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Pilot - SIEMENS SIMATIC Products Quality Improvements

Project: QU4LITY

Updated at: 01-02-2024

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Pathways
Autonomous Smart Factories Pathway
Comment:

The production line in Amberg has a highly automated process with several test stations along the path.

Off-line optimisation
Comment:

The Amberg production line collects all the process and test data an a quality management system data base. This allows reporting and production KPI analysis as well as supply chain management.

Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

Analysing the test results the production process can be adapted and optimized.

Pilot - GHI Real-time cognitive hot stamping furnace 4.0

Project: QU4LITY

Updated at: 01-02-2024

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Pathways
Autonomous Smart Factories Pathway
Comment:

Within Qu4lity use case, GHI with the collaboration of Innovalia and SQS, is building a ZDM scenario based on the development of a smart and connected hot stamping process with the ability to correlate the furnace operation parameters with the quality control of the stamped parts, extending in this way the product lifecycle control loop, making the operator more involved in the process thanks to the new platform developed.

Off-line optimisation
Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

The Beyond Platform also gathers data from other assets, not only from the furnace, so they can potentially optimised as well. On the other hand, there are aspects regarding the industrial furnace that mainly affects to the whole factory level, as for example, a reduction on the energy consumption or a reduction on the defective manufacturing that can be achieved thanks to the data analysis provided through this tools.

Pilot - FAGOR Zero-Defects Manufacturing Digital Press Machine

Project: QU4LITY

Updated at: 01-02-2024

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Pathways
Autonomous Smart Factories Pathway
Comment:

FAGOR ARRASATE as a leading manufacturer of forming machines it is obliged to proactive participate in projects like QU4LITY and led solutions to the customers to improve the availability, performance and quality of their installations and get an optimum cost per part ratio.

FAGOR ARRASATE has a long experience in delivering press machines as well as providing the building blocks of such lines. A press machine is the product par excellence of FAGOR ARRASATE. A typical press machine is composed by two rigid platforms (head and base), a bed, a ram, and a mechanism as well as all the other surrounding components that guarantee the full automation and process control.

Historically, machine tool manufacturers have not had any information of the machine behaviour once they were working at the customer facilities. Maintenance actions by the machine tool supplier, where mainly started by a customer’s call and where mainly related to corrective actions, once the failure had already happened.

Currently many condition issues on the machine are detected afterwards, they appear when a quality matter is detected on the forming parts or a machine component is damaged, causing even machine stoppage.  These problems are fixed by machine adjustment or changing programs or forming process parameters.

Consequently, the only way to avoid future problems is by preventive maintenance or machine adjustment actions. These are carried out either by the machine owner itself or external services which are sometimes delivered by FAGOR ARRASATE.

In QUALITY project, FAGOR ARRASATE will equip a press machine with a SMART CONNECT technology that provides data from the machine, to the owner and to the machine supplier. Within the context of Zero-Defect Manufacturing, FAGOR ARRASATE will develops Smart solutions that will anticipate and avoid failures, reduce downtimes and assure quality.

It has a great complexity from the point of view of the acquisition, measurement and transmission of the parameters and variables. The result that would be obtained from the QU4LITY project, would allow the customers of FAGOR ARRASATE to have total control of a zero defects manufacturing process at machine level and to know at any time how and under which conditions all the parts have been manufactured.

Off-line optimisation
Comment:

FAGOR FA-Link MAP (Fagor Arrasate Link MAchine Platform) is a platform developed by FAGOR ARRASATE in collaboration with IKERLAN. This platform uses cutting edge technologies for big data processing and visualization.  This platform inputs the data from the press machine using the FAGOR (Data-Adquisition System) and provides to the different stakeholders an UI with a set of views to monitor and analyze the press machine performance. The UI is customizable by the end user and the data to be shown is manually configured as different views and alarms in FA-LINK visualization UI.

FAGOR’s monitoring platform, FA-Link machine platform, is being extended with tools focused on ZDM in this pilot and in the related packages of QU4LITY.

FA-Link is composed by two systems, the former that is executed in the manufacturing plant (on premise) and the latter that is executed in the cloud. The data captured in plant via on premise (local view), is uploaded and aggregated in the cloud part (global view).

Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

 

FAGOR’s monitoring platform, FA-Link machine platform, is being extended with tools focused on ZDM in this pilot and in the related packages of QU4LITY.

FA-Link is composed by two systems, the former that is executed in the manufacturing plant (on premise) and the latter that is executed in the cloud. The data captured in plant via on premise (local view), is uploaded and aggregated in the cloud part (global view).

Electronic products manufacturing: Component inspection

Project: ZDMP

Updated at: 21-05-2021

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Pathways
Autonomous Smart Factories Pathway
Off-line optimisation
Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

The quality control is important stage of every production process, as a defected part can significantly affect the product functionality. To be able to find possible defects at the earliest possible stage and minimizing the effect on the whole production process at the factory scale the X-Ray inspection machine in conjunction with ZDMP platform are utilized.

Assembly line: monitoring and control system

Project: ZDMP

Updated at: 21-05-2021

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Pathways
Autonomous Smart Factories Pathway
Off-line optimisation
Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

The ZDMP platform targets more the assembly line layer, than separate workstations. The idea is to aggregate the information coming from the workstations along the assembly line and provide the quality control and performance services.

Assembly line: AI-supported optical defects detection

Project: ZDMP

Updated at: 21-05-2021

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Pathways
Autonomous Smart Factories Pathway
Off-line optimisation
Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

In the case of the negative automatic test, operator performs the manual check of the product comparing it with the reference images. The operator decisions with corresponding images are collected and stored to learn or extract the defects types and acceptance limits.

Stone tiles: equipment wear detection

Project: ZDMP

Updated at: 20-05-2021

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Pathways
Autonomous Smart Factories Pathway
Off-line optimisation
Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

Reduction of the scrap output of the production process, as well as automation of control check operations has significant impact on the quality of the products and leads to a more efficient use of resources.

Construction supply chain: quality control at construction site and quality traceability

Project: ZDMP

Updated at: 20-05-2021

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Pathways
Autonomous Smart Factories Pathway
Off-line optimisation
Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

Coordination of the activities within the construction plays a crucial role. Delays in materials shipping and materials quality issues may significantly affect the construction process. However, not all delays have the same impact. ZDMP platform provides the necessary assistance for delays’ impact assessment and enables agile information exchange among involved partners.

Steel tubes: production monitor

Project: ZDMP

Updated at: 20-05-2021

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Pathways
Autonomous Smart Factories Pathway
Off-line optimisation
Off-line Digital Manufacturing Process Optimisation on factory level
Comment:

The assistance in quality control that is offered by ZDMP platform through the timely warning allows reduction of the amount of waste and increase in the number of quality products per meter of steel sheet.

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