Loading...
Real Factory2018-11-07T15:53:39+00:00

SMART FACTORY – THE FACTORY OF THE FUTURE IS GREEN, MODULAR, PAPERLESS, COLLABORATIVE AND PREDICTIVE

Times change, even factories and the technology they use. Next to the permanent requirements for cost-efficiency and quality there are changing demands regarding production and production facilities. The topic of the green factory, in which the consumption of energy and resources, overall equipment effectiveness (OEE), life cycle cost (LCC), and total cost of ownership (TCO) take center stage, is becoming increasingly important.

Instead of waiting until fixtures, robots or equipment fail, we permanently collect relevant data using predictive maintenance applications, interpret this data online, and so control the maintenance of the lines: not too early, but above all not too late. Predictive maintenance therefore also helps to avoid unnecessary storage costs for spare parts. With the implementation of the paperless factory, a modern factory becomes even smarter: It not only protects the environment, but reduces the error rate and increases productivity and transparency in all phases of production. And last but not least, collaborative robots in the production chain can relieve staff of busy, ergonomically critical activities, can increase process safety and can increase quality and save costs.

AND YOUR ENERGY COSTS?

Have you ever intensively examined the energy costs of your production plants and the costs for their repair and maintenance? For us at EDAG PS, these are important aspects to optimize the production of our clients, and to reduce costs.

Talk to us if you think your company still has optimization potential and you want to reduce your costs.

BENEFITS
FOR CLIENTS:

  • INCREASE IN PRODUCTION QUALITY

    Due to the permanent monitoring of the production, use of robots and exclusion of error sources

  • ENERGY SAVINGS

    By avoiding oversized lines, intelligent control of the components, optimized production processes

  • ADDITIONAL COST SAVINGS

    Due to the reduced use of resources and a customized, effective collaboration between man and machine

  • INCREASED SAFETY

    For employees using collaborative robots and relief from repetitive and ergonomically strenuous work

  • RELIABILITY OF PRODUCTION

    By predictive maintenance, i.e. recording and analysis of production data (Big Data)

Ipad

GREEN FACTORY – PROTECT THE ENVIRONMENT WHILE SAVING ON COSTS AND RESOURCES

We at EDAG PS support our clients in all planning and production phases in the saving of energy and resources. To this end, we analyze existing production procedures and standards, optimize factory and process planning for energy efficiency, simulate energy consumption and replace energy-intensive production machines (for example with compressed-air free production). Energy can also be saved by smart power-down of machines temporarily unrequired, and optimization of robot paths.

  • Significantly lower energy requirements and energy costs through better-dimensioned lines (for example with lightweight grippers that permit smaller-sized equipment and connection lines).

  • Lower acquisition costs

  • Intelligent control of components

Ingnieur mit Tablet

PAPERLESS FACTORY – CREATES TRANSPARENCY AND REDUCES ERRORS

In many factories, production stock and/or warehouse stock is still kept on paper lists. This is not only error-prone, for example during later manual transfer of paper data into computer systems, which ultimately costs time and money. This procedure also wastes resources and reduces efficiency, since the data is available to other areas only after digitization.

We provide numerous benefits to our clients by using digital systems in the production process.

  • Information can be processed in a way that is visually clear.

  • Test plans can be used digitally at every station. The results are ready immediately.

  • The production process can be controlled and monitored very efficiently and intuitively.

  • Employees also have all information at hand using mobile devices.

  • Paper data does not need to be transferred and this saves a lot of time.

  • Resources for paper and printer are no longer required.

Roboter Handshake

COLLABORATIVE ROBOTS – PROFITABLE COLLABORATION OF MAN AND MACHINE

People in production are more flexible and can even handle complex workpieces skillfully, especially “limp” ones. On the other hand, robots have better endurance and advantages in terms of repeatability and positioning accuracy.

The perfectly coordinated cooperation between robots and humans, man-machine collaboration, provides many benefits to our clients. It is only possible through collaborative, sensitive robots, which are equipped with special sensors to ensure accidents and injury to personnel are avoided.

For the efficient and effective use of collaborative robots in the factory of the future, a precise knowledge of the initial situation and the tasks is required, as well as comprehensive knowledge about the numerous methods and features to be used.

From the large range of different approaches and tools, we therefore create tailor-made solutions for our clients that optimally meet their specific requirements.

  • Save costs,

  • Increase the quality of your products,

  • Increase process safety and speed,

  • Reduce the physical strain of employees and so promote their health,

  • Use new production capabilities

HUMAN-MACHINE-COLLABORATION: For a world without fence Read more

Maintenance Service

PREDICTIVE MAINTENANCE – MAINTENANCE AND REPAIRS WITHOUT DOWNTIMES

The most important aspect of production is that it should never fail and should run uninterrupted, 24 hours a day, 365 days a year. This is possible if all relevant components of the plant are constantly data-monitored and the data so collected and compressed can be used to make predictions. In addition to data acquisition from MES and PLC, this requires including a customized additional sensor system (Internet of Things), and the effective processing of large volumes of data (Big Data).

The EDAG PS special know-how is in our intelligent algorithms that derive laws based on the recorded real data and predict the failure of components in a timely and accurate manner. Repair and maintenance work at favorable times can be determined from this and run so that there are only short production restrictions – if any at all.

  • No failures and faults in the production caused by late measures

  • No unnecessary costs thanks to preventive measures

  • No unnecessary storage costs for spare parts

  • Efficient maintenance at minimal cost

HOW TO GET STARTED IN YOUR PREDICTIVE MAINTENANCE PROJECT? Hackathons offer a very smart, cost-efficient and low-risk solution Read more

Qualität 100%

QUALITY 4.0 – INTELLIGENT NETWORKING TO IMPROVE PRODUCT QUALITY

Over time, the machines and tools used in the factories change, and therefore affect the quality of the products and the production. Here, the networking of all machines involved in the production process also plays a decisive role in quality control. For instance, the machines automatically make small corrections between production steps within certain specified tolerance areas (“self-regulating machines”) to compensate for quality fluctuations.

This can only be achieved if you first simulate the process and its individual steps virtually during the planning phase, then check the drift of the measured values and run an analysis to establish which parameters can be changed and how this affects the quality of the product. Actions that only result in low “side effects” can therefore be specified for different scenarios. This horizontal networking in the planning phase provides improved quality in long production periods by means of automatic corrections.

  • No failures and faults in the production caused by late measures

  • No unnecessary costs thanks to preventive measures

  • No unnecessary storage costs for spare parts

  • Efficient maintenance at minimal cost

STILL HAVE
QUESTIONS?

Dr. Frank Breitenbach

PLEASE CONTACT
DR. FRANK BREITENBACH
SENIOR TECHNICAL EXPERT FOR PLANNING METHODOLOGY
E-MAIL: FRANK.BREITENBACH@EDAG-PS.COM

phone
email
share
Social