Integrated industry solution for die-casting and machining

Background of Digital Factory

Digitization: an important means of integrating informatization and industrialization

Intelligence: The Development Trend of Equipment and Mechanical Products

The application of SIGER IoT in the industrial field provides a new breakthrough for "Made in China 2025". The successful application of IoT technology will effectively promote the development of manufacturing towards networked production equipment, real-time information collection, paperless production documents, transparent production processes, less manpower in production sites, and service-oriented production and manufacturing. The application of the Internet of Things can unify the network management of all devices and personnel, enabling close connection and efficient collaboration between devices, devices and computers, and devices and production personnel.

SIGER Digital Factory provides MES (Manufacturing Execution Layer) based services, including: production management module: integration with ERP system to obtain production orders, supporting visual production scheduling; Support work management, associate personnel and equipment status, and associate quality status. Provide management modules such as production management, equipment management, production output monitoring and reporting, work order progress dashboard, process parameter management, quality management, traceability management, etc., to help users improve their operational management level and increase production and operational efficiency by more than 15%.

Die casting workshop - production management challenges

• ■ The pressure of the die-casting machine cannot be monitored in a timely manner
• ■ The temperature of the furnace and the weight of the raw materials cannot be recorded in a timely manner, and can only be manually recorded
• ■ The time and temperature of the deaerator are not guaranteed and can only be managed through manual recording, which is not timely
• ■ The amount of rare metal added can only be estimated, and fracture analysis, chemical composition, mechanical properties, and metallography cannot be statistically analyzed in a timely manner, without intuitive data for reference
• ■ Energy consumption data cannot be statistically analyzed or optimized

• ■ Production statistics rely on manual transcription, with poor timeliness and low accuracy
• ■ The data is not timely and complete, making it difficult to have a clear understanding of the workshop conditions.
• ■ Without a complete data chain, it is impossible to measure the management performance of the factory
• ■ When there are quality problems or user complaints with a product, it is difficult to trace all the production process information of the product, and it is impossible to analyze which side is the cause
• ■ There is no way to automatically collect and analyze the quality inspection data of the product, and it is impossible to accurately distinguish between random fluctuations and abnormal fluctuations in product quality

Current status of machining:

• ■ The degree of equipment automation continues to increase
• ■ The precision of the equipment continues to increase
• ■ The added value of equipment continues to increase
• ■ Diversified customer needs and frequent model changes
• ■ Strict quality traceability requirements

Development trend of machining:

• ■ Automated loading and unloading of materials
• ■ Equipment networking
• ■ Process unmanned
• ■ Digitalization of workshop

The digital workshop includes: kanban system, equipment status monitoring, fault alarm analysis, production parameter monitoring, production execution analysis, and comprehensive efficiency analysis.

Display the real-time operating status of each device in the form of a graphical interface and a list. No need to go to the site, the current operating status of all equipment can be easily seen, including how many machines are shut down, idle, faulty, shut down, and the operating parameters of each machine.

• ■ Slice Status Overview
• ■ Slice data analysis
• ■ Status Management List
• ■ Status settings

Over a period of time, by analyzing the operation of the equipment, it is possible to determine where the machine's time has been lost.

• ■ Production parameter status
• ■ Abnormal parameter settings
• ■ Parameter Exception List
• ■ Parameter exception statistics

Pre set the upper and lower line values of spindle speed, spindle ratio, and feed ratio, monitor and record parameter abnormal events in real time, and facilitate the tracing of abnormal causes when quality problems occur, such as workers intentionally increasing the speed.

Production parameter status

• ■ Abnormal parameter settings
• ■ Parameter Exception List
• ■ Parameter exception statistics

Statistical indicators can be the number of anomalies or the duration of anomalies. At the same time, multi angle statistical analysis can be conducted by day, production line level, and parameter anomaly type.

 Maintain the fault cause and solution corresponding to the alarm code in the system. When the device sends an alarm message, the fault cause and solution can be quickly viewed in the alarm status list.

• ■ Import production plan
• ■ Production scheduling
• ■ Plan Gantt Chart
• ■ Conflict List

Support ERP integration, Excel import, and manual creation to add production plans. The scheduling supports a combination of manual and automatic methods to calculate the start and end times of work orders.

Note: If production has been scheduled in ERP, production will be executed after integration.

• ■ Plan Gantt Chart
• ■ Equipment load analysis

Display the plan arrangement in Gantt chart format, and support manual dragging and dropping of graphics to schedule the plan. Analyze the calibration time, task time, and actual time of the equipment.

• ■ Production execution report
• ■ Work Order Progress Overview
• ■ Query of work report records

By reporting work through the system, the status and progress of the production plan can be presented, and the actual production pace can be calculated, saving a lot of paper records and improving information communication efficiency. Planners can better arrange plans and provide customers with timely responses.

• ■ Production Statistics Report
• ■ Plan execution analysis
• ■ Equipment production statistics

Check the achievement rate, on-time completion quantity, quality qualification rate, as well as the number of non-conforming products and equipment output efficiency of the plan at any time.

• ■ Time utilization rate
• ■ Process beat chart
• ■ Statistics of Quality Qualification Rate
• ■ Production output statistics

With the collection and recording of data on equipment, plans, quality, and other aspects, we can measure the production efficiency of the workshop: time utilization rate, process beat chart, output statistical analysis, and qualification rate analysis

OEE comprehensive efficiency analysis

Performance performance in three dimensions: comprehensive quality, time, and output efficiency, providing comprehensive efficiency across different statistical ranges from the factory level to the specific equipment level.

With the analysis of quality qualification rate, time utilization rate, and production efficiency, it provides comprehensive efficiency from the relatively macro factory level to specific production lines, and even down to individual equipment, helping enterprises measure production performance from different levels.

• ■ Local management in the dataset
• ■ Real time summary and analysis of operational management status
• ■ Intelligent Maintenance Production Management System

Provide corresponding management dashboards for different usage scenarios to maximize the satisfaction of information needs of managers at all levels for the workshop.

Enable management personnel at all levels to truly see the production status in real time and know the production results at any time

Present real-time status of the workshop layer through a large screen to grasp the overall situation of the workshop.

Equipment operation slice chart: time utilization of equipment over a period of time

Production status overview: It can present the real-time status of a production line, including the line's rhythm, output, equipment operation, etc

Overall efficiency of the workshop or factory building, comprehensive dashboard.

Present the operational status of specific equipment and the current output of the production line.

Digital Workshop Production Management - Quality Traceability Module

Collect data in the die-casting workshop

• ■ Furnace: Raw material batch number, weight, furnace number, personnel, time, temperature curve, etc
• ■ Deaerator: associated with furnace number, time passed through the furnace, degassing time, additive weight, personnel, time, etc
• ■ Die casting machine: associated with transfer package, degassing time, furnace time, personnel, time, etc., collects temperature and pressure curves and displays them on a real-time large screen
• ■ Coarse material packaging: generate packaging box number, associated quantity, batch, etc
• ■ Monitoring: temperature, pressure, energy consumption, quality points, etc

Automatically collect production testing data:

• ■ NC machine tool processing data
• ■ PLC detection data
• ■ PC text file data (CSV, Excel, Txt, PNG, etc.)
• ■ Hardware serial port, USB and other data
• ■ Web API Data

Manual collection

When automatic data collection fails, production data can be collected through manual input

• ■ Production process inquiry
• ■ Yield statistics

Retrieve information on WIP work in progress, control production quantities, and avoid parts loss.

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