Studie Engineering 4.0 EN

Engineering 4.
0
A study of the efficiency potential and the use of CAE software in electrical
design for the engineering of machines and plants
PROZESSBERATUNG ENGINEERING-SOFTWARE IMPLEMENTIERUNG GLOBAL SUPPORT

Engineering 4.0
A study of the efficiency potential and the use of CAE software in electrical design
for the engineering of machines and plants
07.05.2019
Study Design: Dr. Thomas Gartzen, Sebastian Schloesser, Michael Mendl-Heinisch
Dr Thomas Gartzen
European 4.0 Transformation Center GmbH
Campus-Boulevard 57
52074 Aachen, Germany
www.e4tc.de
Study Realisation: Uwe Harder, Detlef Harms
Uwe Harder
EPLAN Software & Service GmbH & Co. KG
An der Alten Ziegelei 2
40789 Monheim, Germany
www.eplan.de
2 © 2019 European 4.0 Transformation Center GmbH and EPLAN Software & Service GmbH & Co. KG
Key Words
Industry 4.0, standardisation, Control Cabinet Study 4.0, engineering,

efficiency, methodology, degree of repetition, modularisation,
structuring, configuration, generation
This document contains proprietary information that is subject to copyright,

trademark, design and other laws. All rights are reserved. This document may not
be copied in whole or in part or duplicated in any other way without the express
prior consent of EPLAN Software & Service GmbH & Co. KG.
© 2019 European 4.0 Transformation Center GmbH and EPLAN Software & Service GmbH & Co. KG 3
Engineering 4.0 Study
Table of Contents
1 Introduction to Engineering 4.0 5
2 Overview 6
3 Study Design 7
3.1 Engineering Workflow Model 8
3.2 Method Value 10
3.3 Methodology Efficiency Level 11
3.4 Use Efficiency Level 14
3.5 Study Implementation 15
4 Study Participants 16
4.1 Machine Construction (Mass-Produced and Special Machines) 17
4.2 Engineering Offices/Hardware Planners 18
4.3 Device Manufacturers/Smaller Machine Manufacturers 18
4.4 Control Cabinet Manufacturers 18
4.5 Design Process Engineering 18
5 Efficiency in Engineering: Influencing Factors 19
6 Reference Model 20
7 Application Model 23
7.1 Manufacturing Mass-Produced Machines 23
7.2 Manufacturing Mass-Produced Machines with Special Parts 24
7.3 Manufacturing Special Machines 26
7.4 Engineering Offices/Hardware Planners 27
7.5 Device Manufacturers/Smaller Machine Manufacturers 28
7.6 Control Cabinet Manufacturers 29
8 Fields of Action for Efficiency 30
8.1 Partially Standardised Work Methods (eLevel: 1 -> 2) 31
8.2 Standardised Work Methods (eLevel: 2 -> 3) 32
8.3 Partially Automated Work Methods (eLevel: 3 -> 4) 33
8.4 Automated Work Methods (eLevel: 4 -> 5) 33
8.5 Summary 34
9 Market Trends Forecast 35
10 Appendix (Efficiency Table) 36
Introduction to Engineering 4.0 1
The world is talking about Industry 4.0, a complex and much-discussed topic. The intelligent
networking of machines and processes in industrial manufacturing is already taking shape,
from flexible production to smart logistics to robotics and big-data applications. But what
about the strategic digitisation of design and control engineering for machines and plant
systems?
It’s a pressing question. After all, the central challenge is comparable in both engineering
and manufacturing: the market demands the efficient implementation of individual customer
requirements. Those seeking to efficiently plan and design complex devices, production
machines or even entire plant systems comes up against a “black box” of unanswered
questions: What does Engineering 4.0 even look like for control technology? What mea-
sures can be taken to increase efficiency? Can the optimisation potential be quantified in
correlation to working methods?
The European 4.0 Transformation Center (E4TC) at the RWTH Aachen Campus has investi-
gated this complex of topics. The “Engineering 4.0” research report is based on an eight-
month field study of German machine engineering companies that manufacture mass-pro-
duced machines and special machines, engineering offices/hardware planners and device
manufacturers.
The European 4.0 Transformation Center developed the study design within the framework
of the study. For this purpose, the E4TC researchers in Aachen introduced a reference mo-
del for the engineering workflow and created an evaluation matrix with five levels of effici-
ency. The Efficiency Level Matrix, with detailed statements about Methodology Workflow, is
accompanied by a Use Level Matrix. This describes and evaluates the use of CAE software
for generating the control/technical documentation in the areas of electrical, pneumatic and
hydraulic engineering for the production of machines and plant systems as the basic pre-
requisite for Engineering 4.0. The methodology was validated by way of visits to reference
customers in cooperation with E4TC and Eplan. Eplan then subsequently rolled out the
study within the customer base.
The study specifically looks at the control technology design, hardware construction and
engineering, all with regard to the electrical design and the related control cabinet construc-
tion. The goal of all the process steps is to create digital twin documentation, especially the
digital twin control cabinet, to form a consistent, digital foundation for paperless, automated
control cabinet manufacturing. Based on an empirical survey, the study identified several
fields of action and factors that point to a potential increase in efficiency for engineering,
also in comparison with automation and the necessary efforts required for standardisation,
in some cases in the high double-digit percentage range.
The developed methodology for quantifying potentials and procedures in engineering

enables for the first time a well-founded reflection of current engineering workflows in mass
machine manufacturing and special machine manufacturing on the path to Engineering 4.0.
2 Overview
Engineering can be classified in five efficiency levels (eLevels).
Typically achievable efficiency potentials were determined from eLevel 1 to 5, from

n
traditional to automated engineering.
Efficiency cannot be calculated, however it can be compared and estimated using

n
benchmarks.
n An increase in efficiency of about 20 percent can be realised for the entire process
moving from level to level.
A device-oriented work method (eLevel2) achieves 25 percent time savings for creating
n
schematics (Steps 4 to 7).
Using a circuit library for product functions (eLevel3) achieves 50 percent time savings
n
for creating schematics (Steps 4 to 7).
n Introducing partial automation (eLevel4) brings an additional 25 percent time savings for
creating schematics (Steps 4 to 7).
A company needs six months on average for the initial creation of professional
n
device data.

