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Digital Transformation in
Metal-Casting
AFI Conference 2018
Sea World Resort, Gold Coast, Australia
Christian Kleeberg 16/10/2018 1
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16.10.2018 www.rgu.de 2
Walk down memory lane….
The future Ahead -
”Foundry 4.0” &
Digital Foundry !
The Big Vision in the Digital Transformation of
Metal-Casting Operations
Man – Machine - Material
on unique standardized software platforms
from inquiery to dispatch
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16/10/2018 RGU OPTI - Cast in Software 4
The RGU – “Made in Germany”
• RGU GmbH Founded in 1984 by German foundry experts with profound IT-knowledge
• 85 specialized employees with sole focus on the foundry / HT and special process industry
• 320+ RGU.FRP® installations and foundry projects across the world
• RGU ASIA Pte. Ltd. in Singapore, foundry solutions APAC HQ.
• Distinguished partners in India / ASEAN / ANZ / ZA
• RGU.FRP® Partner – India ➔
Auto-Design-Online with rich foundry experience and strong consultancy partner know-how
Germany – India – Singapore
Serving the APAC foundries
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The RGU – “Made in Germany”
• Distinguished partners in
India / ASEAN / ANZ / ZA
• RGU.FRP® Partner – ANZ
ASQUARED Engineering
Anthony Ashworth & Team
Adelaide, SA
Mobile: 0409 202 909 Germany – India – Singapore
Serving the APAC foundries
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6
References
Since July 2017, 10
customers in 1 year+ in APAC
InhaltsverzeichnisDigital Transformation
IT
Automation
Excel
General
Software
Applications
Digital Transformation
Digital Disruption
Digital Adaption at workplace
Digital Learning & Working
FRP® • Digital Transformation• Foundry 4.0 • Your Organization
RGU.FRP®
FOUNDRY
RESOURCE
PLANNING
SOLUTION
ONE S/W BASED DIGITAL PLATFORM
TECHNOLOGY FOR FOUNDRY ONLY
FRP® • Digital Transformation• Foundry 4.0 • Your Organization
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The Term “FRP“ = Foundry Resource Planning
What Foundry needs v/s. “old school”
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Work flow of general Mechanical engineering
In General mechanical manufacturing process workflow is:
➢ linear, follow a continuous process chain
➢ general “ERP” solutions are suitable for such value stream
CUSTOMER SUPPLIER
PRODUCTION ORDER
Raw Part ➔ Machining Operation➔Finished Part ➔ Assembly ➔ Transport
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Work flow of Foundry
In foundries processes are:
➢ non-linear, have discontinuous process chains
➢ Only demands for FRP® solutions possible!
It’s about co-ordination
of
man – machine – material
and
all resources available
in
the entire process chain.
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12
Why “FRP®’’ – Not just ERP?
Sales/Accounting
Tool Management
Product Planning
PPC
WIP
Quality Management
Purchase / Materials
Inventory - Logistics
FRP®
SAP Integration (optional)
Foundry specific
ERP
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Work flow for FRP®
Sales - Offer
Resource Planning
Cost Calculation
Tool – Pattern Management
Order Booking
Production Scheduling
WIP – Work In Progress
Foundry Info system
Quality Tests
Shipping Order
Invoices
Quality Certificates
Company
Processes
FeedbackStations
from Shop Floor
Overviewat any time
Systematic Foundry
Quality at work and
at Business
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Example for “a foundry“
Raw Material
Charge Prep. Melting
Pattern makinginternally or via ESP
Molding linemanual orautomatic
Coating
Assembly, mold + core
Drag + Cope
Pouring
Cooling time
Shake out
Raw cleaning
Cleaning (shotblasting etc.)
HeatTreatment
Finishing(painting etc.)
Storage cores ifrequired
PackagingDispatchTarget =ship through
Furnace + Ladle
1
2
Production Schedule:
Melt Shop
Mold Shop
Core Shop &
Preparation
Fettling & Grinding +
add-on processes
1
2
Machining
Core delivery
Core supply
Core making
Rawpart
Scrap + Recyclematerial
3
4
4
3
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Continuous and Discontinuous Processes combined
Melting and
treatment
Melt
preparation
Sand conditioning
Core
Making
Molding
Patterns /
Storage
Machining
Fettling
HT
QC
others
Pourin
g
FRP-
System
Sales
Orders
Plan,
Control
Sand conditioning
Dedicated Feedback Stations
Dedicated Feedback Stations
Dedicated Feedback Stations
Dedicated Feedback Stations
Dedicated Feedback Stations
Automatic Resource Planning & Scheduling
Digitization / Digitalization
= Digital Transformation
in
FOUNDRY
The Big Vision and steps to be taken
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• Key areas of Industry 4.0 in Foundry
“Foundry / Metal Casting 4.0”
▪ DIGITIZATION / DIGITALIZATION(commonly known as “digital transformation”)
▪ INTEGRATION
▪ AUTOMATION
16.10.2018 www.rgu.de 18
CONTENT
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➢WHY ?
