Welcome to the second article in this blog series on Industry 4.0! In this series, we address unanswered questions and roadblocks surrounding the term and its implementation in factories or small job shops. We tackle the what, why, and how of Industry 4.0, and why it should matter to you. Our previous article discussed the basics of Industry 4.0 and the obstacles to embracing data-driven stamping operations. In this article, we’ll do a deep dive into the mechanisms of Industry 4.0 as they relate to the importance of data, the cyber-physical system (CPS), and how they relate to data-driven stamping operations. In short, we will cover why data matters in Industry 4.0 and how to become Industry 4.0-ready. Why Data Matters in Stamping Operations Have you ever experienced the frustration of being stopped at a red light with you and a line of cars, while there is virtually no cross traffic? Chances are you have, and you wish there were a better traffic light system to control traffic. What if traffic lights could go a step beyond timers and sensors to actually detect cars from afar and actually control them by accelerating and slowing them down, eliminating the need for traditional traffic lights altogether? How do traffic lights relate to Industry 4.0, you might ask? If Industry 4.0 is all about the exchange of data between the physical and cyber world to control a machine, then traffic lights serve as an excellent example of why data matters. Specifically, achieving a more efficient traffic light system starts with collecting the right data, understanding it, and knowing what to do with it. This same principle applies to data-driven stamping operations. Case in Point Regardless of industry, company size, and business, seasoned machine operators know much about the equipment they operate. They observe patterns, try different remedies to avoid nuisance faults, or find synergies to make their jobs easier. If asked, operators can articulate problems with the production process. However, this information resides within the operator and is subjective. For example, an operator may say that there are “dozens of misfeeds” when starting a new production batch. The operator may have an opinion about the cause, but may not be able to determine if the misfeeds are caused by the improper procedure, maintenance issues, or even a machine design flaw. Operators are typically not trained to question matters outside of their environment. Quite the opposite occurs-- they are often discouraged from doing so. Operators do not have the tools and expertise to make a compelling case to management, but data does. Below, let’s look at how would the statement of “experiencing dozens of misfeeds” in the example above might look, as expressed in a digital format: Batch 1 8:03:01 Batch start 8:03:03 Mis-feed 8:03:56 Run 8:04:01 Mis-feed 8:05:12 Run 8:10:38 Batch complete Batch 2 8:17:59 Batch start 8:20:05 Mis-feed 8:21:12 Run 8:24:26 Batch complete Aggregated in a table: Batch 1 2 Run Time 5:33 5:20 Number of Mis-feeds 2 1 Down Time Due to Mid-feeds 2:04 1:07 Total Time 7:37 6:27 The data reveals that the claim of experiencing misfeeds “dozens of times” is rather an expression of frustration, than an estimated count of occurrences. It's certainly not reflecting the number of misfeeds per batch. The data also shows that the misfeeds do not happen at the start of a batch only. Once a system records data, trends can be observed which may not be as obvious as the above. Suppose the same data was tracked in an identical production system, perhaps in a different part of the world, with the following results: Batch 1 2 Run Time 7:14 7:20 Number of Mis-feeds 0 0 Down Time Due to Mis-feeds 0 0 Total Time 7:14 7:20 Takeaways Data helps identify possible reasons for misfeeds. Looking at the total time for production would indicate that the two plants operate with comparable efficiencies. Since each plant is incentivized to achieve the highest efficiencies, you could conclude that the first plant is more efficient by producing two batches in 14 minutes and 4 seconds compared to the second plant with 14 minutes and 34 seconds. But the second plant has a more tightly controlled process which helps the workflow. Those gains could be far greater than the gain in the average cycle time of plant one. Data helps identify ways to increase stamping efficiencies. Variation at plant one is mainly caused by misfeeds. Running at the production speeds of plant one without misfeed would yield a 2-minute saving per batch, and increase efficiencies by 25% in both plants! The more data, the better. If you investigate the time between batches, the data reveals questions that ought to be asked. The timing from plant one shows over 7 minutes time gap between the end of batch one and the beginning of batch two. Does the second plant have the same time gap? What is the reason for this gap? To address the latter question, the data system would need to be expanded so that the gap can be explained. Then, compare