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Associated Results
In this use-case the main data supplier is the FORD manufacturing facility. The other industrial partner provides the services around the life cycle of the product (machining equipment) deployed within the FORD facility. These services are only possible under the extensive data exchange process between industrial partners (assistance from ZDMP platform), so that the ETXE – equipment manufacturer/supplier, can assist in terms of maintaining the quality of equipment operation.
The main data supplier is the FORM industrial partner. After the data are gathered, they are sent and stored within the ZDMP platform deployed outside of FORM. The data are critical to feed ZDMP platform providing the quality control services. Additionally, data can be shared with FIDIA equipment manufacturer to assist with equipment-related quality problems.
This use-case targets not only the quality assessment process within the CONT plant, but also can be used by the supply partners delivering material and components for the CONT, as the reports/feedback can be also shared with them.
In this use-case, besides the services providing performance check and quality control, ZDMP platform also enables communication of the workstations and the database keeping the relevant data.
This use-case has the goal to optimize the quality check process within the CONT assembly line. Data that are not utilized by the previous quality check process are used by ZDMP platform services to complement the process.
The tools provided by ZDMP are integrated with the steel tube machines automating some critical quality check tasks, while improving the overall quality control process.
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Results:
The usage of ZDMP platform in conjunction with the X-Ray machine allows to automate the quality check process and to improve the inspection scope (as before only few items from each lot of materials/components are checked on compliance with specification due to time constraints). The new approach allows extending the number of inspected parts, only requiring operator involvement, when the deviations from specifications are detected.
All workstations are connected to the driver layer allowing equipment to communicate with server line layer. The data extracted from the equipment are stored, used by services and made ready for visualization.
ZDMP platform assists the internal quality check system. The quality check stations along the assembly line provide the images for optical quality control. These data along with quality test results are accumulated and analysed by ZDMP platform, and the feedback is generated.
The stages of production process are tightly interconnected. If ZDMP platform detects the wearing out of the cutting blades, the production process has to be stopped not to possibly waste the material. Or, if some natural defect of material is being detected, it can be still possible to use the material through adjustment of the moulds and avoid the defected part.
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Results:
ZDMP platform supports the industrial partners by collecting the process data from MRHS and FORD and providing reasoning to be able to detect and predict anomalies and provide some basic recommendation on improvement of the manufacturing process on the MRHS side. Both companies make use from this service, as they are long-term value-chain partners and interested in the costs and scrap output reduction resulting in the improved manufacturing process.
ZDMP platform intends to provide a secure and confident environment, where the industrial partners can exchange their data. The cylinder block manufacturer (FORD) provides the process data to the equipment supplier ETXE, the last, in its turn, provides recommendations on optimization of the production process (e.g. adjustment of parameters, etc.). Moreover, ZDMP platform aims at performing some reasoning actions to simplify the data exchange between the industrial partners.
ZDMP platform quality control services allows for FORM to timely react on the deviations within the manufacturing process. Depending on the data acquisition frequency and number of machine components the data size can reach up to 10MB per production hour. The recommendations generated by ZDMP platform can be utilized for actions planning towards quality improvement.
The reports or feedback generated as result of the quality inspection is shared with material/component suppliers. Based on these reports further actions towards quality improvement can be undertaken.
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Results:
The material suppliers provide the product quality data, as well as data about material types and amount to be delivered. Thus, it is possible for construction to react in agile way and reschedule in the case of unexpected accidents.
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Results:
ZDMP platform, acquiring data from FORM, provides predictive services related to, for instance, equipment degradation dynamics (especially moving parts of the machine) to be able to timely react and replace or fix the corresponding part.
It is important, not only for the construction company, but also for the material suppliers to track the amount of shipped materials and quality, and, if needed, coordinate and adjust activities.
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For the quality assessment and prediction service is crucial to aggregate the data from both the Martinrea Honsel (MRHS) and FORD industrial partners. The quality forecasting or prediction allows optimising and adjusting the production process to achieve better quality of the product – aluminium cylinder blocks, which is not possible or less accurate without digitalized data exchange between industrial partners.