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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
Festo Polymer GmbH 3
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
Festo Polymer GmbH 4
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
Festo Polymer GmbH 5
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
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
Mould construction ->
Festo Polymer GmbH 6
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
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 point
In addition:• In addition:
• Production planning and control
• Project management
• Host computer system
• QA information for production; SPC
• Material management
• SAP
Festo Polymer GmbH 7
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 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
• …….
Festo Polymer GmbH 8
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
Festo Polymer GmbH 9
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)
Festo Polymer GmbH 10
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
Festo Polymer GmbH 11
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 12
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