it to a benchmark, similarly as was done in the above example. Hence, the more data, the better. The Role of Data in Stamping Operations Data plays an important role in data-driven stamping. But, it’s important to understand how it’s used just as much as why it’s used. The process and logic it takes to improve your stamping operations come, in part, from an important concept in Industry 4.0—the cyber-physical system (CPS). CPSs provide value creation (i.e. more efficient traffic lights) by using the cyber world to sense, recognize, and understand data from the physical machines in order to ultimately analyze, predict, optimize, plan, and autonomously control the machines and processes. Essentially, CPSs provide a way for physical machines and cyber networks to exchange bidirectional communication with each other and use raw data to be translated into value-creation insight and predictions for better and more efficient stamping operations in the factory. In a stamping factory, this process could look like this: While a press (physical world) is continuously running a job, the Manufacturing Execution System (MES) (cyber world) receives process data and status data from the press with each stroke. Ex of process data: order no., stroke rate, press force values, no. parts, stroke counter, etc. Ex of status data: operating status (engaged, disengaged), alarm, events, error data, etc. The MES uses this data to analyze, predict, optimize, plan, and control the press. During continuous press operation, run: The end result could be to autonomously adjust the process or predict when intervention is needed. During continuous press operation, stop: The end result could be service help or a new job set-up. The word “data” is used a lot here, but what type of data are we talking about exactly? In the next article titled “Industry 4.0: Data-Driven Stamping, Part 2”, we’ll cover what data matters and how to use it for value creation. We’ll also explain what kind of stampers are best positioned to achieve Industry 4.0. Sangiacomo Presses Americas is ready to help you optimize your stamping press operations with our adjustable stroke press. Learn more about our stamping presses by visiting our main website here. Still considering your options? Our helpful sales reps will gladly answer any questions or concerns you have. Contact us today at 256-275-4701 or email us at info@sangiacomo-presses.com.
Welcome to the first article in this blog series on Industry 4.0! In this series, we'll address unanswered questions and roadblocks surrounding the term and its implementation in factories or small job shops. We'll tackle the what, why, and how of Industry 4.0, and why it should matter to machine manufacturers and suppliers alike. By now, you’ve probably heard of the buzzword humming in your social media, conference rooms, and industry news outlets. You guessed it—“Industry 4.0”. Let's go over this term’s origin, why it’s relevant, and why this latest revolution has been challenging for some to embrace and implement. In this article titled Industry 4.0: Manufacturing Then vs. Now, we'll cover the following: What is Industry 4.0 and Why is it Relevant? Industry 4.0: Then vs. Now 4 Obstacles to Embracing Industry 4.0 Moving Forward with Industry 4.0 What is Industry 4.0 and Why is it Relevant? Interconnected devices are nowadays commonplace in households with phones, Smart TVs, security cameras, appliances, etc. Thanks to the quick adoption of Industry 4.0 (I4.0) in these industries, the convenience of insight gained from these commonly interconnected devices is done with ease—at least to the common consumer’s eyes. However, if you take a closer look at Industry 4.0 adoption, you’ll see that it’s not so simple after all. When considering Industry 4.0 adoption, there are big differences between industries. This is especially true for the traditional manufacturing industry. For industrial machinery, the intricacies and risks of implementing two-way communication between machinery and computers are much more apparent. This is in part because our industry is historically characterized by lethargy, risk aversion, and resistance to change. This helps explain why the adoption of interconnectivity and the use of data has been slower in industry and between different industries. Notoriously, the adoption of Industry 4.0 in traditional manufacturing has been much slower than in modern technologies, such as additive manufacturing, and in logistics or healthcare. Industry 4.0: Then vs Now To understand more about the buzzword that’s gotten people talking, let’s go over how we got to Industry 4.0 over centuries of innovation: Industry 1.0 The first industrial revolution occurred in the mid to late 18th century, when much of the hand labor was replaced by mechanical devices. Industry 2.0 Near the end of the 19th century, electrification marked the second industrial revolution where mechanical devices were replaced by independently powered machines. Industry 3.0 The third industrial revolution started in the mid-20th century with the arrival of the programmable logic controller. Automation has radically transformed manufacturing ever since. Industry 4.0 The fourth and current industrial revolution grew out of an effort launched by the German government to promote the computerization of traditional manufacturing. The aim of the research was to realize a smart factory by connecting machines based on the Internet of Things (IoT). The term Industry 4.0 was publicly introduced at the 2011 Hannover Fair to indicate that the use of machine data would radically transform manufacturing like the previous three industrial revolutions. 