Enclosure engineering is a time-consuming task which can be significantly rationalised by using the EPLAN circuit dia-gram generator. This is confirmed by Aixtron, the German-based company which speciali-ses in high-tech coating plants: By introducing the CAE tool EPLAN 5 and the circuit diagram generator, the company has managed to cut its through-put times for the development of standard circuits by around 80 %.

Originally created as a spin-off of RWTH Aachen around 17 years ago, Aixtron now generates more than 90 % of its sales abroad, with a workforce of more than 500 and an annual turnover of EURO 241 million. As developers and manufacturers of machinery for the production of compound semi-con-ductors, Aixtron's key technology is incorporated into the initial phases of the production chains of modern indu-stries whose products are now wide-spread throughout the consumer world. „These include such products as LEDs for more light with less energy con-sumption, mobile transistors, laser diodes, and the gigabit memory of the future", explains Production Manager Gronostay. 
Two years ago, in autumn, the company decided to focus its attention on quality and rising productivity. Its old CAE project planning tool was no longer able to keep pace with the latest requirements, which prompted Aixtron to search for a replacement. A comprehensive system of benchmarking was carried out before making a selection. The new system should be innovative, meet international requirements, offer adequate flexibility for additional adaptations, and last but not least, support links to manufacturing requirements planning (MRP) and bus systems. 

Circuit diagram generator ‘the icing on the cake’
Bernd Gronostay, Production Manager at Aixtron, explains succinctly why his company eventually opted for EPLAN 5 from Monheim-based producers EPLAN Software & Service: „The system simply had the widest range of functions as far as our requirements were concerned". The fact that the software is widely known and is also used by Aixtron's own suppliers, was an added bonus. 
„This software has virtually become a standard in electrical project manage-ment. What is more, because our own suppliers already use the software, we were able to avoid interruptions to the information flow from the outset". In addition to the aforementioned arguments, another key factor also played a part in the final decision. „We had always planned to integrate the circuit diagram generator from EPLAN. We were expecting this tool to produce dramatic rationalisation and automation effects", stresses Gronostay.

The technical production structures at Aixtron were such that the circuit diagram generator seemed likely to produce maximum benefits, because the company’s production system is very modular, and developers are able to draw on certain basics. „It was a matter of integrating these basics into a system in such a way that by clicking on the required components, the circuit diagram generator would automatically combine them into a circuit dia-gram", stresses the production expert.

From project repetition levels of 30 % or more, it makes sense to standardise or automate the planning process. New projects and plants based on old electrical designs and projects are soon generated using the circuit diagram generator. Thestandardised component circuit  diagrams are stored in a project as the basic originals. An Excel spreadsheet is used to administer new projects and modify the variable information and values. By accessing all circuit diagram data within the spreadsheet structure, it can be edited directly.

Support from Excel functions
In this way, not only are all properties easily edited; furthermore, entire pages or component circuit diagrams can also be replaced with a different variant. Moreover, project management can be supported with Excel functions, for example in order to link various data of the CAE tool to one another.
Dependent values in the circuit diagram can also be linked together in the spreadsheet. For example, if a larger motor is used in a project, the circuit diagram generator will automatically execute all the information linked to this, including for example the corre-sponding dimensioning of cables with a larger cross-section or protective devices. Overall, such functions create substan-tial potential for reducing project throughput times and costs. At the same time, the designers’ work methods are standardised and automated. 
If used effectively, a reduction in planning work of up to 70 % is feasible with the circuit diagram generator. Bernd Gronostay quotes similar figures: „The rationalisation effect is based on the fact that on average, over 80 % of our production is standard, whilst the rest consists of modifications". He has found that standard circuitry can now be created in one day with the circuit diagram generator; in the past, this process took up to five days. „As a result, work time on this area is reduced by 80 %. Put differently, we have achieved a productivity increase of 400 %. Of course, this also has an extremely beneficial effect on the total project throughput time. Whereas in the past, we might have estimated up to six weeks, this period can now be reduced to a maximum of two weeks". The CAE tool EPLAN 5 is then used for project planning the entire enclosure of an Aixtron coating plant. This task incorporates the complete control, regulation and monitoring system for the entire plant. For example, in the area of signal electronics, up to 2,000 signals must be planned and the circuit diagrams prepared. 
Two years ago in autumn, Aixtron started out with five systems; it now has 19 licences in use. The rationalisation success achieved with the system is, of course, also due to thorough preparation. The CAE tool and the circuit diagram generator were phased in gradually. „We were unable to do everything at once; we could not afford to interrupt operations", explains the Aixtron Production manager. 
The staff were trained in two groups, classified according to basic users and key users. Basic users work with the system at shop floor level, and must be capable, for example, of reading circuit diagrams. Meanwhile, the actual engineering tasks are performed by the key users, who receive intensive trai-ning .„First of all, we needed to acquire in-depth expertise to enable us to utilise the benefits of the circuit diagram generator in full", says Bernd Gronostay, explaining the training strategy used by their service-providers. Following basic training, both parties -the users and the service-providers -sat down again and drew up a pilot project for introduction of the circuit diagram generator. The outcome was a resounding success: „For just over a year now, the circuit diagram generator has produced a full rationalisation effect", exclaims Bernd Gronostay delightedly.

Plans to link the CAE tool to the MRP system
In Aachen, new plans are already in the pipeline to link the CAE tool to the in-house manufacturing requirements planning (MRP) system. The aim is to achieve complete transparency, both on the cost side and with a complete listing of all components and parts in a coating plant. „This is the only way of ensuring an international service", says the Production Manager, explaining the reasons behind the strategy. After all, Aixtron plants are exported worldwide, and even customers at remote locations must be able to access components or data in the MRP system very quickly. 
Another benefit of the planned link is increased planning confidence. Not only will a complete overview of costs be available at all times; furthermore, users will also have a comprehensive insight into the current development status of individual projects. „Buyers and engineers will access a shared data pool which is constantly updated", says Gronostay, outlining his vision of the future. Decisions made in the commercial sector will be available online, i.e. synchronously, to the developers. Of course, a problem-free data flow between the different departments of a company also offers significant benefits when it comes to planning project throughput times as early as possible, and keeping costs within a narrowly defined budget. 
According to Gronostay, the company’s ongoing cooperation with EPLAN Software & Service should help to ensure that this vision soon becomes a reality. „We are in close contact with one another. We hope to have it up and running in the first quarter of 2002". 

Last edited: 2003-01-15 09:09