The smart factory Industry 4.0 elements for in-house ... · Approx. 2,300 moulds ... • Part optimisation using injection moulding simulation ... • Mould construction without drawings;

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Festo Polymer GmbH The smart factory Industry 4.0 elements for in-house production

Festo Polymer GmbH 2

Our Industry 4.0 productionApplying elements to in-house processespp y g p

Outline

• Introducing Festo Polymer GmbH

• Industry 4.0 aspects

• The smart processThe smart process

• The smart factory

• Outlook: The smart factory and sustainability

Festo Polymer GmbH - facts and figures

Founded in 2013 (previously under the umbrella of Festo AG und Co . KG)

New factory construction, 2013/2014

Transfer of operations, 1 January 2015

197 employees

77 injection moulding and rubber processing machines

Approx. 2,300 moulds

Highly automated mould construction


Energy efficiency principles during construction of new Festo Polymer GmbH factory

Energy efficiency as a key consideration for cost efficiency and sustainability

- Specific energy consumption

- Process energy consumption

- Factory energy consumption

Workshops on the topic of energy efficiency with ARBURG

Analyses of energy values at the old production location

Construction of the new factory using the resulting concepts

Energy efficiency approach during construction of new Festo Polymer GmbH factory

• No heat recovery from the injection moulding process!!!

• Flow temperature in cooling circuits, 25°C

• Machines with energy-saving drives (hydraulic/electric)

• Conversion of old machines to controllable drives

• Deactivation of the drives on the rubber processing machines during vulcanisationp g g

• Insulated plasticising cylinders

• Insulated moulds

• Block-type thermal power plant

• Energy-saving lighting system

• Ventilation and extraction with heat exchangers using the air stratification principle


ARBURG Energy Efficiency Award 2014 for Festo Polymer GmbH

Industry 4.0 aspects

First of all, processes must be optimised (lean manufacturing aspects, value flow l l l f t ti )analyses, level of automation)

Better knowledge of my components (machines, processes, moulds, materials)

Process data acquisition and monitoring during production

Exploitation of all the latest useful digital options for a good product

Integrate / control complete processes (from planning to delivery)

Preventive maintenance

Self-regulating processes (AQC)

Traceability

Labelling of individual parts as necessary and forwarding of process/product information

…..

Smart moulds; internal pressure/temperature sensors, temperature control sensors in the mould, flow temperature measurements, final forming forces, slide/final spindle forces


The smart process at Festo Polymer GmbH

• Part optimisation using injection moulding simulation

• Mould construction with follow-up simulation

• Mould construction without drawings; highly automated production cell for mould parts

• Use of mould cavity pressure sensors

• Prototyping with statistical test scheduling (DOE)

• Measurement via computer tomography / strip light projection

• Mould corrections / setting the final dimensions at the best possible operating point

• All information is available at some location









• All information is available at some location

Mould construction ->


Mould construction

Digital component in mould construction

Mould design comes from the CAD system

MES

CAM system

Job management software in automated production

Operating systems of the individual machines

Measurement software in the measurement machine

CAD viewer on the work bench

Reports to SAP

Data backup

Office software









• All information is available at some point

In addition:• In addition:

• Production planning and control

• Project management

• Host computer system

• QA information for production; SPC

• Material management

• SAP










• All information is available at some point

In addition:• In addition:

• Production planning and control

• Project management

• Host computer system

• QA information for production; SPC

• Material management

• SAPNow, just imagine if all of this could be achieved with a single system

The smart factory

• Everybody sees the specific information that is of relevance to them• Everybody sees the specific information that is of relevance to them

• Planning is comprehensive

• for mould store, production, quality assurance, material preparation and transport

• The technician is shown all the relevant information automatically

• The quality assurance department knows what capacities will be required and when

• Material supply and machine utilisation are transparent, end-to-end

• The finished part dispatch planning is always up to date

• …….


The smart factory

• Everybody sees the specific information that is of relevance to them• Everybody sees the specific information that is of relevance to them

• Planning is comprehensive

• for mould store, production, quality assurance, material preparation and transport

• The technician is shown all the relevant information automatically

• The quality assurance department knows what capacities will be required and when

• Material supply and machine utilisation are transparent, end-to-end

• The finished part dispatch planning is always up to date

• …….

But further enhancements are always possible......

• Big data analyses identify the machines with the lowest running costs

• Internet purchasing will grow, e.g. through platforms such as PlastBay

• The start-up factory model will become more widespread

The smart factory and sustainability

Continuous development and use of the opportunities that arise enable th f t t b t d hthe factory to be smart and to stay that way.The aim must be: to achieve added value at all times

Example: Energy; an important aspect!

The bottom line is the energy requirement of the factory as a whole

Minimising energy consumption often renders heat recovery redundant

Evaluating scrap as energy loss


The smart factory and sustainability

Continuous development and use of the opportunities that arise enable th f t t b t d hthe factory to be smart and to stay that way.The aim must be: to achieve added value at all times

Example: Energy; an important aspect!

The bottom line is the energy requirement of the factory as a whole

Minimising energy consumption often renders heat recovery redundant

Evaluating scrap as energy loss

Switch to machine technology

Sustainability of injection moulding machine technology (figures from 2011)


Sustainability of injection moulding machine technology(estimate of technological development from 2011)

Sustainability of injection moulding machine technologyServo drives are less expensive than expected in 2011Servo drives can be used in almost all machinesServo drives can be used in almost all machinesMachines with servo pumps are almost as efficient as fully electric machines.Machines with constant drives and variable pumps have all but disappeared from the market since 2015.

Assessment of technological development in 2016


Outlook: The smart factory and sustainability

Continuous development and use of the opportunities that arise enable th f t t b t d hthe factory to be smart and to stay that way.

Software systems must/will become more integrated; consistent use of digitisation … of data … all data

Interfaces should no longer be a problem

Big data analyses will be used for medium-term improvementsBig data analyses will be used for medium-term improvements

The bottom line is the energy requirement of the factory as a whole (logging)Minimising energy consumption often renders heat recovery redundantEvaluating scrap as energy loss

Tapping into the potential for using multi-purpose oils in injection moulding

Festo Polymer GmbH Injection moulding production

• ~ 1800 injection moulds• 57 injection moulding machines• Approx. 140 thermoplastic polymers


Festo Polymer GmbH Rubber parts manufacturing

• approx. 500 rubber moulds• 20 rubber processing machines• 40 different elastomers

Festo Polymer GmbH Mould construction with automated production cell

HSC cutter

Cleaning systemMeasuring machine

Robotic system

Electrode cutter

Die sinking 2

Die sinking 1


Thank you very much for your attention

Documents

The smart factory Industry 4.0 elements for in-house ... · Approx. 2,300 moulds ... • Part optimisation using injection moulding simulation ... • Mould construction without drawings;