4 Obstacles to Embracing Industry 4.0 Small-size and even mid-size companies are cautious or struggle with implementing Industry 4.0. Here are four possible obstacles to embracing Industry 4.0: Lack of clarity. Companies lack clarity on how to transition to a digital data-driven manufacturing process. In addition, over 850 terms and acronyms are now associated with Industry 4.0 (Fachlexikon MES & Industry 4.0, L. Schleupner, MES D.A.CH Verband e. V). Depending on the industry, equipment manufacturers are equally slow in investing in the technology until it is clear that efforts will help their bottom line or until they're forced to do more. Currently, most of the equipment can be connected to a network which makes them Industry 4.0 ready, but that in itself is useless without software for data exchange. No established software platform. Without a clear winner, the adoption of a software standard stalls until an established software platform is apparent. Remember in the 1980s when consumers delayed video cassette purchases until there was a declared winner between the VHS (Sony) and Beta Max (Toshiba) formats? Decades later, a similar battle ensued between the HD DVD and Blue Ray formats. A similar situation is at hand here with the adoption of I4.0. Security and financial risks. Data exchange software and networked machines require proper security and network maintenance to prevent havoc caused by hackers, automatic updates, malware, and outages. Most companies cannot handle such an IT burden. Reluctant company culture and management. Many factors are at play here, but risk-aversion in company culture and management is one reason that some companies are not willing to embrace a revolutionary change or let data speak. On one hand, it may be due to an inherent resistance to change, or fear about what the data may reveal. In most cases, though, it's an uncomfortable truth that keeps them from embracing change. However, that is exactly the fundamental driver of Industry 4.0— the removal of human biases and limitations such as egos, forgetfulness, stubbornness, etc., and personal politicking. A blog by Pardhasaradhi Reddy Chelikam on the SAP website summarizes the obstacles of digital transformation as follows: High capital investment Business model adaptation Unclear ROI (Return on investment) Lack of adequate skill set to expedite the transformation towards I4.0 functionalities IT security issues (Letting critical process networks open) Reliability/stability of communications between machine-to-machine/user interfaces Reluctance to change management IT system outages/failures that would cause huge re-investment Moving Forward with Industry 4.0 The most common obstacle verbalized is that business is too hot and the human resources are too few. This means that still, so many have not even invested enough to arrive at the above-cited objections. But this trend is changing, as Tim Heston noted in the December 2022 issue of the Fabricator. The focus is shifting from capacity and capability, towards reliability and efficiency. So, we’ve gone over the background, history, importance, and obstacles of Industry 4.0. But how do you overcome those obstacles to embrace the idea of a smart factory? It starts with examining what’s within your reach and control. In the next segments of this blog series, we’ll cover why data matters in Industry 4.0, and what kind of data to start tracking. Stay tuned and subscribe to our blog for more on this. Sangiacomo Presses Americas is ready to help you optimize your stamping press operations with our adjustable stroke press. Learn more about our stamping presses by visiting our main website here. Still considering your options? Our helpful sales reps will gladly answer any questions or concerns you have. Contact us today at 256-275-4701 or email us at info@sangiacomo-presses.com.