n “Create all reports” (Step 6) is completely eliminated by introducing standardisation
(eLevel3).
n Using a comprehensive circuit library (eLevel4) can reduce the time needed for checking
the schematics (Step 5) by 75 percent.
Approximately doubling the efforts on standardisation is the prerequisite for partially to

n
fully automated configuration.
The key to higher efficiency in engineering lies in the division of labour into order
n
processing and product management in engineering.
n The partial-automation level results in the best ratio between effort and benefit from
a business point of view.
Study Design 3
The study’s goal was to determine a quantified reference process that could be used as
a comparison for efficiency in electrical engineering. This entailed, first, the creation of
an initial reference process for electrical engineering. For the next step, reference values
were determined that indicated the efforts needed in the various engineering levels for
the different steps of the engineering reference processes. Finally, a reference curve was
derived from the available results.
“Efficiency in Electrical Engineering” study design
To start, reference customers were selected for the study. They then each participated in
a workshop and a structured process interview using a questionnaire. The questionnaire
addressed the various steps of the reference process and the work methods within the
steps. This allowed an Engineering Efficiency Level to be determined for each work step.
Furthermore, the relevant effort required was determined for various company projects.
On the basis of the collected data, a connection could be shown between the Enginee-
ring Efficiency Level and the required effort, for each of the recorded process steps.
3.1 Engineering Workflow Model
A general model of order processing was developed to quantify the individual efforts and
was applied to all companies participating in the study. The work steps could be carried
out in parallel or in an iterative manner.
Engineering Workflow Model “Design & Construction” (Work Steps 1–8)
1. Clarify specifications:
Work Steps:
The technical and functional aspects of the task are clarified.

Results:
The technical specifications for order coordination are reconciled and defined.
2. Clarify the basic conditions:

Work Steps:
The order’s basic conditions (terms of delivery, installation, on-site power supply)
are clarified.
Results:
The order’s basic conditions (terms of delivery, installation, on-site power supply)
are reconciled and defined.
3. Design the functions and infrastructure:

Work Steps:
The technical product functions (sensors, actuators) are designed.
The infrastructure functions (inputs, control, operation, monitoring, emergency stop)
are designed.
Results:
The schematics for product and process functions and the infrastructure functions
are designed in CAE.
4. Create schematics:
Work Steps:
The schematics for the production and process functions are created.
The schematics for the infrastructure functions are created.
They are designed in CAE.
Results:
The schematics for product and process functions and the infrastructure
functions are designed in CAE.
5. Check schematics:
Work Step:
The schematics are checked, corrected and finalised.
Results:
The schematics are available in the final and error-free version.
6. Create bill of materials:

Work Steps:
The bill of materials (BOM) is created.
Reports are created.
Results:
The bill of materials (BOM) is available.
All required devices are contained in the bill of materials.
7. Create manufacturing documentation

Work Step:
The documents required for manufacturing are created.
The manufacturing documentation includes terminals, wires and connections.

Results:
All the necessary manufacturing documentation – including terminals, wires and
connections – is documented and can be handed over to manufacturing.
8. Design control cabinet

Work Step:
The control cabinets are designed in 2D or 3D.
Results:
All control cabinets and housings are designed.
The designs are either in 2D or 3D.
9. Create device standards
Work Step:
Data for the devices being used is updated and maintained.
Results:
Device data is available.
10. Create macros and templates

Work Step:
Macros and templates are created for later applications.

Results:
Macros and templates have been created and can be used for later applications.
3.2 Method Values
A schematic reference project was created to compare the customer analyses. It

consisted of a 100-page schematic with 30 typical functions (product and infrastruc-
ture). This reference project was used to ensure a neutral value for the comparison of
different companies. To this end, the typical activities during the implementation of this
engineering task were first described:
Technical clarification/development
Creation of graphic schematic
Creation/use of the necessary devices
Derivation of BOMs
Derivation of labels
Derivation of manufacturing documentation
Design of control cabinet
Rework/Corrections
For the initial design (100 percent engineering to order – ETO), meaning a completely
new design, an industry-typical value of 1 hour per schematic page was assumed. For
a reference project with 100 pages of schematics, this means a workload of 100 hours.
In the next step, these 100 hours are assumed to make up 100 percent of the time
worked as the basis for calculation. The higher the degree of repetition for a task, the
higher the potential of automation, which can reduce the time required for creating the
schematics.
Hypothesis: A higher degree of automation can reduce the method value, me-
aning the effort necessary for creating a schematic page. In turn, the effort for
standardisation increases with a higher degree of automation.
Design time and effort for standardisation depending on the engineering method
3.3 Methodology Efficiency Level
To evaluate the efficiency of each work step, a scaling into five different efficiency levels
was carried out. This concept allowed the specific engineering performance among
different companies to be abstracted and thus compared and classified. In this way, the
efficiency level of each process step could be objectively evaluated through targeted
questioning in the form of a questionnaire. The following is a brief presentation of some
sample questions:
1. Clarify specifications: How are the order data and requirements handled in
the design department?
The storage of order data and requirements is predominantly analog
(e.g. scanned PDFs, sketches, etc. on file servers).
The storage of order data and requirements is predominantly digital
(e.g. digital Excel templates).
The storage of order data and requirements is completely digital
(e.g. documentation in a PDM system).
2. Clarify the basic conditions: How does the customer deal with the basic
conditions for orders (norms, factory standards, etc.)?
Basic conditions for an order are individually clarified and taken into account.
Templates and references already incorporate the potential variance of the
basic conditions.
An automatic mechanism can be used to react to different basic conditions.
3. Design functions and infrastructure: What is the approach for developing

new technical solutions (ETO)?
New technical solutions are designed in a manual process (e.g. in consultation,
mainly with sketches).
New technical solutions are designed in a system-supported process
(e.g. transparent history through the use of software).
4. Create schematics: How are schematics created?

