CPT International 02/2019

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ENGINEERING OF FOUNDRY PLANTS Figure 2: The simulation model of a production plant. the processes within it, must be expanded and adapted to achieve the goal of an efficient factory. In this regard, it is also vital to constantly keep up with all the new and relevant developments and, if necessary, implement them. The following tendencies can be seen in individual corporate processes: Sales The age of digitalization opens up new possibilities for sales because the focus is on individual customer requirements. Central data management plays a major role in core tasks – such as the registration of enquiries, costing, and the preparation of offers – by centrally and digitally administrating all the important customer and product data, and enabling consistency of the information. It is therefore possible to offer customers tailor-made solutions whose details are adapted to their specific needs. The use of product lifecycle management systems also provides further advantages. Material procurement and storage The monitoring of warehouse capacities and stocks, as well as the associated material planning and procurement, can change fundamentally and also affects supplier management. Material lists can, for example, be generated using existing 3-D models of the components and variants. An intelligent and automated stock monitoring and ordering system shortens delivery times and procurement processes. Fully automated storage systems and automated guided vehicles are increasingly being used, saving space and time – and thus costs. Production Digitalization enables the automation of many production processes, the comprehensive tracing of products, and the allocation of certain post-processing steps. More and more processes will in future be monitored and evaluated via sensor or radio-frequency identification (RFID). Errors and defects can be more rapidly detected and corrected by means of monitoring during production, with the aim of minimizing production problems and downtimes. Interdisciplinary processes In addition to the core processes of molding, melting, casting and machining, there are interdisciplinary processes that are positively influenced by digitalization. These include, for example, pattern construction and storage, an area that is subject to high customer requirements. Storage and transport can be supported by automated logistics and intelligent component tracing in order to increase process transparency. The state-oriented maintenance (condition monitoring) of plant technology is also being used increasingly in foundries. It is very important to be able to predict a breakdown before it happens – damaging the plant technology and causing long downtimes – particularly with automated processes and interlinked plants. Work preparation Pattern designs are created during work preparation, followed by material requirements planning and, on this basis, process planning including machine utilization. The use of new technologies such as planning in 3-D, simulation tools (Figure 2) and virtual reality allows process and value stream analyses to be carried out before initial operation. This enables an examination of work stations and their safety, as well as comprehensive planning and documentation, to be carried out before implementation. Figure 3: A three-phase model is used in factory planning. 22
Potential solutions in foundry planning Different demands are made along the value creation chain at all the above-mentioned areas. When these are implemented, a linear unstructured production flow can be transformed into a circular networked production site. This makes new demands of factory and production planning, to which factory planners such as Hörmann Rawema Engineering & Consulting GmbH react by using a variety of tools and methods (Figure 3). 3D laser scanning, material flow simulation and virtual commissioning are used here, for example. As a result, a variety of planning variants can be examined in a short time, significantly increasing planning security. For customers this means a considerably lower level of risk in implementation, and the prevention of potential follow-up costs. In addition, the visualization and dynamic representation of processes increase the comprehensibility and transparency of the planning solution. The methodical, structured and holistic approach towards planning is intended to ensure the provision of solutions that are as sustainable and efficient as possible, and that meet the aspirations of future factories in the context of global competition. Void in casting, after machining, seen with a Hawkeye Pro Hardy 7” Inspection Solutions... 80 different borescopes, and 20 years experience helping you select just the right one! Sand visible with a Hawkeye Pro Slim 12” Rigid Borescope Flash as seen with a Hawkeye V2 Video Borescope High-quality rigid, flexible and video borescopes, at far lower prices than comparable instruments! The factory planner for manufacturing industries Hörmann Rawema Engineering & Consulting GmbH is a member of the Hörmann Group. As innovative producer-neutral factory planners, 50 engineers and technicians concentrate on providing specialist technical planning in industry, focusing on production technologies and logistics. Hörmann Rawema Engineering & Consulting supports customers from the most varied of sectors (such as forming, casting and recycling technology; the automotive sector; mechanical engineering or logistics), offering consulting, planning, process optimization and project management. www.hoermann-rawema.de www.der-fabrikplaner.de Robin Freitag, Project Manager, Axel Edlich, Manager, Forming and Cast ing Technology Competence Centre, Frances Barchmann, Project Engineer, Hörmann Rawema Engineering & Consulting GmbH, Chemnitz We stock over 80 models of rigid, flexible and video borescopes, and accessories. Hawkeyes deliver detailed images of sand, voids, flash, surface-finish irregularities, and numerous other defects that can affect the quality of a wide range of mission-critical castings. gradientlens.com 800.536.0790 Made in USA
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CPT International 02/2019

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