• Traceability, Transparency, Productivity and Efficency increase on all levels
• Easy to adapt to fast changing world and products / services needed (The product becomes secondary)
• Raising profits when margins are reduced ➔ Trend!
• Stay competetive with less waste
• Eliminate inefficiencies
Digitization / Digitalization of Metal Casting – Processes
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• The first industrial revolution mobilisedthe mechanization of production using water and steam power. (James Watt, weaving machines) (~1800-1850)
• The second industrial revolution then introduced mass production with the help of electric power (Henry Ford, conveyor belt) (~1880-1930), followed by the
• The third industrial (digital) revolution and the use of electronics and IT to further automate production (invention of mainframes and later personal computers) (~1970-2002)
2015-11-18 20
Where do we come from?
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Foundry Process Planning
www.rgu.de
Are you ready for the 4th
industrial revolution?
• Hollistic IT-deployment in
production engineering
• Establishing cyberphysical
systems
• IIoT – Indutrial Internet of
Things to support the same
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• New and unchartered territory for every
foundry ➔ Innovation
• No standards or standard solutions. No blue-
print! ➔ Innovation
• Different process / organizations and set-ups
require multiple flexible approaches (e.g.
sand casting vs. die-casting) ➔ Innovation
• No values of experience are available (e.g.
Proven track record of a known technology)
➔ Innovation
WHY is „Foundry 4.0“ so difficult to achieve??
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• It‘s NEW , no matter what you do ➔ Innovation
• Every IR had same of similar issues to deal with
• IR - Disruption leads to (R)Evolutions leads to
innovation (in manufacturing)
▪ Example from IR 1 (about 200+ years ago)
Imagine you sell weaving machines begining 1800
– you have many good arguments in favour (of
expensive machinery) but since it was
revolutionary there was no experience – so you
had to transfer arguments from „new“ world to
„old“ world to succeed.
WHY is „Foundry 4.0“ so difficult to achieve??
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• WHY is casting such a special process?• A „product is created from a liquid“ & moves through production and informs
all Production Resources „Labour“ and „Machines“ and „Material“ what they
have to do.
• While doing this all relevant DATA Concerning Technical Values and
Comercial Values are collected and tracked back to the product ➔ LIVE
product DATA management
The AIM of „Foundry 4.0“ in Die Casting (Example)
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• The 4th industrial revolution
▪ Hollistic IT-deployment in production
engineering
▪ Establishing cyber-physical systems
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What is Foundry 4.0?
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Example in a Foundry:
• Biometric recognition of castings
through „augmented reality“
• Semi-intelligent machine interaction
with sensor/actor functionality
• Control of processes with the help of
„digital identifiers“ like RFID, Data-
Matrix / QR Codes or Barcodes
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What is Foundry 4.0?
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Requirement for a Foundry:
• COMMON DATA - PLATFORM FOR
▪ Database
▪ Analytics
▪ Visualization
▪ Interaction
▪ Planning and Controlling
▪ Better Organization
▪ Better Business
▪ START making DATA DRIVEN decisions
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What is Foundry 4.0?
Digitisation / Digitalisation (IR 4.0)
The Big Vision and steps to be taken
INTEGRATION
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Biometric, camera-supported fault recognition
• A camera identifies faults in
the mold and lock the
molds for pouring
automatically (biometric
comparison to target
values)
• All process data to the
mold a stored in a database
to enable retrospective
analysis auf faults
LEARN ➔ PROCESS CONTROL ➔ SAFE MONEY
InhaltsverzeichnisBetter View of Data for Better Planning
30
RAW MATERIAL
SCENARIO
MANAGER
InhaltsverzeichnisPlanning for the melting shop (Gantt)
31
Mo
uld
ing
F
urn
ac
e &
Tre
atm
en
t E
ne
rgy
Me
lt
Re
ad
y
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HT – HEAT TREATMENT
• HT Stand Alone:
▪ Technically and organizationally
possible
▪ HT cycle is part of the QM
module
▪ Link up of the resource plans via
checklist and QC plans as well
as individual item master
▪ Checklist one level with
measured vs. standard levels
(depending on HT cycles)
▪ Start and Feedback is required,
that’s it
▪ Charge per HT cycle may need
to be defined depending clients
interest
11/08/2018
33
System integration
Production
Process Control
Purchasing
Materials Logistics
Manpower Machines
Reference:
11/08/2018
34
How to apply to HamiltonJet
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16.10.2018 35
Foundry 4.0 Example – Mould
www.rgu.de
• Paperless reporting -Recording of LIVE
mould production data using Counters
• Display ongoing mould production rate,
molding instruction, guideline, tips helpful
to the workers
• Automatic mould sequences on molding
line, as per the core sequence in tray
among different parts to be mould
• Color coding of mould – to trace the casting
till dispatch
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Foundry 4.0 Example – Mould
www.rgu.de
• Heat code, date of pouring, batch number
etc. printed on casting to trace the chemical
composition, pouring temperature, quality
test report/details from FRP® system in
future whenever required
• Mould quality details – Strength, Sand
parameter can be also saved, to do any
root cause analysis regarding rejection
• If any pattern not poured (blocked pouring),
record the same
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Foundry 4.0 Example – Mould
www.rgu.de
• If humidity, sand parameter failed to achieve defined values,
stop from pouring – with alert system!