Schematics are created mainly in a graphical, interactive way through the placement
of symbols or partial circuits (e.g. copy and paste).
Schematics are created based on a central macro library with product functions and
stored data tables.
Schematics are created mainly through automatic generation by connecting to
a configuration.
5. Check schematics: How are the schematics checked after they’ve been created?
Schematics are checked manually by reviewing all the schematic pages.
Schematics are checked through mass processing and corrections using navigators
(e.g. multiple cross-page processing).
Schematics remain almost completely unchecked for functionality.
6. Create bill of materials: How is the bill of materials created?

The bill of materials is created manually from the CAE.
The bill of materials is automatically created from the CAE and manually compared
with the ERP system.
The bill of materials is automatically created from the CAE and automatically
compared with the ERP/PDM system.
7. Create manufacturing documentation: How complete is the electrical

documentation for manufacturing?
The manufacturing documentation is created manually by the user.
The manufacturing documentation is created partially automatically using
evaluation templates.
The manufacturing documentation is created automatically through an
ERP/PDM integration.
8. Design control cabinet: How does the customer methodically handle the
control cabinet design?
The control cabinets are laid out schematically using sketches and without
device references.
The control cabinets are laid out graphically in 2D.
The control cabinets are laid out graphically in 3D.
9. Create device standards: At what level of detail does the customer create
3D data for the devices?
3D device data contains only geometric dimensions.
3D device data includes additional manufacturing data (drilling patterns, milling
patterns, etc.).
3D device data includes additional NC data and routing.
10. Create macros and templates: How systematically does the customer use
and manage macros?
Macros are not used for electrical engineering.
Macros are used by a few individual users in electrical engineering.
Macros are centrally managed in electrical engineering and used by everyone.
With the help of the sample questions above, each process step could be assigned an “Ef-
ficiency Level” listed below. While a three-step scale was considered sufficient for the sur-
vey, a total of five efficiency levels were defined. Intermediate levels in the overall evaluation
result from the fact that several questions exist for each of the individual process steps.
“Methodology Workflow” Efficiency Level (eLevel) Definition
eLevel Work Method Characteristics per Work Step
1 “traditional” Graphically oriented work method, symbols, manually created schematics,

typical design of new circuits (ETO share)
2 “partially Device-oriented work method, use of product macros, creation of device

standar- databases, device selection
dised”
3 “standar- Graphical and device-oriented work methods, use of a circuit library for pro-
dised” duct functions, central macro projects, modularisation, consistent reuse, fully
automatic report creation, introduction of division of labour in engineering for
order processing and product management
4 “partially Use of a comprehensive circuit library and of design methods including

automated” options, variants, importing data, offline ERP/PDM integration
5 “automa- Use of generation and configuration functions, integration into the entire
ted” process (ERP/PDM), sales configurations (a degree of automation up to
100 percent)
Efficiency Level (eLevel)
Ten Fields of Action
1 (tradi- 2 3 (stan- 4 5 (auto-

tional) dardised) mated)
1 Basics, same symbols/graphic X X X

design, copying
2 Device databases, structure and 50 % 100 %

degree of utilisation
3 Creation of templates, macro tech- X X

nology/library, reutilisation
4 Rules for preparing design manual, 50 % 50 % 50 - 100 %

central specifications
5 Division of labour, processing and X X X

standardisation
6 Product structuring for reutilisation, X X X

modularisation
7 Consideration of working methodo- 50 % 100 % X

logy, platform
8 Consideration of data continuity, X X X

preplanning
9 ERP/PDM integration, device data, X X

mechanics
10 Automation in process, configuration X
3.4 Use Level Efficiency
To evaluate the efficiency of each work step, five steps of scaling were carried out. This
concept enabled the abstraction and thus the comparability and classification of compa-
nies into their specific engineering performance.
The degree of use of CAE software can be represented by a Use Level (uLevel).
Evaluation of the performance of the utilised CAE software
Assessment of the user’s depth of use of the CAE software
The Use Level und Methodology Level were both necessary prerequisites to be able to
demonstrate an actual and target state with possible potential savings in engineering
processes.
The higher the level, the greater the efficiency. The difference between the
actual and target state represents the achievable savings potential.
“Use of Software Functions” Use Level (uLevel) Definition
uLevel Characteristics of function usage in the CAE software (excerpt)
1 “basic“ Graphically oriented work method, no overviews, no templates,

no translations, no reports
2 “enhanced“ Graphically oriented work method, copy and paste, macro use,
use of online numbering functions
3 “advanced“ Graphically and device-oriented work method, macro projects, use of

navigators, use of standards IEC 81346 & IEC 61355
4 “professional“ Use of mass data processing, import and export
5 “high Use of automatic functions, scripting, comprehensive customising in

professional“ the work method
Increasing the uLevel (“Use of Software Functions”) – achievable through training/coaching

