The right formula for successfully expanding global market reach
KC Samyang Water Systems
Company realizes 20 percent faster design turnaround, 15 percent gain in employee productivity and 25 percent improvement in product reliability and quality
Korea’s first general water treatment facilities maker
KC Samyang Water Systems specializes in designing and manufacturing water supply and sewerage treatment equipment, industrial water and waste water treatment systems and sea water intake equipment. Established in 1968, the company is Korea’s first general water treatment equipment maker and the fifth largest water intake equipment provider in the world. Now with 50 employees, the company is operating sea water screening equipment in many domestic nuclear and thermal power plants, steel mills and liquefied natural gas (LNG) receiving terminals. KC Samyang Water Systems also has a strong export record, representing more than $10 million in revenue and more than 300 units of screening system equipment to desalination plants in the Middle East.
Through its continuous technical development, KC Samyang was awarded the Silver Tower Order of Industrial Services Merit from the Korean government. The award recognized KC Samyang’s important contribution to the development of domestic industries through 100 percent localization of water treatment technology, which had depended exclusively on foreign technology until the 1990s.
Requirements and challenges
KC Samyang’s business strategy promotes new product development, public use and re-use, knowledge management and improved production efficiency. But successfully employing this strategy had been increasingly restricted by its existing 2D computer-aided design (CAD) system, which couldn’t meet the company’s priority to continuously improve its design efficiency and overall process.
Management had been considering implementing a 3D system and realized that the right 3D technology was necessary to most effectively optimize design and data management, utilize visualization for structural interpretation, make design changes throughout the development cycle and facilitate product innovation.
Using its prior system, it used to take as long as two years for product delivery. The price of such an expansive development cycle was not only burdensome in terms of time, but also in terms of cost efficiency and maintaining a competitive edge.
The move from a 2D tool to a 3D CAD system just made good business sense, particularly for design optimization. The move to 3D would also eliminate the outsourcing work required for model testing because virtual testing could be performed within CAD. Finally, because design innovation was one of management’s highest priorities, taking a step further toward a higher-level design through 3D was critical.
Therefore, KC Samyang chose Solid Edge® software with synchronous technology to meet its strategic and operational objectives. “The key requirements for selecting a PLM (product lifecycle management) solution were its capacity to improve our product development process, its ability to enhance product innovation and its faculty to easily integrate with our ERP (enterprise resource planning) systems,” says Kuk Hyun Kim, project manager at KC Samyang Water Systems. “In our evaluation process, Siemens PLM Software’s technology helped us achieve our goals better than any other solution on the market.”
Focal point: innovation
KC Samyang is now utilizing Solid Edge with synchronous technology to design its equipment. After just nine months of use, management is giving Solid Edge very high marks for quality, ease-of-use, interference checking, and bill of materials (BOM) and weight calculations. Moreover, compatibility with AutoCAD® software made the transition much easier because 2D drawings can be used to initiate the 3D design process.
Learning Solid Edge was easy: “We conducted a series of customized Solid Edge training sessions for our designers,” notes Kim, “and this accelerated productivity significantly.” He adds, “Solid Edge with synchronous technology provides uncomplicated design methods tailored to the needs of the product development team. Solid Edge delivers a streamlined CAD design workflow that enhances the productivity of designers without additional training.”
Positive results are easily seen. For instance, KC Samyang is meeting its 2D-based clients’ requests by adapting their drawings for use in 3D. “Using Solid Edge has resulted in performance we can measure – a more than 15 percent improvement in product reliability and a more than 25 percent gain in overall product quality,” says Kim Guk Hyeon, general manager at KC Samyang Water Systems.
Visualization played an especially important role. Hyeon explains, “Due to the characteristics of our products, we can only effectively understand relationships in assembly structures. It was difficult to capture the overall appearance and operations of 2D designs. However, faults and errors are easy to locate and correct using the 3D capabilities of Solid Edge, especially in the context of the overall plant layout. Ultimately, we are now performing at what we consider peak levels relative to project turnaround time and have made innovation a focal point for continuing to expand our global reach.”
Product data management extends knowledge and value
As part of its strategic technology decision, KC Samyang also selected Teamcenter® software, preconfigured for rapid deployment and fast return on investment, in order to bring advanced structure to the management of design data. The company wanted to ensure that its engineers were always using the latest version of a design, and that such information could be explicitly leveraged throughout the product development lifecycle, especially in production.
KC Samyang conducted a brief test period for its new product data management (PDM) system. “We did so in order to get familiar with the new system and to realistically define our expectations,” says Hyeon. “This adaptation period was very useful not only in aligning the interests of the various departments involved, but also for opti-mizing the new change order process. The test period was brief, smooth and impactful. In very little time, we were 100 percent operational using Teamcenter to manage our customers’ requests for revisions.”
The company is now completing its implementation of Solid Edge with synchronous technology and Teamcenter. It is already showing a more that 20 percent increase in design turnaround, a more than 25 percent improvement in product quality and a more than 20 percent gain in customer satisfaction.
Management expects the figures to be even greater once all the Siemens PLM Software products are fully implemented after the completion of its trial stage with Femap™ software. Femap is an advanced engineering simulation software program that creates finite element analysis (FEA) models of complex engineering products and systems, and displays solution results to predict and improve product performance and reliability. Femap is especially advantageous for evaluating and optimizing different designs and reducing material usage. “Based on early trials, we anticipate outstanding gains as a result of using Femap,” says Hyeon, noting, “especially relative to structural interpretation and optimization of designs.”
Once the Siemens PLM Software lineup of Solid Edge, Teamcenter and Femap is fully deployed, KC Samyang expects a more than 50 percent improvement in work performance/productivity. But until then, KC Samyang is concentrating on delivering more innovative equipment solutions and improving its profit margins.
“KC Samyang plans to continuously evaluate its opportunities to employ appropriate technologies to fine-tune its world-class competitiveness,” says Hyeon. “We strongly believe our business development opportunities can be best leveraged through continuous improvement using Siemens’ products, which we consider to be the most advanced and comprehensive PLM tools available. We are confident we have the right formula for long-term penetration into new markets.”