Industry 4.0 The complete integration

Transcription

1 Industry 4.0 The complete integration In partnership with:

2 Industry 4.0 overview The Italian plan - Hyper-amortization The first time Industry 4.0 has been used was in 2011 Hannover Messe. This term refers to the forth industrial revolution which aims to increase the factories productivity, to involve new business models and more customized services. The production process will be more harmonized and interconnected, controlled by intelligent machines able to collaborate with humans, while the Big Data analysis will radicalize the corporate strategies. However, these concepts are pure abstractions and managers have a lot of difficulties in focusing and implementing the scenarios regarding industry 4.0 concepts; despite this they know how are and what are the benefits from this revolution: Flexibility Speed Productivity Quality Competitiveness Prdouction of small lots with the costs of the large scale.. From prototype to serial through innovative technologies. Minimal set-up times, errors and machine shutdowns reduction Sensors for real-time production monitoring and less waste. More functionality and interconnections. The government is focusing on the industrial politics. The Industria 4.0 plan, which take place between 2017 and 2020, will include a series of actions to increase investments in innovation and productivity. Between these we have the incentive to private investments, tax credit for research, infrastructures for ultra wide band, an enlargement of the guarantee fund and the hyper-amortization for the material goods bought in the Smart Factory contexts. The hyper-amortization This is the goods over evaluation for the amortization: 250% for material goods and 140% for software; these goods will have to respect the standards defined by the Piano Industria 4.0 and described inside the attached A to the law 232/2016. To benefit of the hyper-amortization, the company vshall declare from his CEO about the compliancy of the technical requirements of the machines. To support this declaration is possible (mandatory for investments larger than ,00 ) to include technical expertise report to confirm the compliance of the machine to the Industria 4.0 standards. 2 It will have access to the incentive during the drafting of the budget for the goods bought in 2017, or for the ones which have received a 20% advance payment during 2017 and will be delivered before 30 June 2018.

3 To have access to the hyper-amortization the machine shall be inserted in an industry 4.0 context. This aspect is underlined by the second and the third of the mandatory and the second of the optional requirements of the attached A defined inside the law 232, 11 December 2016: 2. Interconnection with the informatics systems of the factory with remote upload of instruction and/or part program; 3. Automatic integration with the logistic system of the factory or with the supply chain and/or other machines of the production cycle; Working condition and process parameters continuous monitoring trough opportune sensors set and process drifts;...the LEAN MANUFACTURING concept MONITORING ORDER UPLOAD DATA MANAGEMENT MONITORING ORDER UPLOAD DATA MANAGEMENT KPI 3

4 TEMI Plast 4.0 Your production management system TEMI Plast 4.0 is a system created for the plastic molding companies, to manage and monitor the production process in an automatic, simple and efficient way. TEMI helps the monitoring process from the order upload, through the definition of the process data for each production lot and ending with the printing of a label or QR-code showing the macro characteristics recorded inside the production server database. Thanks to the web-browser architecture and the TCP/IP communication protocol is possible to visualize the TEMI interface on a variety of devices; this guarantee wide flexibility and versatility. The secure storage system make the company compliant with the most restrictive quality standards ensuring efficient product traceability. The simple use and the soft impact on the factory resources minimize the change in the working habits, without sacrificing the benefits from interconnectivity following the industria 4.0 logics and the lean manufacturing approach. INJECTION MOLDING MACHINE WITH WITTMAN-BATTENFELD INDUSTRIA 4.0 PACKAGE EUROMAP OPC-UA DATABASE MY-SQL AND SERVER SQL TCP/IP PROTOCOL CONNECTION 4

5 Pezzi: di % 75% Pezzi: di %! ICE Flex 2017 PRODUCTION PLANNING MONITORING Ethernet with TCP/IP protocol MICRO PC TEMI WB 35/110 Articolo: Alfa WB 60/110 Articolo: Beta STATO MACCHINE PRODUCTION TEMI Plast 4.0 has been developed with a flexible architecture for integrating different devices possibly already present in the factory and for reaching all the injection molding machines inside the productive departments. A powerful microcomputer controls the TEMI software through the customer Ethernet LAN with the TCP/IP communication protocol. The data storage system has been engineered with HDD and SDD technology to increase the stability of the OS and the data safety, while the access to the software pages is possible using a web-browser compatible with the larger part of the network devices. 5