as well as the purchase of additional modules – is the basic prerequisite for more efficient
engineering. Yet this alone does not lead to higher efficiencies.
3.5 Study Implementation
The study took place at the locations of different reference customers in a half-day to full-day
workshop. To accomplish this, various company employees were interviewed individually and/
or in groups using a process interview. To start, the company’s basic conditions were noted.
The processes for electrical engineering were then recorded in the form of the previously intro-
duced sample questions. Finally, time expenditures for projects typical for the company were
noted so that a connection could be made between the company’s specific work methods
(Engineering Efficiency Level)
and the corresponding effort
required for a project. From
this data specific reference
points could be determined,
which could then be transfer-
red into an anonymised refe-
rence curve. The study design
was initially implemented and
validated in a cooperation
between the E4TC and Eplan
reference customers.
4 Study Participants
Each manufacturing company produces different products and is thematically integrated
into industry-specific end customers and supplier relationships. Different focal points and
workflows in engineering can sometimes be assigned to specific industries to enable
them to carry out their respective business activities.
Industries Examined
1 Plant design, plant technology, Engineering of continuous processes – predominantly

process technology the design of measuring point technology and pro-
cess control technology
2 Machine engineering, mass- Engineering of discontinuous processes – predom-

produced or special machines inantly the use of actuators, sensors and control
systems
3 Product manufacturers Manufacturing of near-series products, devices,

testing systems
4 Building equipment Implementation planning in the area of “Building

Information Modelling” (BIM)
This study looked at the segment of machine engineering for mass-production or special
machines, device manufacturing, suppliers, engineering offices and cooperation partners.
Traditional Share of ETO per Industry
Target Group Degree of Repetition for Products – With or without in-

Estimation of New Engineering (ETO) house control cabinet
construction
1.1 Machine Engineering <5% Both

(mass produced)
1.2 Machine Engineering 5–30 % Both
1.3 Machine Engineering > 50 % Both

(special machines)
2 Device see Machine Engineering see Machine

Manufacturing Engineering
3 Engineering Offices Per order Without
4 Control Cabinet Per order X

Construction
4.1 Machine Engineering (Mass Produced and Special Machnies)
This study examined the typical engineering processes in hardware engineering and the
creation of schematics and manufacturing documentation for control cabinet manufac-
turing. The engineering process in control technology starts with the customer order and
leads through design and manufacturing to delivery and commissioning of the machine
at the end customer’s site. The amount of control/technical documentation can run from
one hundred pages to several thousand per machine. Machines are typically character-
ised by functions with variants and options. Control cabinet designs (in 2D or 3D) are
also created for manufacturing.
Breakdown:
1. Engineering: Design of the control technology/hardware
2. Manufacturing: Production of the control cabinets
A machine builder with in-house control cabinet construction has the entire value
creation (1, 2) in-house. All workflow steps are its own responsibility.
Classification according to the share of total value creation:
1 Machine builder with in-house (1) Design process of the control technology/hardware
control cabinet construction
(2) Manufacturing process of the control cabinets
2 Machine builder with contractor (1) Design process of the control technology/hardware
for control cabinet construction
3 Control Cabinet Manufacturer (2) Manufacturing process of the control cabinets
Classification according to product type:
1. Design and manufacture of mass-produced machines (low ETO content,

typically 5%, < 30%)
2. Design and manufacture of special machines (large ETO content, > 50%)
There are different and varying efficiency potentials depending on the proportion of
value creation and the type of product.
4.2 Engineering Offices/Hardware Planners
Engineering offices/hardware planners usually handle the control engineering design

for many different end customers and industries. This engineering is characterised by
the differing specifications and basic conditions of the machine builders or plant opera-
tors that hire them. A special mention should be made here of the sphere of automotive
engineering, where control cabinet construction is usually outsourced to control cabinet
engineering companies.
4.3 Device Manufacturers/Smaller Machine Builders
The number of schematic pages per project is between 20 and 100 pages for device man-
ufacturers/smaller machine builders. In this study, the participating companies had either 1
or 2 engineering employees. The 8-phase design from traditional mechanical engineering
may also be applied to this segment of device manufacturers/smaller machine builders.
4.4 Control Cabinet Manufacturers
Control cabinet manufacturers work on behalf of machine builders and manufacture the
control cabinets based on delivered schematics. There are only schematic or 2D overview
drawings for 90 percent of these orders. Such delivered schematics cannot be used for
automatically controlled manufacturing.
4.5 Engineering Design Process
Some companies covered different areas and therefore could not be clearly be classified
into the group of mass-produced or special machine builders. Several design processes
exist simultaneously with a certain distribution across the products.
Example of a typical machine builder:
Share of Manufacturing Main Work Method in Engineering
1 30% manufacture of mass-produced Template-based creation of schematic docu-

machines ments based on planned maximum projects
(model range)
2 50% manufacture of mass-produced Creation of schematic documents based on exis-

machines with 30% ETO ting templates and subprojects through copying
and manual adjustments
3 20% mainly manufacture of special Individual schematic designs

machines
Efficiency in Engineering: 5
Influencing Factors
To evaluate the engineering processes, it was necessary to classify the essential influ-
encing factors. Some factors can be directly influenced, others only indirectly. The time
horizon must be considered as a further dimension: some factors are adjustable over
the short term, others over the medium term or long term. The complexity of the many
variables that had to be considered can be seen in the Influencing Factors in Enginee-
ring overview.
Influencing Factors in the Engineering Process
1 Workflow This describes the steps of the order processing, from the start in the
engineering department until completion of all the control engineering
documentation (schematics) that are required for assembly and com-
missioning of the machines and for the manufacture of control cabinets.
2 Methods in This describes the manner in which the engineering is performed. An