McLoone Metal Graphics Story: Stamping Solutions at any Production Volume If you’re anything like McLoone Metal Graphics, you’ve probably experienced the same problem when shopping for a smaller press: finding a stamping press supplier who will work with what you have and customize a press to your specific needs. Matt Dearman–Tooling, Maintenance, and Engineering Manager of McLoone– shares his insight on how Sangiacomo Presses Americas catered to their small press needs and capabilities as a facility doing a lot of small volume jobs to produce product IDs. McLoone purchased three 30-ton C-frame Sangiacomo punch presses in late 2018 to use in their process of manufacturing metal nameplates. This adjustable stroke press is well suited for applications with higher production speeds for increased productivity, like blanking and stamping. The T-30CE press features the following, plus standard features not listed here: 13.78-inch max die height (table to ram distance) 80-200 strokes per minute 0.31-2.99 inches adjustable stroke length 2.36-inch ram adjustment (slide adjustment) 300 kN max capacity Additionally, McLoone recently installed their fourth Sangiacomo press—a 50-ton adjustable stroke press. For technical details on this press and the 30-ton press, download our C-frame product brochure here. The Dilemma It was time for McLoone to replace their old 22-ton gap frame presses, but other press suppliers weren’t offering the needed solutions. Specifically, they needed new presses compatible with the library of 10,000 dies they’ve used since the ’60s. This meant that they needed smaller presses with clearances compatible with the dies. If you’ve ever been in McLoone’s shoes, you know what this implies. They had to seek out smaller, niche suppliers of smaller ton presses willing to sell you only what you need and nothing you don’t. Matt explains, “A lot of press manufacturers want to sell you a 200-ton straight-side press. So, the market for a smaller gap frame press is a bit more laser focused. I guess there are just not as many companies that even want to get into that business. That said, there are still some niche manufacturers out there. We considered a few of them, but again– we're looking at the size of the actual press itself, the compatibility to what we had, the speed of the press, the ease of setup, and the changeover time.” The Solution Matt continues, “As I said, there's not a ton of manufacturers out there that are selling new, smaller presses, so we chose Sangiacomo because of their willingness to build a machine that was close to what we wanted. It was also nice working directly with the manufacturer in Italy. We made some modifications to the presses, so it wasn't just off of the assembly line. The shank-sized pole was different from what you typically have, and we had custom poles in the bolster plates and bolster plate thicknesses. So, by being willing to work with us instead of selling what they make, they provided us a machine that we could use.” Better Changeovers and Feed System Integration Aside from the initial impression of working with Sangiacomo, Matt highlights the ease of changeovers and feed system integration with a Sangiacomo adjustable stroke press: “We do a lot of smaller volume runs, meaning we have orders for 500 pieces. We might change a die in and out of a punch press three times in an 8 to 10-hour shift, so that changeover time is important to us. We don't want to spend two hours changing a die over. With Sangiacomo, our changeovers usually only take 15 to 20 minutes. We have a good system down for SMED, and we try to keep our changeover times down with the flexibility of the guarding and everything else”, Matt says. Regarding the feed system integration, Matt adds, “We use a specific feed system that allows a tight register between the printing and the cutting for our nameplates. Since the feed manufacturer also uses Sangiacomo presses in building integrated systems that they sell, we knew that it would adapt very well and enable us to wire the feed into the control of the press and have the needed handshake of the feed and the press. In our industry, we don’t just stamp raw aluminum–it’s mostly all screen printed to suit our customers’ designs, logos, and artwork. Because of this, we have to maintain a tolerance of 10 thousandths of an inch between the printing and the cutting. So, it has to be right there– regular pneumatic feeds just don't work for our industry.” To summarize McLoone’s experience with the initial design and use of their adjustable stroke presses from Sangiacomo, Matt concludes, “We had to have something that was going to work with our feeds at the right speed with safety. Those are our biggest three criteria, but with the price and, again–the adaptability and willingness to work with us to build the size of presses that we needed rather than what you sold– was a big decision maker.” To learn why Sangiacomo Presses Americas offers some of the best stamping presses, check out other timesaving and productivity-increasing advantages of an adjustable stroke press here. Related Pages: C-Frame Presses About McLoone Metal Graphics McLoone is a product identification manufacturer in La Crosse, WI. They specialize in ID plates, custom nameplates, labels, and graphic overlays for commercial and industrial applications in nearly every industry. To learn more, visit their website here. McLoone Metal Graphics 75 Sumner St La Crosse, WI 54603 Phone: 800-624-6641 Email: info@mcloone.com