6 TEMI: the software Easy, immediate and intuitive : Maflex JOBS TO BE ASSIGNED: Item pezzi Order A del 11/05/2017 Duration: 22h - 15m Item pezzi Order B del 11/05/2017 Duration: 13h - 03m Item pezzi Order C del 11/05/2017 Duration: 07h - 17m Item pezzi Order D del 11/05/2017 Duration: 01gg - 03h - 12m Setup Injection molding Over-prdouction Add Assign Add Assign Add Assign Add Assign PLANNER PLANNING OF THE JOBS: Machine 1 Active Machine 2 Stand-by Machine 3 Active Machine 4 Error Day Week Month Up to:! Espandi Item: Z Order: gamma Parts: Item: X Order: alfa Parts: Item: Y Order: beta Parts: Increase Change Increase Change Increase Change mar 09 mer 10 THE PLANNING Planning is a crucial moment in the production cycle and consists of two steps: Order loading Activity planning Using configurable product cards, optionally importable from existing management system, it is possible to create a job to be allocated to machines. Planning relies on a simple and intuitive Gantt chart: the production manager, knowing the machines operative status, organizes new orders easily while interested departments are effectively notified. ICE Flex 2017 Jobs waiting to be assigned Production Gantt MACHINE MONITOR Each machine is given a useful and meaningful page. It consists of a real-time view of order progress and planning data accompanied with process data: cushion constancy, dosing times, injection times, alarm history and other useful data are automatically retrieved and aggregated to lot information. This screen also enables printing of an adhesive label (or QR code) whose allow to retrieve product details like article code and description, number of produced parts, lot number and product code. Tracing production code in TEMI database provides even more info on the product. : Maflex JOBS PLANNER Item: X Order: alfa Total parts: Parts produced: Now 75% Setup Injection molding Over-production INJECTION MOLDING MAC MONITOR mon 08 Day Week Month Up to: MACHINE STATUS Increase Change Over-production: parts tue 09 wed 10 WB - 110/350 (n 1) vprint started at 03:10:34 Program Log 2300 Press type set: overlod 365 LogT1 245 LogT2 200 LogT3 220 LogT4 204 Quality table: ON Remote contrlo: ON Service status NEUTRAL logging to D://user/controlmaflex/DBpress/WB-110/350n1.filelog... ICE Flex 2017 Data from the machine 6

7 MACHINES STATUS % 50% 90% WB 35/110 WB 60/110 WB 60/210 Item: Alfa Item: Beta Error code an. injec Parts: di Parts: di % 75% WB 90/350 EN 50 EN 80 Articolo: Gamma Stand-by Item: Sigma Pezzi: di Parts: di ! MACHINES STATUS This screen shows the real-time process data. Machine status is color coded and a progress bar reports lot completion percentage. A simple and intuitive view is provided to show the global process advancement and to access with a single touch to each machine specific production details. AR 250 Stand-by ICE Flex 2017 Intuitive display of the machines PRODUCTION KPIs Key Performance Indicators (KPI) represent process markers useful to monitor, understand and improve the efficiency of a production plant. Merging process and quality data that TEMI retrieved from the machines gives meaningful insight on the system. Average press setup time, alarms quantity and recurrence, injection times constancy and repeatability are just some of the obtainable performance critical indicators. The production manager may take advantage of these information to improve product quality, enhance moulding efficiency and calibrate the workload h Life hours 0 Last hour alarms 97% Percentage of compliance products 1,5 h Average setup time 75% Machine performance 100% Last cicles steadiness 34h Monthly standby hours 114 Item codes printed 7

8 Optional packages An expandable system ICE Flex completes the system offer with the possibility to integrate solutions aimed to best reach the inter-connection requirements: the package TOUCH, the PRINTtoPRESS and other interesting solutions. Beyond that we give the possibility to implement the system following the customer needs thanks to development time packages with our engineers and programmers. TOUCH package provides a wide wall touch display together with a micropc for networking (WI-FI or Ethernet). This allows operators to monitor production, alarms and machine status keeping up to date on new orders planning. machine touch screen with production and planning details PRINTtoPRESS package consists of a compact capacitive touchscreen with micropc for networking to be installed on the machine: that is an open window on TEMI world to manage directly the molding machine, starting and stopping tasks. The package also provides a label printer for text and barcodes/qr. The printer is controlled by TEMI system and enhances quick product lot traceability through identification of molded parts. Label and QR-code printer for the full traceability thanks to the software TEMI 4.0 8

9 PESA PESA package enhances printable information details allowing for the exact count of parts inside boxes. Also estimates of rejected parts count, consumed raw material and performance indexes are more accurate. Magazzino MAGAZZINO package implements raw materials load/unload logic for an extensive control of the process. An alert system readily notifies the purchase department with supply depletion forecast. 9

10 WITTMANN BATTENFELD GmbH Wiener Neustädter Strasse Kottingbrunn Austria Tel.: Fax: ICE Flex S.r.l. Via Bergamo, Saronno VA Tel.: Fax: info@ice-flex.com TEMI Plast Article number: (italian) 2017/06 Printed in Italy