Engineering essential factor is recognising and utilising the reuse (degree of repe-
tition) of an order and the documentation. Customer requirements are
implemented with “Engineering to Order” (ETO) and “Configuration to
Order” (CTO).
3 Standardisation This describes the degree of standardisation. What is assigned is the

relative time required for standardisation procedures that increase the
degree of repetition and increase the efficiency in engineer-
ing for specific orders or across orders.
4 Tools This describes the software solutions used and the consistency of the
process flow in engineering. The tools run the gamut from standard
solutions to self-programmed solutions to aids such as scripting.
5 Integration This describes the degree of integration of control-technology engineer-

ing in the entire process, such as mechanical engineering, ERP/PDM
and software development.
6 Organisation This describes the organisational structure, qualifications of the employ-

ees, workload, division of labour, motivation, spatial arrangement of the
workstations and responsibilities.
7 Customer This describes the order, the requirements, basic conditions, customer
specifications and also possible shares in the value chain.
8 Supplier This describes the cooperation with external suppliers such as coope-
ration with external control cabinet manufacturers.
6 Reference Model
Creation of a schematic with 100 pages (30 percent ETO share) and assess-
ments such as bill of materials and manufacturing documentation (terminal
diagrams/wiring diagrams)
Engineering Workflow Model “Design & Construction” (Work steps 1–8)
The effects of the different work methods on the reference schematics are shown in the
time savings that can be achieved in schematic creation.
eLevel Work Steps 4–7: Savings Work Steps 9, 10: Resulting total
of direct work on the sys- Efforts for standardi- potential for all
tem (schematic creation) sation, pro rata basis Work Steps 1–10
per order
1. “traditional” – – –
2. “partially 25 % 5% 20 %
standardised”
3. “standard- 50 % 10 % 40 %
ised”
4. “partially 75 % 15 % 60 %
automated”
5. “automated” 100 % 20 % 80 %
Up to 50 percent savings can be achieved by changing from the creation of schematics

from sketches (eLevel1) to completely standardised schematic creation (eLevel3). Another
halving of the time needed can be achieved by partial automation (eLevel4). An efficien-
cy gain of 15 to 20 percent can be assumed as one moves from level to level, taking into
account the efforts required for standardisation.
Creation of a control cabinet structure (standard control cabinet)
3D design (assembly plan, reference project in eLevel3)
eLevel Work Step 8: 3D Control Work Methods

Cabinet Design Time
Required
1. “traditional” – Graphically in 2D, only a schematic represen-

tation, no export possibilities (NC and routing)
for manufacturing
2. “partially Starting point (100%) Placement from a device list

standardised”
3. “standard- Up to 50% savings Use of templates and elimination of

ised” non-utilised parts plus manual additions
4. “partially Not used Generated from the schematics

automated”
5. “automated” Not used Configuration, integration with the sales

configurator
The time required to create a 3D control cabinet layout depends largely on the available
master data and the share of ETO. On average it takes about 4 hours to create a standard
control cabinet layout. In this reference model, this is two pages of 3D layout (mounting
plate + door).
Changing from a partially standardised work method (eLevel2) to a completely standard-

ised work method (eLevel3) brings a time savings of 50 percent.
The time necessary for the creation of a schematic in relation to that required for the design
of an appropriate control cabinet layout has a ratio of between 10:1 and 20:1, meaning it
takes 10 to 20 times longer than the corresponding creation of the control cabinet layout.
Results: Reference Engineering Efficiency Curve
The calculation basis (Y axis) can refer to each schematic page or, as seen here, to entire
schematic projects.
Order processing requires additional, cross-project and in part order-related standardi-

sation activities.
Standardisation Activities
Grouping of Activities Activities
1 Creating Device Data Inputting purchased devices in ERP and CAE sys-
tems
2 Creating Templates Creating partial schematics (macros) for reuse in

schematics (characterised in variants and options)
Application Model 7
7.1 Manufacturing Mass-Produced Machines
Mass-produced machines are standard products. The machine prototype (model) is de-
veloped and then ordered, configured, manufactured and built several hundred times. The
engineering consists of creating “as built” documentation from a master template for each
order for variants and options.
Efficiency Levels 3–5 Are Used.
eLevel Work Method Work Method Characteristics
3 “standardised” Schematics are created based on master plans by slightly

adjusting and inserting selected variants and options
4 “partially Use of variants and option techniques, partial generation of

automated” schematics and the appropriate manufacturing and customer
documentation
5 “automated” Complete, automatic generation of schematics and the appro-

priate manufacturing and customer documentation based on a
sales configurator. No user action is required.
eLevel3: Initial situation

Thirty percent of companies don’t produce any documentation; they refer to a master plan.
A separate order indicates the current configuration being ordered. There is no “as built”
documentation.
eLevel4: > 40% savings potential

Sixty percent of companies produce “as built” documentation by using a master project.
Duplicates not used are deleted, the plan is then manually completed by connecting un-
connected potentials, tracking missing wiring, etc.
eLevel5: Up to 100% savings potential

Ten percent of companies have an automated configuration solution.
Examples of Typical Savings in Mass Production/200 Machines per Year
(absolute values)
eLevel Time for Creating Documents Savings [%] Savings for 200 Orders
per Order [h] per Year [h]
3 3 – –
4 1.5 50 % 300
5 0 100 % 600
7.2 Manufacturing Mass-Produced Machines with Special Parts
Machine-building companies have their own control cabinet construction departments or

work with external control cabinet companies. The proportion of new engineering (ETO) is
around 20 to 30 percent.
Typical Time Requirements for Order Processing in Engineering Departments
1 2 3 4 5 6 7 8
Clarify spe- Basic con- Design Construction Check Bill of Reports Cabinet
cifications ditions 30% materials construction
5% 5% 18 % 42 % 10 % 5% 5% 10 %
Directly influenceable (about 62% of the time)
Engineering uses one or more copy templates, variants and options based on page mac-
ros that are first copied for every order and then manually amended.
Efficiency Levels 2 and 3 dominate engineering for manufacturing mass-produced
machines with special parts. Work in Efficiency Level 4 is also prevalent.
2 “partially Creation of schematics based on master plans, copies of page

standardised” macros, manual additions
3 “standardised” Creation of schematics based on master plans through the

adjustment and insertion of selected variants and options, use of
import functions
4 “partially Creation of schematics based on master plans, partial generation

automated” of parts of projects
eLevel2: Initial situation

Thirty percent of companies in the study create new projects based on one or several
master plans. Page macros are frequently used. The page macros are often redundant and
employee-specific. Several thousand page macros are being used as templates. Updating
these templates takes a lot of time.
eLevel3: 45–50% savings potential