• Send SMS, email – if Sand parameter, molding quality control
fails for specified numbers repetitively
• SMS Alert for unplanned maintenance of molding line
• Automatic door control, HVAC optimization to achieve required
sand properties
Visualisation of relative humidity
Sensor installation for measurement
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EXAMPLE : CORE MAKING
Core Data
FeedbackStations
from Shop Floor
Overviewat any time
Core Shop
Efficiency
Cost reduction
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Foundry 4.0 Example – Core Making
www.rgu.de
• Paperless reporting -Recording of LIVE
core production data using Counters – no
manual entries of core production
• SMS/Email alert if core rejection > 5% or
production target missed by >5% during
shift / day / hour
• Display ongoing core production rate,
corresponding core shooting instruction,
guideline, tips helpful to the workers
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Foundry 4.0 Example – Core Making
www.rgu.de
• Inspect core (dimension, crack etc.) using
Light Scanner to ensure no core defects,
before placing to mould – ensure zero
defects due to core
• Different color coding of good cores and
bad / rejected cores such that logistic staff
from colors can identify which core tray
need to be shifted to warehouse / molding
line – ensures 0% - chances of bad /
rejected core to be placed inside mould
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Foundry 4.0 Example – Core Making
www.rgu.de
• Core trays are equipped with RFID tags or barcodes
• The FRP®-system automatically tracks stock core location
• Cores dryness data
• Core and corresponding mould info saved hence right mould will be placed on molding line, no mismatch of core & mould
• Only cores with the right dryness, hardness will be placed in the mould thanks to RFID / barcode system
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Foundry 4.0 Example – Mould Moving / Melting / Pouring
www.rgu.de
High temperature RFID
at the automated melt
handling device →
defines path and
destination
High temperature RFID at
the ladles‘ automated
handling device → Defines
pouring time and speed
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Foundry 4.0 Example: HPDC : DIE-CASTING
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Foundry 4.0 Example – DC- Mould
www.rgu.de
• Paperless reporting -Recording of LIVE
mould production data using Counters
• Display ongoing mould production rate,
shots booked, casting produced, materials
consumed …
• Automatic shot profiles and deviation of the
same analyzed online against sample and
standard shot profile
• Casting code – to trace the casting till
dispatch
InhaltsverzeichnisReporting with standard PC and/or BC-scanner
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Foundry 4.0 Example – (HPDC) Die-Casting
www.rgu.de
• Paperless reporting - Recording of
LIVE terminals for (here) machining
operations.
• Identifiers / markers at Die-Casting
parts PER casting OR per casting
LOT (box)
• Feedback on operations via terminal
➔ manual entry / BC/QR entry /
Automatic entry
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Foundry 4.0 Example ➔ Die – Casting
www.rgu.de
DATA BASE ➔ DATA ANALYTICS ➔ PROCESS CONTROL
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Cast & Alloys in Rajkot
www.rgu.de
• 1st industrial FRP® client in India
➔total “4.0” vision within the operation
• FRP® phase 1 ➔ match the work flow
• FRP® phase 2 ➔ data integration
• FRP® phase 3 ➔ digital control
• In addition IoT solution deployment
(example: Machining center digital control –
see next slide)
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Cast & Alloys in Rajkot
www.rgu.de
• 1st industrial client in India ➔ total “4.0”
vision within the operation
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FRP - Feedback Stations in Foundry
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Foundry 4.0 Example – WIP and Information Flow
www.rgu.de
• Control the information YOUR PEOPLE
have access to
• PLAN for this
• Ensure they feedback correctly, which they
will, like when using paper
• Make the system / organization of work-
flow intelligent and with this you make your
workers intelligent
• WIP works best if the systems is limited per
resource
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Examples for Traceability / Trackability / Digital Control
Digitalisation – threat or
opportunity for ferroalloys trading
for foundries ….
confidential
57
Digitalisation – optional or inevitable?
