Workshop on making our Foundry “Smart” through Internet of Things (IOT) …...….Industry 4.0……….. Manish Kothari Advisory Board – Ecolibrium Energy, Managing Director – Rhino Machines Pvt Ltd Faculty – IOT – Symbiosis, Chairman IMC (ITI) Santrampur, Director – Composite Solutions 28th July 2018
Hotel Ramada, Jalandhar
Making our Foundries/Industries “Future Ready”
Session 1: Industry 4.0 perspective Ecolibrium Footage on CNBC Approach to Smart Foundry Examples & Demo of Solutions implemented in Foundry
Session 2: Summarizing the Google Form Data Roadmap to implementing IOT in our Foundries Interpreting the feedback and finding solutions Techno-Commercial Feasibility of implementation The Agenda for Today
Evolution of Industry Industry 4.0 Industry 3.0 Industry 2.0
Industry 1.0 Mechanical Production using water & steam power
Industry 4.0 perspective
Mass production based on division of labour using electricity
Use of Electronics & IT to automate production
Cyber-physical systems, automation and the Internet of Things (IoT) to create smart factory
Industry 4.0 – CYBER PHSYICAL ENGAGEMENT Industry 4.0 involves improved automation, machine-to-machine and human-to-machine communication, artificial intelligence, continued technological improvements and digitalisation in manufacturing. Areas
Key Result Areas
Impact Ensuring stability & accuracy in production planning
Improvement in Productivity Operations
Improving asset utilisation & reducing downtime Higher labour efficiency Harmony in supply chain & better cost management Managing raw material prices & availability
Reduction in Risk
Managing warranties & recalls effectively Minimising geographic risks Improve aftermarket revenue streams
Incremental Revenues Growth
Strengthening customer integration & channels Ensuring additional sources of revenue in the core business Understanding customer demands better Developing new products & services
New Opportunities Industry 4.0 perspective
Expanding globally in newer markets Identifying strategic investment opportunities
MIF 2018 Awardee Ecolibrium Bytes • MIF Interview – Harit Soni • CNBC Footage - https://youtu.be/yUZT6KhtL1Y?t=4m15s • Manish Kothari Interview by MIF on IOT Impact
MIF = Marico Innovation Foundation
Are we as a Management Clear why?
4
Foundry 4.0 Energy
Environment
Productivity Sand Resin
Maintenance
CORE
METAL
70%
Compressed Air 10%
5%
Handling
FETTLING
Lining
Inspection & Painting
Mould
Alloys
OEE Rejections
Lighting 5%
Gas Temperature Measurement
Process
Dispatch
7%
Metallic
Shots Grinding Wheels
Manpower
Bentonite
Discard
Reclaim
Sand
Costs Approach to Smart Foundry
Coal Dust Water
SAND
Waste
SMART Foundry – How?
The key elements required to make the Foundry SMART Process automation – most challenging Machine automation – most common, needs process integration Machine learning – very critical for foundry 4.0 Systems integration – Bringing all Digital Devices to one platform Upskilling Human Resources – key to success of Foundry 4.0 Copyright - Rhino Machines Pvt Ltd Approach to Smart Foundry
8
4 Step Approach to Foundry 4.0
Foundry 4.0 IOT Technology
Culture • Shop Floor Practices • Lean Manufacturing • Documenting Processes
• Digitization of Process, Production & Documentation • Connectable Devices & Machines
• Connecting Machines • Connecting People
Copyright - Rhino Machines Pvt Ltd Approach to Smart Foundry
• Analytics • Actionable Insights • Automation of Insights to physical actions
9
Melt shop Overview Metal Tapped Weight Melting Energy, P.F., …all energy parameters
KPI’s/Objectives
Pouring temperature Furnace kW/kWh kWh/Ton Spectro / CEV Meter
Water Consumption Water Pump Energy
Hrs/Heat Consumptions/Heat
Scrap/Metallics
Deviations= Issues/Alerts
Spectro / CEV Meter Melting Heat Time/Tapping Time / Holding Time
Implemented at: • Sky Technocast – Ahmedabad • Shree Jayaram Foundry - Coimbatore
Green Sand Process – Variables at Macro Level Sand Preparation
Moulding Machine
• Control and Consistency in Instantaneous properties • Logging of all inputs to the sand preparation e.g. return sand, new sand, bentonite, coal dust, water, temperature..etc
• Control of Mould Quality & Consistency • Recording of process parameters for each mould and casting • Monitoring and control of mould and casting rejection in realtime • Production capacity and availability
Return Sand System • Management of System sand properties • Control of Sand Temperature • Control of Silica Content, AFS, Clay, VM, LOI in sand, Grain Shape • Relation of Defect with Sand properties
Waste Sand • Controlling Waste at Knock out, Shot Blast, Dust Collector, Screen, etc • Excess Sand disposal validation • Sand reclamation & recovery integration Copyright - Rhino Machines Pvt Ltd