Fifty percent of the companies create new projects based on one or several master plans.
The standard is very often built on redundant page macros. Here a central company
standard is used for the first time. The task is to reduce redundancy and to restructure and
modularise the templates.
eLevel4: > 50% savings potential

Sixty percent of the companies create “as built” documentation by using a master project.
Non-used duplicates are deleted, the plan is then manually adjusted and completed. Non-
connected potentials are connected, missing wires added, etc. Partial configuration tech-
niques are used. The infrastructure, including the PLC, is additionally supplemented.
eLevel5: No 100% configuration solutions are being used at the moment
Examples of Typical Savings for 100 Orders (absolute values)
eLevel Time for Creating Documents Savings [%] Savings for 100
per Order [h] Orders per Year [h]
2 16 – –
3 8 50 % 800
4 4 75 % 1,200
7.3 Manufacturing Special Machines
The production of special machines can be considered a completely new development:

a relatively high time expenditure for finding a solution stands in contrast to a low syste-
matic expenditure. Typical lead times are a total of six months.
In special machine manufacturing, the measure “time per page” has proven itself for
comparing engineering across companies.
Engineering primarily within the scope of Efficiency Levels 2 and 3
2 “partially Creation of schematics based on master plans, copies of page

standardised” macros, manual additions
3 “standardised” Creation of schematics based on master plans through adjusting

and inserting the selected variants and options, use of import
functions
Examples for Typical Savings (absolute values)
eLevel Time for Creating Documents Savings [%] Savings for 5 Order
per Order [h] per Year [h]
2 500 – –
3 425 15 % 375
7.4 Engineering Offices/Hardware Planners
Typical Time Requirements for Order Processing in the Engineering Department
1 2 3 4 5 6 7 8
Clarify spe- Basic Design Construction Check Bills of Reports Cabinet

cifications conditions 30% materials construction
50 % 20 % 15 % 10 % – 5% –
Directly influenceable (about 30% of the time)
Practical example: An engineering office/hardware planner is focusing on the design in

Points 3 and 4. Cooperation with other departments or other companies or contracted
partners is required for all other process steps. This means that work is always being
carried out to specifications. If there are several clients, several different specifications
must be adhered to for each order.
Examples of specifications
Approval lists for devices to be used
Schematic specifications with DT designations
Macro libraries
Design specifications
Automotive standard specifications
Wiring specifications
Specifications for addressing IOs
For engineering office/hardware planner users, the efficiency of the engineering can also
be mapped with the generally valid model from machine engineering.
7.5 Device Manufacturers/Smaller Machine Manufacturers
The number of schematic pages per project is between 20 and 100 pages for device
manufacturers/small machine manufacturers. In this study, the participating companies
had either 1 or 2 engineering employees.
The 8-phase design from traditional mechanical engineering may also be applied to this
segment of device manufacturers/smaller machine builders.
The classification is more in the range of mass-produced machines with 10 to 20 percent

special parts, depending on the degree of repetition.
To change from a traditional work method to a standardised work method, engineering

mostly uses the “maximum project technique” or “option technique”.
The most common form of documentation is the use of “maximum project technique”. A
typical 150 percent project with redundant circuits is transformed, through deletions, into a
commissioned project and manually adapted to the current requirements.
Example for typical savings (absolute values)
eLevel Time for Creating Documents Savings [%] Savings for 200
per Order [h] Orders per Year [h]
2 8 – –
3 4 40–50 % 800
7.6 Control Cabinet Manufacturers
Control cabinet manufacturers work on behalf of machine manufacturers and build the con-
trol cabinets based on delivered schematics. Only schematic or 2D overview drawings exist
for 90 percent of the orders. Such delivered schematics cannot be used for automatically
controlled manufacturing.
Digitally evaluable plans are delivered for just around 10 percent of orders; for example, NC
data for processing mounting plates and for door cut-outs can be extrapolated based on
these plans.
If the control cabinet manufacturer has automated production systems, a “post engineering”
or data optimisation takes place to utilise the NC manufacturing process or the routing.
The digital twin of the control cabinet is predominantly “rebuilt” in 3D by the control cabinet
manufacturer. The creation of wiring lists for wire assembly is based on Excel.
There is no logical correction of the schematics because the separate creation of the wiring
list is easier and faster to implement than the correct redrawing of the delivered schematics.
Generators and configurators are not being used.
It is the declared wish of control cabinet manufacturers with respect to the ordering parties
– the machine manufacturers – to receive more and more 100-percent digital models for
housings to be able to seamlessly transfer Engineering 4.0 information into the process flow
of Industry 4.0 manufacturing processes.
8 Efficiency Fields of Action

The time required per process step differs from company to company depending on the
product portfolio and proportion of mass-produced and special designs, as well as the
associated degree of repetition in the documentation.
Typical Time Requirements for Engineering Steps (1-8) in % assuming an eLevel of 2
The tasks partly overlap; there are also iteration loops in part. The time required per work
step can have a slightly different distribution in a specific case. The representation shows
an average value and provides a framework for orientation for the specific consideration of
one’s own time expenditures.
Essential criteria for potentially achievable efficiency levels stem from the share
of ETO and the methodology for creating schematics.
8.1 Partially Standardised Work Method (eLevel: 1 -> 2)
The key to increasing efficiency from “traditional” (eLevel1) to “partial standardisation”

