Influence of the natural aluminium oxide layer on ... - ALU-WEB.DE

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EXTRUSION naces pass through this inspection stage. The heat treatment process data are recorded by <strong>the</strong> transport management system (TMS), archived, and sent on to <strong>the</strong> superordinated operational computer level <strong>of</strong> <strong>the</strong> plant for charge tracking in <strong>the</strong> context <strong>of</strong> <strong>the</strong> QA system. The checked racks are again stored intermediately and are <strong>the</strong>n taken to individual packing positions as necessary. In this area too <strong>the</strong>re has to be unrestricted flexibility: any rack can be assigned to any packing position. To be able to achieve this a hi<strong>the</strong>rto unique transport and storage system was developed. Owing to <strong>the</strong> numerous transport options and <strong>the</strong> consequently large storage area involved, a system comprising several automatic cranes was provided. The cranes operate redundantly, i. e. <strong>the</strong>y match <strong>the</strong>ir actions to one ano<strong>the</strong>r in a flexible manner. Fur<strong>the</strong>rmore, as a special feature automatic optimisation <strong>of</strong> all transport and storage movements is provided and this covers all <strong>the</strong> transport units. In practice this means that for every task <strong>the</strong> optimum procedure (shortest path, smallest number <strong>of</strong> individual movements, etc.) is sought. This takes place having regard to <strong>the</strong> system as a whole, i.e. <strong>the</strong> rack movements are co-ordinated automatically in accordance with <strong>the</strong> specified optimum. A fur<strong>the</strong>r automatic crane is provided for goods to be separated out, which are taken in special racks to Plant 2 for fur<strong>the</strong>r processing. These sections have to be re-stacked in <strong>the</strong> special racks. The same crane provides transport to <strong>the</strong> re-stacking station. The detailed planning <strong>of</strong> this area had to ensure that <strong>the</strong> floor <strong>of</strong> <strong>the</strong> shed remains freely accessible and not obstructed by transport units. This was achieved by locating <strong>the</strong> rack transport so far as possible around <strong>the</strong> edges. Full racks are transported at floor level whereas in contrast empty racks are generally moved three metres above floor level. The packing positions are located after <strong>the</strong> store areas. Here too, <strong>the</strong> packing positions can receive material automatically from any part <strong>of</strong> <strong>the</strong> store. For this, <strong>the</strong> racks are placed by one <strong>of</strong> <strong>the</strong> automatic cranes onto <strong>the</strong> appropriate roller track and taken automatically to <strong>the</strong> packing position intended. At present a total <strong>of</strong> seven packing positions are available. Each <strong>of</strong> <strong>the</strong>m is equipped with accessories which facilitate <strong>the</strong> work <strong>of</strong> <strong>the</strong> packers and help to increase packing output. The system as a whole is controlled by a central transport management system. This Automatic crane No 4 with overhead roller track for empty racks at <strong>the</strong> back system, which also assists production planning, was developed by H+H toge<strong>the</strong>r with <strong>the</strong> company Aberle Steuerungstechnik in Leingarten. At Pandolfo <strong>the</strong> new system was installed already during <strong>the</strong> first phase <strong>of</strong> project implementation, so that <strong>the</strong> areas completed one after ano<strong>the</strong>r could be integrated into <strong>the</strong> system step by step. The central transport management system records all <strong>the</strong> section racks by means <strong>of</strong> barcodes and controls <strong>the</strong>ir movements up to <strong>the</strong> storage <strong>of</strong> <strong>the</strong> packed goods. It is consequently in a position at anytime to provide information about <strong>the</strong> current position and processing status <strong>of</strong> each and every rack. This ability makes <strong>the</strong> transport management system a valuable aid to production planning. Moreover, it was decided at Pandolfo to integrate scrap transport as well into <strong>the</strong> automatic system. Any scrap produced in or arriving at <strong>the</strong> packing area, which has to be returned to <strong>the</strong> foundry, is taken <strong>the</strong>re fully automatically by a central transport system. To maximise value recovery, this even takes place after sorting into distinct alloys. Success factors: flexibility and low operating costs Already at <strong>the</strong> beginning it was stated that automated section transport through <strong>the</strong> plant – under <strong>the</strong> conditions prevailing in <strong>the</strong> work <strong>of</strong> central-European extrusion plants – has economic advantages and substantially improves <strong>the</strong> competitiveness <strong>of</strong> an appropriately equipped extrusion plant. The prerequisite for this is, firstly, that operations must take place absolutely faultlessly. For that reason particular attention is paid to <strong>the</strong> aim <strong>of</strong> ‘maximum availability’. At Pandolfo, for example, <strong>the</strong> design <strong>of</strong> a new rack type adapted to <strong>the</strong> system has proved to be a decisive factor. Before being fed into <strong>the</strong> transport system each rack is checked for damage. In this way and with a series <strong>of</strong> o<strong>the</strong>r measures, a total availability <strong>of</strong> 98.5 percent over <strong>the</strong> year, and for some parts <strong>of</strong> <strong>the</strong> plant even more than 99 percent, is achieved. The end result is that <strong>the</strong> logistical objectives <strong>of</strong> <strong>the</strong> project have been fully implemented: • automated material transport • absolute flexibility, i. e. all aggregates can freely be called into action • linking <strong>of</strong> <strong>the</strong> material flow to and from Plant 2 • automatic return transport to <strong>the</strong> central scrap collection point and <strong>the</strong> foundry, etc. The conditions set by <strong>the</strong> customer: • maximum availability <strong>of</strong> all units • no damage during transport • implementation without interfering with operations • high safety standards • unobstructed shed floor surface have also been met in full. Fur<strong>the</strong>rmore, at <strong>the</strong> conclusion <strong>of</strong> <strong>the</strong> project it emerged that <strong>the</strong> forecast planning figures are in some cases being substantially exceeded. The extrusion enterprise is benefiting from <strong>the</strong> automation <strong>of</strong> its mat flow in many ways. The rationalisation effect is directly visible in <strong>the</strong> reduced personnel needs and <strong>the</strong> troublefree operation. Transport-generated scrap, a not negligible cost factor during <strong>the</strong> operation <strong>of</strong> a conventionally equipped extrusion plant, has never yet been produced so far! Above all, however, <strong>the</strong> company is in a position to respond, with <strong>the</strong> same staff, to changing market circumstances. In <strong>the</strong> case <strong>of</strong> Pandolfo Alluminio it has proved possible in this way to increase <strong>the</strong> plant’s capacity by more than <strong>the</strong> promised 35 percent. If necessary <strong>the</strong> company is now capable <strong>of</strong> producing 35,000 tonnes a year. Should <strong>the</strong> market weaken, however, as it did unexpectedly for extrusion plants at <strong>the</strong> end <strong>of</strong> 2008, production can be adapted flexibly thanks to <strong>the</strong> lower staffing level. To what extent economy and flexibility can be increased in specific, individual cases depends on <strong>the</strong> initial situation and on <strong>the</strong> circumstances <strong>of</strong> <strong>the</strong> case. No generally valid figure can be given, for that reason. However, <strong>the</strong> projects implemented until now show that <strong>the</strong> return <strong>of</strong> investment (ROI) for <strong>the</strong> resources devoted to extrusion plant automation is not longer than four to five years. � 46 ALUMINIUM · EAC CONGRESS 2011
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Influence of the natural aluminium oxide layer on ... - ALU-WEB.DE

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