicle body construction to the paintshop and assembly, mobile data memory devices – so-called transponders –are found on all skids, which carry the individual vehicle bodies. Eachtransponder contains all the necessary production data for the individualvehicle bodies such as vehicle color, type and order number. This data isread at each step in the production process and updated again after thestep is completed. Special high-temperature data memory devices areused to cope with the especially harsh environmental conditions in thepaint shop. Thanks to the RFID system, the updated production data ofeach individual vehicle is available at each production step throughoutthe entire production process. The permanent availability of this dataenables maximum production quality.

SITRANS – Process Instrumentation

“Detailed fault messages are indispensablefor early, precise fault detection.”

Using Totally Integrated Automationyou will benefit from our completeservice and support

Totally Integrated Automation is at home no matter where in the world

your plant is located or where you deliver your machinery. Our service

and support is available to you and your customers everywhere. And we

provide comprehensive support from planning, through start-up, to

modernization, for all of your automation solution needs.

Online support

Online support is available 24/7 viathe Internet.

Technical support

Technical support is available to helpyou get the answers to the questionsyou may have concerning our prod-ucts and technologies.

Technical consulting

Consulting services can be used tohelp apply the latest technology andproduct into your new and existingsystems.

Configuration and softwareengineering

A full range of configuration and pro-gramming services can be employedto help you during system implemen-tation and maintenance.

Field service

Leverage commissioning and main-tenance services to meet yourmachine availability requirements.

Repairs and spare parts

Complete spare parts planning helpsyou maintain equipment availabilitythat meet your production require-ments.

Optimization and modernization

Services to help you maintain the op-erating conditions and improve perfor-mance during the systems operatinglife.

Design andEngineering

Installation andCommissioning Operation Maintenance

Modernizationand Upgrade

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Totally Integrated Automationwww.siemens.com/totally-integrated-automation

Solutions for your Industrywww.siemens.com/industrysuites

Service and Supportwww.siemens.com/automation/service&support

Products, Systems and Contactswww.siemens.com/automation

The information provided in this brochure contains merelygeneral descriptions or characteristics of performance whichin actual case of use do not always apply as described or whichmay change as a result of further development of the products.An obligation to provide the respective characteristics shall onlyexist if expressly agreed in the terms of contract.

All product designations may be trademarks or product namesof Siemens AG or supplier companies whose use by third partiesfor their own purposes could violate the rights of the owners.