Casting Data • Relation of Rejection with Mould • Validation and control of cooling time • Establishing relationship between sand, mould and casting rejection in realtime 11
Green Sand Plant – Machine to Cloud PLC
Sand Preparation
Mixer Motors
Water Addition Additives
Cooling Sand Controller
Copyright - Rhino Machines Pvt Ltd
12
Scope of Foundry 4.0 in Sand Preparation System Data Collected • Sand Temperature • Compactibility – set, measure and deviation • Water Addition • Cycle time • No of Batches • Additives addition • Return Sand & New Sand
Present usage of data • Graphical representation of data • Analysis on same time scale of different parameters • Average consumption, variation
Scope for Foundry 4.0
Data Acquisition, Repository, Analytics & Call to Action Process
Production
Asset Health
Consumptions
Copyright - Rhino Machines Pvt Ltd
• Machine learning to understand sand behavior based on material consumptions • Machine utilization, production efficiency • Relationship with Rejection (when connected on macro network) • Consumption Ratios w.r.t. casting production • Prediction & thereby control of process varation 13
Green Sand Moulding– Machine to Cloud PLC
High Pressure Moulding
Moulding Machine
Mould Handling
Process Pressure
Production Data
Copyright - Rhino Machines Pvt Ltd
Data Acquisition & Data Analytics being done – User Interface under preparation • Moulding production data – hour, shift, day, week and any period • Energy consumption per mould, per kg casting • Casting moulding and production analysis • Mould rejection analysis • Asset maintenance – alarms, preventive maintenance, predictive maintenance analytics 14
Steps to get on IOT Platform – Points to Ponder
Electricity Metallics Process Readings PLC Data Painting & Finishing Casting Dimensions Casting Dimensions
Data Analytics Data Interpretation
Data Gateway to Cloud Data Mining The source • Determining the parameters influencing the process • Determining the data source - PLC, Sensors, Spreadsheet, Tables,…
• Determining the deployment of IOT for data acquisition • Determining the grain size, data formats for uploading data
• Defining the relationship of the data with the process • Defining the interrelationship of different data
• Algorithms to connect the data collected • Algorithms to find trends
Moving Forward to Implement Foundry 4.0 Proactive – Predictive Analysis Building the User Interface
Insights into Data • Determining types of insights to be developed • Determining how the data will be displayed in real time • Creating visualisation graphics for insights • Predictive insights - algorithms and development
• Determine Alerts & Updates for user • Create summary report formats • Create Decision making reports & alerts • Create dashboards - flexible and user dependent
• Create Machine Learning & AI Insights for improvements • Resource efficiency & utilisation analytics • Integrate with manufacturing analytics • Enable forecasting analytics for manufacturing & process
Summarizing the Data Shared by Foundries for this Workshop
Electricity Metallics Process Readings PLC Data Painting & Finishing Casting Dimensions Casting Dispatch
Back to Foundry 4.0 Energy
Environment
Productivity Sand Resin
Maintenance
CORE
METAL
70%
Compressed Air 10%
5%
Handling
FETTLING
Lining
Inspection & Painting
Mould
Alloys
OEE Rejections
Lighting 5%
Gas Temperature Measurement
Process
Dispatch
7%
Metallic
Shots Grinding Wheels
Manpower
Bentonite
Discard
Reclaim
Sand
Costs Approach to Smart Foundry
Coal Dust Water
SAND
Waste
The Partners in Foundry 4.0 – Leveraging Expertise of Each to Grow Together Rhino Machines – Foundry Projects & Machines
www.acefound.org
ACE Foundation – Creating the Culture Change
Industry Experts onboarding as we progress
Foundry Process & Operation Experts
IOT Foundry 4.0
www.rhinomachines.net
Ecolibrium Energy – IOT Enabler
Composite Solutions – Business Analytics
www.ecolibriumenergy.com
www.cspl.net.in
Media Coverage & Some Pictures
Responses Tabulation from Industries – an important participation Need Timestamp 7-7-2018 12:49:18
W hich area(s) are the key for your foundry Melt Shop, Sand Plant, Mould Plant
7-17-2018 18:24:42 Melt Shop
W hich Data you wish to get collected Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, PLC Data from Furnace, Sand Plant, Moulding Line etc Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc
How do you collect the data today Manual Register Recording, W eighing System, Machine PLC, Excel Spreadsheet Manual Register Recording, W eighing System, Analog (Manual) Instruments like Pressure Gauge, Temperature meter etc
7-17-2018 18:37:43 Sand Plant, Mould Plant
PLC Data from Furnace, Sand Plant, Moulding Line etc
