CPT International 02/2019

ENGINEERING OF FOUNDRY PLANTS
Figure 2: The simulation model of a
production plant.
the processes within it, must be expanded
and adapted to achieve the goal of
an efficient factory. In this regard, it is
also vital to constantly keep up with all
the new and relevant developments
and, if necessary, implement them. The
following tendencies can be seen in
individual corporate processes:
Sales
The age of digitalization opens up new
possibilities for sales because the focus
is on individual customer requirements.
Central data management plays a major
role in core tasks – such as the registration
of enquiries, costing, and the preparation
of offers – by centrally and
digitally administrating all the important
customer and product data, and
enabling consistency of the information.
It is therefore possible to offer
customers tailor-made solutions whose
details are adapted to their specific
needs. The use of product lifecycle
management systems also provides
further advantages.
Material procurement and storage
The monitoring of warehouse capacities
and stocks, as well as the associated
material planning and procurement,
can change fundamentally and also
affects supplier management. Material
lists can, for example, be generated
using existing 3-D models of the components
and variants. An intelligent and
automated stock monitoring and ordering
system shortens delivery times and
procurement processes. Fully automated
storage systems and automated guided
vehicles are increasingly being
used, saving space and time – and thus
costs.
Production
Digitalization enables the automation
of many production processes, the comprehensive
tracing of products, and the
allocation of certain post-processing
steps. More and more processes will in
future be monitored and evaluated via
sensor or radio-frequency identification
(RFID). Errors and defects can be more
rapidly detected and corrected by
means of monitoring during production,
with the aim of minimizing production
problems and downtimes.
Interdisciplinary processes
In addition to the core processes of molding,
melting, casting and machining,
there are interdisciplinary processes
that are positively influenced by digitalization.
These include, for example,
pattern construction and storage, an
area that is subject to high customer
requirements. Storage and transport
can be supported by automated logistics
and intelligent component tracing
in order to increase process transparency.
The state-oriented maintenance
(condition monitoring) of plant technology
is also being used increasingly in
foundries. It is very important to be
able to predict a breakdown before it
happens – damaging the plant technology
and causing long downtimes – particularly
with automated processes and
interlinked plants.
Work preparation
Pattern designs are created during work
preparation, followed by material
requirements planning and, on this
basis, process planning including
machine utilization. The use of new
technologies such as planning in 3-D,
simulation tools (Figure 2) and virtual
reality allows process and value stream
analyses to be carried out before initial
operation. This enables an examination
of work stations and their safety, as
well as comprehensive planning and
documentation, to be carried out
before implementation.
Figure 3: A three-phase model is
used in factory planning.
22