HEINRICH GEORG GMBH Maschinenfabrik Kreuztal, Germany

Transcription

1 HEINRICH GEORG GMBH Maschinenfabrik Kreuztal, Germany SESSION 8 A - OPERATION EXCELLENCE II REDUCTION OF OPERATIONAL COST FOR ROLL SHOPS AND GRINDING MACHINES DIRK SCHMIDT HEAD OF ROLL MACHINING

2 OUR COMPANY founded in 1948 approx. 550 employees worldwide 4 subsidiaries % family owned

3 GEORG IN GERMANY & USA Plant I Plant II GEORG AUTOMATION CAPCO USA 3

4 OUR BUSINESS DIVISIONS transformer division machine tool division finishing line division 4

5 MACHINE TOOL DIVISIONS 5

6 INDUSTRY 4.0 STATUS 6

7 CONDITION MONITORING: POTENTIAL & BENEFITS 7

8 CONDITION MONITORING EXAMPLE: GEORG ULTRAGRIND Sources: 8

9 CONDITION MONITORING: ROLL GRINDER Vibration Sensor Flow Sensor Temperature Sensor Vibration Sensor Vibration Sensor Vibration Sensor Sources:

10 SIEMENS COMPONENTS FOR INDUSTRY 4.0 > Siemens Total Integrated Automation Portal (TIA Portal) for possible remote connection to: > Tablets > Smartphones > PC, etc. > For monitoring of all integrated components 10

11 ELECTRICAL EQUIPMENT & CONTROL SYSTEM > Siemens 840Dsl > Siemens standard Synamics motors > Siemens S7 PLC control > Spare parts and service from local markets > Spare parts supply independent from machine supplier > Industry 4.0 ready 11

12 GEORG MAINTENANCE SYSTEM GMS WHAT ARE THE DETAILS? Example: Condition Monitoring of roller bearings > Headstock main bearing monitoring 12

13 GEORG MAINTENANCE SYSTEM GMS WHAT CAN GMS OFFER ME? Condition Monitoring of roller bearings >Analysis of measuring data >Diagnosis Software from ifm electronic gmbh 13

14 GEORG MAINTENANCE SYSTEM GMS WHAT ARE THE BENEFITS? > Monitoring of: > Pressure > Filter Elements > Flow Control > Temperatur > Maintenance schedule > Roller Bearing conditions, etc. > Access to machine documentation 14

15 GEORG MAINTENANCE SYSTEM GMS WHAT ARE THE BENEFITS? STATUS DISPLAY OF: >HEADSTOCK >TAILSTOCK > GRINDING CARRIAGE >STEADY REST, ETC. 15

16 ROLL SHOP MANAGEMENT SYSTEM (RSMS) > Roll Shop (Level 3) > Automatic roll shop solutions > Condition monitoring solutions > Industry 4.0 ready Rolling Mill System ETHERNET SWITCH Level 3 Level 2 Printer Roll Shop Server Communication Computer ETHERNET SWITCH Operation Panel Operation Panel Operation Panel Remote Control MMI Grinder 1 Grinder..n Loader 1&2 16

17 RSMS EXAMPLE: KRAKATAU/ POSCO STEEL Roll Master Data Input (Example) 17

18 ROLL SHOP MANAGEMENT SYSTEM (RSMS) RFID Scanner >Features future possible solutions: >Scaning of: RFID Tags & Sensors in the roll neck RFID Tags & Sensors in the grinding wheels Comfortable data logging Increased working safety 18

19 ROLL SHOP Automatic Roll Loader with industry 4.0 capabilities 19

20 ROLL SHOP Automatic Roll Grinder & Roll Loader with industry 4.0 capabilities 20

21 ROLL SHOP REVAMPING Roll Grinding Machine after Revamping with industry 4.0 capabilities 21

22 YOU LL NEVER WORK ALONE GEORG connected service 22

23 REMOTE SERVICE GEORG connectedservice Communication kit for GEORG connectedservice consisting of: Tablet PC, with preconfigured software, for making photos or videos, initiating service requests or spare part inquiries Headset for easy communication with GEORG service WLAN Router at PC for connecting Tablet PC Service hotline 24h 23

24 REMOTE SERVICE GEORG connectedservice GEORG Central Server: Ticket system Service request in the GEORG Service Cockpit 24

25 REMOTE SERVICE GEORG connectedservice Online diagnosis via conference center 25

26 REMOTE SERVICE GEORG connectedservice Finishing of a service request Service request is reported in the machine file 26

27 MAINTENANCE GEORG connectedservice Current solution Integrated maintenance module gives overview of the machine s maintenance status and allows to organize maintenance work in time 27

28 SPARE PARTS GEORG connectedservice Creating a spare parts inquiry Transmitted spare parts inquiry 28

29 ROLL SHOP Summary: > Cost reduction for maintenance time > Cost reduction for spare parts due to SIEMENS standard parts > Less down time due to sudden machine break down > Online monitoring of machine conditions with early warnings of maintenance work > Management of service activities from outside with remote monitoring > Remote access by Tablet, Smartphone or PC > Better planning of spare parts inventory > Target: reduction of unscheduled machine stops of 60% to 70% 29

30 HIGH QUALITY MACHINE TOOLS MADE BY GEORG & GEORG CAPCO THANK YOU FOR YOUR ATTENTION. Dirk Schmidt Head of Roll Machining Phone: +49 (0) Heinrich Georg GmbH Maschinenfabrik Langenauer Straße Kreuztal Germany georg.com 30