” Every company in every
industry will be
dramatically affected”
Booz&Co 2011
” Digitalization is inevitable”
Siemens CEO 2018
58
Trends provide strong tailwind for digitalisation of ferroalloys
industry
Rise of “digital natives”• A new generation of buyers and sellers has arrived
Industry is looking for efficiency gains• Industry is under intense pressure to reduce costs and
working capital
No alternative to growth• Companies require digital strategy to access financing from
banks
59
Clear opportunities arising from digitalisation
Lower
transaction
costs
• Lower customer
acquisition costs
• Immediate access
to customer
information (KYC)
• Higher liquidity
and more spot
opportunities
• Higher efficiency
over entire
sales/purchasing
process
• Faster
contracting
process
• Comparable
requests &
offers
Higher
liquidity
Digital stan-
dardisation
• Higher degree of
standardisation
through
• User friendly
forms
• Neutral Terms
& Conditions
• Multilingual
platforms
Lower customer
acquisition costs
907
BNP Paribas Survey 2017:
85% of respondents see a benefit in using
digital trading platforms for buying and
selling metals for foundries
#1 incentive to use platforms: extending
the company’s customer or supplier base
61
” Digitalisation is one of the great movements of our time.
[…]
Whilst some companies are being forced “reactively” to
adapt to the new world order, the real leaders are pro-
actively changing their business structures to fit”
HSBC Oct 2016
62
Get in touch!
www.metals-hub.com
The Big Vision and steps to be taken
AUTOMATION
The future Ahead -
”Foundry 4.0” &
Digital Foundry !
The Big Vision in the Digital Transformation of
Casting Operations
InhaltsverzeichnisAUTOMATION EXAMPLES
• Automated cells
• MCT – manufacturing
control towers
• Market demands towards
more complex parts
• Automated defect
recognition ➔ DATA
management
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Prerequisites to reach level 4.0
www.rgu.de
• THE FOUNDRY has to be controlled by means of IT and digital databases (Excel is way NOT sufficient)
• Proper details of resource plans (FRP® system) of all the castings and its stages (melt, tools, core, machining, etc. ) must be known otherwise impossible to reach “foundry 4.0”
• Foundry intelligence
▪ Display/avail Pro-active workers information, before they commit a mistake on shop floor
▪ Sensor – machine integration to act autonomously for predefined situations/criteria
▪ Real time foundry data availability on Mobile, Tab, Laptop for better traceability, quick decision, avoid damages/rejections
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• FIRST STEP ➔ SOFTWARE
• You need a perfect description of what you are doing in production in form of a Database (Software) ➔ FRP®
• Knowing where a part comes from? ➔Traceability
• Knowing where it is ? ➔Transparency
• Knowing where it goes to? ➔Trackability
• Knowing PRECISELY HOW MUCH IT COST TO MAKE? ➔ Priceless
• PRE-REQUISITE: A good description of a Resourceplan for production planning and controlling (involvement of Man – Machine – Material in form of Bill of Materials and Bill of Operations and Bill of „Labour“ , and many more used in production) ➔ DATA management
How to achieve „Foundry 4.0“
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• SECOND STEP ➔ DATA Collection in an
INTEGRATED SYSTEM (➔ FRP®)
• Start collecting all technical and commercial information in an integrated
FRP® System. You will need this information now and in future.
• Describe your production capacities so the Software can aid you in planning
and steering of production ➔ Establishment of Resource Plans (RP) (Man –
Machine – Material)
• Remember a machine or single instrument or Excel CANNOT PLAN....
• Use the RP for all steering & controlling activities ➔ AI in production
How to achieve „Foundry 4.0“
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• THIRD STEP ➔ INVESTMENT INTO HR
• Do not forget to take Labour seriously (invest into them, train them, motivate
them )
• Create WIP chain that is reliable, in an intergrated system you will see
IMMEDIATELY if WIP is not working, use this to your advantage
• DO NOT FORGET : „Intelligent Machine“ is A SINGLE solution - It is stand-
alone and it CANNOT do the planning and steering of the whole production.
• Barcode / QR Code / Laser Marking are DATA ENTRIES only
• It is usefull but needs to be connected and integrated to the whole FRP® -
foundry solution, else ...
How to achieve „Foundry 4.0“
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Changing the industry perception
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Changing the industry perception
From 3D = dirty, dangerous, difficult
TO
D3 = digital, dynamic, different
InhaltsverzeichnisRGU ASIA Pte Ltd
www.frp-solutions.com
www.rgu-asia.com
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IT SOLUTIONS FOR FOUNDRY
Let’s Go Digital
Foundry
Industry
Foundry Resource Planning
THANK YOU !