…to zero defects production! · Container glass forming today Focus on zero defects delivery A...

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From zero defects delivery…

…to zero defects production!

� 1994 Introduction of industrial infrared applications in container glass industry

� 2000 Introduction of infrared camera system, IR-21

� 2007

� New generation infrared camera system, IR-D

� Consultancy approach

� 2010-2012 Introduction new hot end solutions:

� XMIS

� Gob Assist

� BTC

XPAR Vision history – mile stones

XPAR Vision characteristics

� Independent, privately owned

� Focused

� Customer

� Hot end inspection and forming process control

� Development and implementation

� Innovative and technology leader

� Decades of experience

XPAR Vision references

From zero defects delivery…

…to zero defects production!

Customers are demanding!

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Environment is pressing! Competition is tough!

Your focus should be:

� Faster

� Less energy

� Lighter & stronger

� More reproducible

Sustainable production!

What are you doing today?

Container glass forming today

� Focus on zero defects delivery

� A poor (forming) efficiency and effectiveness� PTM

� Weight / volume� Speed of production

� Resorting level

� Customer complaints

Process variation!

A poor (forming) efficiency and effectiveness…

� Prof. Dr.-Ing. H. Hessenkemper, Glas- und Emailtechnik (TU Bergakademie Freiberg)

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…resulting in a lot of waste!

� From the outside it looks ok, but……there is a structural imbalance between customer requirement and (forming) process capability / variation

Weight / volume: a mirror

Vertech-data (at random, 7 factories, > 1000 containers)

(Forming) process variation

� Gob shape, temperature, weight

� Gob length, diameter

� Gob speed, position, time of arrival, trajectory

� Temperature blank mould, plunger, neck ring

� Ware spacing

� Glass distribution

� Material change

� Swabbing

� Operator remedial actions

� Job change

� Other factors: day/night, IS machine configuration

Glass for a safer and greener life…

� In order to survive…

� …you should fight against the waste

� …you should strongly focus on improving your

forming process capability / variation

� …you should strongly focus on zero defects

production as necessary precondition for faster, less

energy, lighter & stronger and more reproducible

…requires a strong focus on… How?

� Measurement as precondition for control!

� Manual control

� Replacing opinions by facts is a big step towards

reducing forming process variation!

� Automatic control

� Optimization

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Measurement of what?

� Gob shape, temperature, weight

� Gob length, diameter

� Gob speed, position, time of arrival, trajectory

� Temperature blank mould, plunger, neck ring

� Ware spacing

� Glass distribution

� Material change

� Swabbing

� Operator remedial action

� Job change

� Others: day/night, IS machine configuration

Forming process control tools

XPAR Vision HE platform XPAR Vision HE platform

� IR measurement � glass distribution� The bottle is centre point of measurement

� The bottle is where process capability and customer requirements meet

� Individual parameter measurement� High accuracy measurement

� Individual parameter measurement only is not enough!

� Relate measurements� Central and open database

� One central HE U/I

XPAR Vision HE platform IR-D: InfraRed Dual

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IR-D: extension of your quality control system

� Process monitoring & supervision: visualizing process variation, on cavity/section/machine

� Increasing overall process capability

� Inspection: eleminating critical defects� Increasing overall inspection capability

Inspection

� Bird swing

� Fin

� Choked neck

� Freak

� Leaner

� Thin spot

� Thin bottom, neck, shoulder, body

� Wedged bottom

� Inclusion

� Shape, dent, bulged

� Stuck ware, fallen ware

Examples re: inspection

Shape, dent, bulged

Bird swing Leaner Thin bottom

Choked neck

Fin

Process monitoring & supervision

� Monitoring of

� Gob temperature variation

� Weight variation

� Composition (redox)

� Loading

� Section performance

� Ware handling

� Cooling

� Speed

� Condition / design

� Operator behavior (swabbing)

� Start up sections

� In terms of

� Statistics of rejected bottles

� Glass distribution

� Intensity variation

� Transport variation

� Signalizing trends, early warnings

Examples re: process monitoring and supervision

Ware handling

Swabbing: predictable but causing waste No influence swab and no waste

Gob Assist

Scoop

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Material change based upon facts

Defle

cto

r change

Relate measurements

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1. Loading not perfect

2. Loading

optimized

3. Re- adjusted to bad loading

Poor glass distribution

Controlled loading… …reduced swabbing!

Effect of stable and better positioned loading: reduced frequency of swab from 3 to 1 per hour

Operator remedial action most effective

Higher speed, less variation, less sections stops

Blank side Temperature Control

� ‘Continuous’ measurement of temperature of blank halfs, neck ring,

plunger, gob, parison

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Plunger temperature day / night Mould temperature: ∆ 40°C within one cycle

Gob Assist and BTC: high accuracy measurement

� Timing + Position

� Potentially dramatic improvements are within reach!

� Being satisfied with less would be very conservative!

Resulting in…

Reduced

variation!

Sustainable

production!

Perfect bottles!