(eLevel2) lies in the complete use of CAE systems for setting up device data. As of yet,
devices are mainly available only with commercial data such as descriptive texts and a few
technical parameters. This is not sufficient for entering into a device-oriented work method.
Procedure: Creating high-quality device data

Results: Device-oriented work method
Device-oriented means that the schematics can be created from the devices using drag
and drop. The graphic representation immediately fits and no reworking is required. The
device/component representations are the basic building blocks for later developing the
complete schematic templates.
Graphic schematics can also be very easily and quickly supplemented with device data.
Inconsistencies are immediately noticed when entering such data and can promptly be
corrected.
Schematics can be created 25 to 30 percent more quickly using device-oriented tech-

niques. The time required for initial set-up depends on the company and the number of
devices currently being used.
The study showed that companies have an average of an average of approximately 3,000
active devices. Since devices are used in series products and a repetition factor must also
be considered here, the time required to create device data is reduced by about 50 per-
cent. The means that only about 1,500 devices need to be processed in a device-oriented
manner.
Empirical values from the companies indicate time expenditures of up to six months to ob-
tain a professional, workable foundation of device data. Afterwards, the only time required
is for ongoing processing of newly added devices.
Efficiency
Schematics can be created up to 25 to 30 percent more quickly using device-oriented
techniques. Since the creation of schematics only makes up a portion of the entire engineer-
ing process, the entire process is shortened by at least 15 percent. The reports, assembly-
related manufacturing lists, can be created automatically in part. Time savings of 50 percent
can be achieved.
Fifty percent time savings can be achieved through the partial automation of the creation of
bills of materials (BOM).
8.2 Standardised Work Method (eLevel: 2 -> 3)
The key to increasing efficiency from “partially standardised” (eLevel2) to “standardised”

(eLevel3) lies in the complete use of CAE systems for setting up repeating partial circuits,
variants and options that can used as basic building blocks for schematics.
Procedure: 1. Product structuring
Methods for structuring machines and plants in product functions

Actuators, sensors, creation of variants and options
Modularising the infrastructure
Developing reusable functions (based on IEC 81346)
Considering manufacturing structures
2. Creating a library of circuit templates
Results: Structuring as the basis for creating design templates
A modular construction kit of design templates can be built based on product structuring.
This construction kit serves as the basis for creating schematics.
Projects are then composed of previously tested partial circuits. Product functions (ac-
tuators) can usually be copied together from partial circuits (depending on the degree of
complexity). Furthermore, manual additions can be made such as the dimensioning of the
control technology and infrastructure.
Efficiency
Schematics can be created about an additional 25 percent more quickly using design
templates. The entire engineering process (all 8 phases) is shortened by a further 15 per-
cent. The reports, assembly-related production lists, can be generated fully automatically,
meaning. 100 percent time savings can be achieved.
One hundred percent time savings can be achieved with the fully automated creation of
bills of materials (BOM).
8.3 Partially automated work methods (eLevel: 3 -> 4)
The key to increasing efficiency from “standardised” (eLevel3) to “partially automated”

(eLevel4) and on to “fully automated” (eLevel5) lies in changing the design methodology.
Document creation is now increasingly configured and generated automatically.
Procedure: Introduction of division of labour in order processing and standardisation.
If not yet introduced, the automation of the division of labour must be

implemented for the set-up. Selected, dedicated employees create
the templates.
Order processors use these templates to create the schematics.
Results: Maximum projects, option technique or generation configuration
A modular construction kit of design templates can be furnished with rules based on the
product structuring. The construction kit serves as the basis for putting together a solution
for the automatic creation of schematics.
In partial automation, the project is automatically assembled from previously tested partial
circuits. Furthermore, manual additions are made such as the dimensioning of the control
technology and infrastructure.
This automation of the final manual steps had not been completely implemented by any of
the examined companies.
Efficiency
Schematics can be created about an additional 25 percent more quickly using design
templates. The entire engineering process (all 8 phases) is shortened by a further 15
percent.
8.4 Automated Work Method (eLevel: 4 -> 5)
“Automated” (eLevel5) is understood as the consistent continuation of the activities in “par-

tially automated” (eLevel4).
The transition from the final manual steps to 100-percent automation depends largely on
the degree of reutilisation and the complexity and frequency of the tasks.
8.5 Summary
To what extent automation (in percent) enables an increase in efficiency essentially

depends on the variance of the engineering task, the share of ETO [%], the programming
expertise, the engineering department’s level of experience and the specific share of
special engineering.
Although efficiency cannot be calculated directly, it can be compared and estimated

using benchmarks.
Therefore, the study concludes that standardization of devices and design templates
(eLevel3) can save 50 percent of the time required to create schematics (Steps 4–7).
With subsequent partial automation (eLevel4), an additional 25 percent of the time for
creating schematics (Steps 4–7) can be saved.
The study further shows that the key to higher efficiency in engineering lies in the division
of labour into order processing and data generation for standardisation; the time required
to create schematics can thereby be halved.
This can be used as the basis for a subsequent, step-by-step automation of schematic
creation.
The prerequisite for partially to fully automated configuration is a doubling of the standar-
dization effort.
Because of this, in many cases the stage of partial automation results in the
best ratio between effort and benefit in business terms.
Market Trends Forecast 9
Complete, digital engineering documents such as schematics and 3D control cabinet

designs – known as digital twins – enable considerable optimisation in manufacturing. This
potential is very well illustrated in the document “Control Cabinet Manufacturing 4.0” from
the Institute for Control Engineering of Machine Tools and Manufacturing Units (ISW) at the
University of Stuttgart.
All the surveyed companies that rely on automation, configuration and generation of manu-
facturing documentation identified the following success factors for increasing efficiency:
1. The deliberate decision to divide labour into comprehensive standardisation and