Machine PLC, Analog (Manual) Instruments like Pressure Gauge, Temperature meter etc, Excel Spreadsheet
Melt Shop, Sand Plant, Mould Plant, 7-17-2018 18:42:54 Compressor, Shot Blasting & Fettling, Painting & Finishing
Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc, Painting & Finishing
Manual Register Recording, W eighing System
7-17-2018 19:10:44 Melt Shop
Electricity
Manual Register Recording, Excel Spreadsheet
Melt Shop, Sand Plant, 7-17-2018 19:16:36 Compressor, Shot Blasting & Fettling
Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc
Manual Register Recording, Excel Spreadsheet
Melt Shop, Sand Plant, Mould Plant, 7-17-2018 19:17:18 Compressor, Shot Blasting & Fettling, Painting & Finishing
Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, PLC Data from Furnace, Sand Plant, Moulding Line etc
W hat is your expectation from implementation of IOT Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance Establishing Realtime Consumptions Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Implementing TPM, Lean, 6Sigma in realtime, Production Management & Monitoring Improvement in Plant utilisation, Establishing Realtime Consumptions, Production Management & Monitoring
Establishing Realtime Consumptions
7-17-2018 19:56:32
Electricity, Metallics (Scrap, R/R, Borings etc) & Sand Plant, Mould Plant, Alloys W eights, Process Readings such as Compressor temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc
Manual Register Recording
7-17-2018 20:10:29
Melt Shop, Sand Plant, Mould Plant
Manual Register Recording, W eighing System
Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Production Management & Monitoring Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Production Management & Monitoring Improvement in Plant utilisation, Production Management & Monitoring
7-17-2018 21:23:56
Melt Shop, Sand Plant, Mould Plant
Manual Register Recording, Machine PLC
Improvement in Plant utilisation
Machine PLC, Excel Spreadsheet
Improvement in Plant utilisation, Asset Management - Predictive & Preventive Maintenance, Implementing TPM, Lean, 6Sigma in realtime, Production Management & Monitoring Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Production Management & Monitoring
Process Readings such as temperature, CEV meter, Pressure etc Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc
Process Readings such as temperature, CEV Sand Plant, Mould Plant, meter, Pressure etc, PLC Data from Furnace, 7-18-2018 7:42:18 Shot Blasting & Fettling, Sand Plant, Moulding Line etc, Cast Part Machining dimensions
Manual Register Recording
Melt Shop, Sand Plant, Mould Plant, Compressor, Shot Blasting & Fettling
Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc
Manual Register Recording, W eighing System, Analog (Manual) Instruments like Pressure Gauge, Temperature meter etc, Excel Spreadsheet
Melt Shop, Sand Plant, Mould Plant, 7-18-2018 12:12:38 Compressor, Shot Blasting & Fettling
Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc
Manual Register Recording, W eighing System, Analog (Manual) Instruments like Pressure Gauge, Temperature meter etc, Excel Spreadsheet
Melt Shop, Sand Plant, Mould Plant, 7-18-2018 14:58:19 Compressor, Shot Blasting & Fettling, Painting & Finishing
Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc, Painting & Finishing
Manual Register Recording, Analog (Manual) Instruments like Pressure Gauge, Temperature meter etc, Excel Spreadsheet
Melt Shop, Sand Plant, Mould Plant, 7-18-2018 15:00:30 Compressor, Shot Blasting & Fettling, Painting & Finishing
Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc, Painting & Finishing
Manual Register Recording, W eighing System, Machine PLC, Analog (Manual) Instruments like Pressure Gauge, Temperature meter etc, Excel Spreadsheet
Melt Shop, Sand Plant, Mould Plant
Electricity, Metallics (Scrap, R/R, Borings etc) & Alloys W eights, Process Readings such as temperature, CEV meter, Pressure etc, PLC Data from Furnace, Sand Plant, Moulding Line etc
Manual Register Recording, W eighing System, Machine PLC, Analog (Manual) Instruments like Pressure Gauge, Temperature meter etc
7-18-2018 10:10:57
7-18-2018 19:44:08
Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Implementing TPM, Lean, 6Sigma in realtime, Production Management & Monitoring Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Implementing TPM, Lean, 6Sigma in realtime, Production Management & Monitoring Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Implementing TPM, Lean, 6Sigma in realtime, Production Management & Monitoring Improvement in Plant utilisation, Establishing Realtime Consumptions, Asset Management - Predictive & Preventive Maintenance, Implementing TPM, Lean, 6Sigma in realtime