evoTrQ

Component tracking system

evoTrQ_evopro-systems-engineering-AG

Extends the possibilities in your press shop

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evoTrQ means:

  • Increase in added value
  • Reduction of defective product components
  • Improvement of the component quality
  • overall cost reduction

evoTrQ offers innovative system modules that benefit the manufacturing processes in your press shop.

Sophisticated data acquisition and near-real-time visualization enable the adaptation of running production processes and support the development of comprehensive analysis potentials. This allows you to continuously expand your knowledge of the entire process handling.

evoTrQ combines the terms Industry 4.0 and Internet of Things in a modular system and establishes the Smart Factory in the press shop. Our system collects production and process data and makes them available for analysis. This enables an active optimization of the production process - before, during and after production in the press shop.

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evoTrQ supports the development of savings potentials in the area of material procurement

  • Extension of the material tolerance ranges for coils

Up to now, tolerance ranges of the coils used with regard to material thickness have been determined by the experience and the respective know-how of the plant operators. evoTrQ provides an empirical basis for the definition of limit values by collecting diverse information on the quality of the end products and making it available for analysis.

As a result, tolerance limits can be determined much more precisely and savings potential in the area of material procurement can be revealed.

evoTrQ collects data and makes them available for analysis so that you can draw the right conclusions, increase the proportion of qualitatively perfect components and increase your productivity.

evoTrQ makes it possible to proactively adapt the pressing process to changing material properties.

  • Identification of material changes in a stack of blanks

There are a number of proven solutions that can record production and quality-relevant data during the cutting process.

But as soon as the cut blanks are stacked or mixed, material differences can usually no longer be detected and assigned to individual components.

With evoTrQ you make these differences traceable by analyzing production data and detect changes in component-related material properties early on.

The predictive component recognition with evoTrQ helps to adapt plant settings for the pressing process to changing material properties in time and to increase efficiency and quality.

evoTrQ creates the right starting points:

  • Reduction of a quarantine store
  • Easier detection of defective components

evoTrQ provides useful optimization tools for the work steps after the manufacturing process. If a faulty component is detected during subsequent processing, a considerable number of identical parts in the warehouse must be checked for similar defects, which usually requires an enormous amount of time and money.

evoTrQ creates the possibility to identify affected components precisely. With the help of collected production data you can significantly limit the number of parts to be inspected. This allows you to reduce your quarantine stock and save valuable working time.

evoTrQ Decision support

The company evopro is a system supplier and integrator and certainly has some experience in the press shop environment by now. However, it is also clear that we ourselves are not a press shop operator and therefore do not know every detail about press shop processes, let alone the costs for certain processes, components or even certain qualifications. We have invented the values in the following examples, respectively estimated them to the best of our knowledge and belief. Every reader who has better knowledge about them may replace the values with the right ones if they are wrong. We believe, however, that we have taken a relatively conservative approach with our assumptions.
A direct savings potential can be identified in the forming of parts in the press shop: If it is possible, for example, to precisely identify the part transition in the event of a sudden change in thickness or oiling or other influencing parameters and to correctly adjust the system based on the experience of the workers, the following effect is achieved:
  1. If, due to changes in the material parameters, poor quality occurs in e.g. the first stage of a 6-step press, then at least another 8 parts are produced without knowledge of this change before the End of Line Quality Control detects the problem.
    1. (without component identification) Assumed value of a complex component 80€ * 9 defective components = 720€
    2. (with evoTrQ) Assumed value of a complex component 80€ * 1 defective component = 80€
Savings potential per material change in order 640€

Savings potential in machine time can be explained using the same example:
In case of a quality problem, evoTrQ gives you the possibility to take a closer look at the input material that enters the forming process:
  1. For some reason there is a quality problem at the end of line which needs to be analyzed and the plant has to be stopped because it is not clear what the cause of the problem is. With information about changes in material and process parameters in the coil line, causes can be excluded or found faster based on the material.
    1. (without component identification) Assumed costs/plant hour 5.000€ * 30min plant downtime/order due to troubleshooting = 2.500€/order
    2. (with evoTrQ) Assumed costs/plant hour 5.000€ * 10min plant downtime/order due to troubleshooting = 833€

Savings potential per order 1.667€

Using the example "saving machine time", the loss of sales can also be calculated alternatively:
In case of a quality problem, evoTrQ gives you the possibility to take a closer look at the input material that enters the forming process:
  1. For some reason there is a quality problem at the end of line which needs to be analyzed and the plant has to be stopped because it is not clear what the cause of the problem is. With information about changes in material and process parameters in the coil line, causes can be excluded or found faster based on the material.
    1. (without component identification) assumed price/component 50€ * 10strokes/min * 30min plant downtime/order due to troubleshooting = 15.000€/order
    2. (with evoTrQ) assumed price/component 50€ * 10strokes/min * 10min plant downtime/order due to troubleshooting = 5.000€/order

Reduction of the loss of sales by 10.000€

Savings potential in search time for specific components in body shell or paint: Thanks to the laser number, which is still legible after the forming process, all parts that are attached to a car body in the bodyshell can be identified and linked to the VIN number:
  1. When a complete body is blocked due to an overlooked end-of-line error and the neighboring components are searched for or a problem occurs after paint and parts that may also be affected are searched for:
    1. (without component identification) Assumed cost/working hour quality engineer 100€ * 16 hours = 1.600€ + several blocked car bodies
    2. (with evoTrQ) Assumed cost/working hour quality engineer 100€ * 1 hour = 100€
Savings potential per searched error 1.500€

  1. Material savings per month:
    1. 1.640€/order * 1 order/shift * 15 shifts/week * 4 weeks/month = 38.400€
  2. Savings in machine time per month:
    1. 1.667€/order * 1 order/shift * 15 shifts/week * 4 weeks/month = 100.020€
  3. Alternative approach Loss of revenue:
    1. 10.000€/job * 1 job/shift * 15 shifts/week * 4 weeks/month = 600.000€
  4. Saving of time for troubleshooting after installation of the parts in the body shell or even after painting:
    1. 1.500€/error * 3 errors/month = 4.500€

The sum of the simple extrapolation shown here yields a savings potential of around 143T€ (alternativ rund 640T€) monthly.

Certainly, the savings in machine time cannot be seen directly as monetary savings, but these additional investment costs for a new line may be postponed because the existing line has capacity for additional parts.

 

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