order-related activities
2. Use of the many years of experience/services of the CAE software manufacturer
for properly redesigning processes
3. Development of a company’s own expertise in software development to assess
solution possibilities
4. Prioritised handling of the topic of standardisation in day-to-day business
5. Agile and rapid approach for quick initial successes
6. Integrated consideration of the effects for the entire process, no exclusive focus
on engineering as a cost centre
Furthermore, these engineering documents open up additional potential benefits along

the product life cycle, particularly in the areas of maintenance and repair during ongoing
operations.
Augmented Reality
Professional and complete electrical engineering documentation that is digitally available
offers considerable added value during machine operations for rapid troubleshooting and
minimising downtimes.
Assistance can be provided for complex tasks when additional information from the engi-
neering documentation is displayed. For instance, if a machine’s equipment is “labelled”
for maintenance technicians, they can navigate to the correct documents and receive the
appropriate servicing and/or working instructions.
Future Service Models

Data for the digital twin from engineering forms the foundation for building future business
fields such as predictive maintenance. This data can also be used to document any chang-
es made in the control technology during machine operation. The technology for worldwide
data availability from cloud-based systems exists. The first practical applications for data
access during machine and system operation is already available.
10 Appendix (Efficiency Table)

The effects of the different work methods on the reference schematics are shown
in the time savings that can be achieved in schematic creation.
eLevel Work Steps 4–7: Savings Work Steps 9, 10: Resulting total po-
of direct work on the sys- Efforts for standardi- tential for all Work
tem (schematic creation) sation, pro rata basis Steps 1–10
per order
1. “traditional” – – –
2. “partially 25 % 5% 20 %
standardised”
3. “standard- 50 % 10 % 40 %
ised”
4. “partially 75 % 15 % 60 %
automated”
5. “automated” 100 % 20 % 80 %
37
EPLAN Software & Service GmbH & Co. KG
An der alten Ziegelei 2 · D-40789 Monheim am Rhein · Germany
Phone: +49 2173 3964-0 · Fax: +49 2173 3964-25
info@eplan.de · www.eplan-efficient-engineering.com
PROZESSBERATUNG ENGINEERING-SOFTWARE IMPLEMENTIERUNG GLOBAL SUPPORT

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Engineering 4.

PROZESSBERATUNG ENGINEERING-SOFTWARE IMPLEMENTIERUNG GLOBAL SUPPORT

Study Design: Dr. Thomas Gartzen, Sebastian Schloesser, Michael Mendl-Heinisch

Study Realisation: Uwe Harder, Detlef Harms

Industry 4.0, standardisation, Control Cabinet Study 4.0, engineering,

This document contains proprietary information that is subject to copyright,

5 Efficiency in Engineering: Influencing Factors 19

9 Market Trends Forecast 35

10 Appendix (Efficiency Table) 36

Introduction to Engineering 4.0 1

The developed methodology for quantifying potentials and procedures in engineering

Typically achievable efficiency potentials were determined from eLevel 1 to 5, from

Efficiency cannot be calculated, however it can be compared and estimated using

Approximately doubling the efforts on standardisation is the prerequisite for partially to

“Efficiency in Electrical Engineering” study design

Engineering Workflow Model “Design & Construction” (Work Steps 1–8)

2. Clarify the basic conditions:

3. Design the functions and infrastructure:

6. Create bill of materials:

7. Create manufacturing documentation

8. Design control cabinet

10. Create macros and templates

3.2 Method Values

A schematic reference project was created to compare the customer analyses. It

3.3 Methodology Efficiency Level

3. Design functions and infrastructure: What is the approach for developing

4. Create schematics: How are schematics created?

6. Create bill of materials: How is the bill of materials created?

7. Create manufacturing documentation: How complete is the electrical

“Methodology Workflow” Efficiency Level (eLevel) Definition

eLevel Work Method Characteristics per Work Step

1 “traditional” Graphically oriented work method, symbols, manually created schematics,

2 “partially Device-oriented work method, use of product macros, creation of device

4 “partially Use of a comprehensive circuit library and of design methods including

1 (tradi- 2 3 (stan- 4 5 (auto-

1 Basics, same symbols/graphic X X X

2 Device databases, structure and 50 % 100 %

3 Creation of templates, macro tech- X X

4 Rules for preparing design manual, 50 % 50 % 50 - 100 %

5 Division of labour, processing and X X X

6 Product structuring for reutilisation, X X X

7 Consideration of working methodo- 50 % 100 % X

8 Consideration of data continuity, X X X

9 ERP/PDM integration, device data, X X

10 Automation in process, configuration X

3.4 Use Level Efficiency

uLevel Characteristics of function usage in the CAE software (excerpt)

1 “basic“ Graphically oriented work method, no overviews, no templates,

3 “advanced“ Graphically and device-oriented work method, macro projects, use of

4 “professional“ Use of mass data processing, import and export

5 “high Use of automatic functions, scripting, comprehensive customising in

Increasing the uLevel (“Use of Software Functions”) – achievable through training/coaching

3.5 Study Implementation

1 Plant design, plant technology, Engineering of continuous processes – predominantly

2 Machine engineering, mass- Engineering of discontinuous processes – predom-

3 Product manufacturers Manufacturing of near-series products, devices,

4 Building equipment Implementation planning in the area of “Building

Traditional Share of ETO per Industry

Target Group Degree of Repetition for Products – With or without in-

1.1 Machine Engineering <5% Both

1.2 Machine Engineering 5–30 % Both

1.3 Machine Engineering > 50 % Both

2 Device see Machine Engineering see Machine

3 Engineering Offices Per order Without