evoTrQ - Component tracking

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Industry 4.0 in your press shop

Quality inspection during the forming process

Extends the possibilities in your press shop

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

Sophisticated data acquisition and near real-time visualization enable ongoing production processes to be adapted and support the development of extensive analysis potential. In this way you can continuously expand your knowledge of the entire process.

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 the production process to be actively optimized – before, during and after production in the press shop.

Supports the development of savings potential in the area of material procurement

So far, 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 operator. evoTrQ offers an empirical basis for the definition of limit values by collecting a wide range of information on the quality of the end products and making it available for analysis.

This allows tolerance limits to be determined much more precisely and potential savings in the area of material procurement to be revealed.

evoTrQ collects data and makes it available to you for analysis so that you can draw the right conclusions from it, increase the proportion of high-quality components and increase your productivity.

Proactively adapt the pressing process to changing material properties

There are a number of tried and tested solutions that can capture production and quality-related data during the cutting process. But as soon as the cut blanks are stacked or mixed, material differences can usually no longer be recognized and assigned to individual components.

With evoTrQ you can make these differences comprehensible by analyzing production data and identify changes in component-related material properties at an early stage.
The predictive component detection with evoTrQ helps to adjust system settings for the pressing process in good time to changing material properties and to increase efficiency and quality.

Creates the right starting points

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

EvoTrQ makes it possible to precisely identify affected components. With the help of collected production data, you can significantly limit the number of parts to be checked. This allows you to reduce your quarantine warehouse and save valuable working time.

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evoTrQ - component tracking - your complete solution in Industry 4.0

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evoTrQ - Dashboard

Thanks to our development work, we were able to quickly experience our evoTrQ dashboard. How fast? You can find out in this video.

Dashboards in evoTrQ are implemented as websites and are fed from the central evoTrQ backend. The advantage of this is that we can view all the information available on our servers. On the other hand, all data from the evoTrQ machine interface must also be sent to our cloud backend and back to the browser that displays the dashboard.

In this video we use a simulation program to display measurements coming from a coil cutting machine. The data is sent to the telemetry collection (an Azure IoT hub), processed and sent back to the browser. This data transfer usually takes less than 300 ms.

evoTrQ savings potential

Evopro is a system supplier and integrator and has many years of experience in the press shop environment. However, it is also clear that we are not a press plant operator ourselves and therefore do not know every detail of all press plant processes, let alone know the costs for certain processes, components or special qualifications, as these are different for each operator and are under lock and key.

The values in the following examples are assumptions and are conservatively estimated to the best of our knowledge and belief. Every reader who has a better knowledge of this should replace the values if they are wrong with values appropriate from their experience.

A direct saving potential can be determined when forming the parts in the press shop.
If you manage to precisely identify the transition between parts, e.g. in the event of a sudden change in thickness or oiling or other influencing parameters, and if the workers adjust the system correctly based on their experience, you have the following effect:

If due to changes in the material parameters z. If, for example, poor quality occurs in the first stage of a 6-stage press, then at least another 8 parts are manufactured without knowledge of this change before the end-of-line quality control discovers 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 change of material in the order € 640

Potential savings in machine time can be explained using the same example.

In the event of a quality problem, evoTrQ gives you the opportunity to take a closer look at the input material that goes into the forming process:

For some reason there is an end of line quality problem that needs to be analyzed. The system must be stopped for this, as it is not clear what the cause of this problem is. With information on changes to the material parameters and process parameters in the coil line, causes based on the material can be excluded or found more quickly.

    1. (without component identification) Assumed costs / system hour € 5,000 * 30min system downtime / order due to troubleshooting = € 2,500 / order
    2. (with evoTrQ) Assumed costs / system hour € 5,000 * 10min system downtime / order due to troubleshooting = 833 €

Savings potential per order € 1,667

About the example “ Saving of machine time “Alternatively, the loss of sales can also be calculated.

In the event of a quality problem, evoTrQ gives you the opportunity to take a closer look at the input material that goes into the forming process:

Assuming end of line, a quality problem is discovered which should be analyzed in more detail. The system must be stopped for this, as the cause of this problem is not apparent. With information on changes to the material parameters and process parameters in the coil line, causes based on the material can be excluded or found more quickly.

    1. (without component identification) Assumed price / component € 50 * 10 strokes / min * 30min system downtime / order due to troubleshooting = € 15,000 / order
    2. (with evoTrQ) Assumed price / component € 50 * 10 strokes / min * 10min system downtime / order due to troubleshooting = € 5,000 / order

Reduction of lost sales by € 10,000

Potential savings in search time for certain components in the shell or for paint.
Thanks to the identification number, which is still legible after the forming process, all parts installed in the body-in-white can be identified and linked to the VIN number:

If a complete body is blocked due to an overlooked error End of Line and the neighboring components are searched for or even a problem arises for paint and possibly also affected parts are searched for:

    1. (without component identification) Assumed costs / hour of work Quality engineer € 100 * 16 hours = € 1,600 + several locked bodies
    2. (with evoTrQ) Assumed costs / hour of work Quality engineer € 100 * 1 hour = 100 €

Savings potential per error sought € 1,500

Material savings / month:

€ 640 / order * 1 order / shift * 15 shifts / week * 4 weeks / month = € 38,400

Saving of machine time / month:

667 € / order * 1 order / shift * 15 shifts / week * 4 weeks / month = 100,020 €

Alternative approach to loss of sales:

1000 € / order * 1 order / shift * 15 shifts / week * 4 weeks / month = 600,000 €

Saving time for troubleshooting after installing the parts in the shell or even after painting:

€ 500 / error * 3 errors / month = € 4,500

The sum of the simple extrapolation shown here results in a savings potential of around 143K € (alternatively around 640K €) per month.
The saving in machine time is certainly not to be seen directly as a monetary saving. However, due to free capacities in the existing system, investment costs for a new line may be postponed.

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