Contact: JOE EVERETT [email protected] Beginning in this simple way helps operators, production managers and engineers learn more about their process and how to extract knowledge from the data — expertise they can apply and extend in future. CASE STUDY — REDUCING WASTE WITH DIGITAL MONITORING At one premium tool manufacturer who piloted our solution early on, forged parts were blast-cleaned and then coated, so blasting had a major influence on product quality. The business had reduced rework rates substantially using conventional techniques but realized that it needed data-driven insight to identify further improvements. For the pilot project, it digitized a Wheelabrator Tumblast machine to make real-time process data available. With its process now dashboards were created to generate and track relevant metrics and KPIs. One of the most important goals was to constantly optimize the abrasive mix which would have a major influence on blast quality, intensity, and stability. Digital data revealed regular unexplained spikes in abrasive consumption which turned out to be the rotary screen clogging due to insufficient cleaning — a simple maintenance error. Clogged screens meant the abrasive overflowed, straight into the waste. Discovering and correcting this error significantly improved process stability, cut abrasive consumption and reduced the rework rate. With real-time digital monitoring, a traffic light system alerts operators and managers if target values are exceeded. The company can now better control and stabilize its blast process — and so improve quality. The project lead at the customer said: “The operating mix has been easy to neglect because you have to go up the ladder on the machine and look inside to check the screens. When something goes wrong, you often only see it at the end; and that means rework. With one glance at the dashboard, we can see when maintenance is needed and can intervene before the blast process runs off course. We are finally driving with a clear view of the road ahead.” ARTIFICIAL INTELLIGENCE FOR BETTER BLAST MACHINE MAINTENANCE The digital tools described above are effective, but only a starting point. Their delivery platform is capable of running even more advanced digital technologies such as artificial intelligence (AI). These tools can cut shot-blast maintenance (through AI-driven early warning systems, for example) and cost. They could even eliminate unscheduled downtime entirely, making better use of scarce maintenance personnel. For maintenance-intensive equipment like shot-blast machines, this could be a game changer. Another development currently underway employs digital image analysis to monitor abrasive condition in real time. The idea: automatically recognize substandard abrasive particles to keep the operating mix at the precise optimum. This opens the door to completely automatic, digital process control. Advanced process control tools for high-spec blast processes have enormous potential, with almost no limit to the number and type of data feed they can process. From built-in AI capabilities to automatic 12 corrective measures that kick in when set values are exceeded — we are not that far away from a selfcorrecting blast process. TRANSFORM BLAST PERFORMANCE Current digital applications monitor process parameters and tackle the main shot-blast cost drivers, but there is immense additional potential for improved process control and traceability. Once you’ve digitally enabled a machine and start collecting, storing and analyzing process data, it’s easy to take the next step: add further sensors, run extra analyses or add enhanced digital applications. By finally overcoming some of blast equipment’s historic challenges, digital technology will put operators in the driving seat, give them greater control, a more modern, safer working environment and greater scope for collaboration and learning. This is vital when skilled labor is scarce: the digital system supports experienced operators, enabling them to do more, while helping to train the less experienced staff. Digital tools make it straightforward to enhance your shot blasting process. They are user-friendly and offer a quick return on investment. They don’t necessitate specialized skills; rather, they bring valuable insights and expertise to your operations. These insights have the potential to bring about a transformative and positive change in your blast operations, ultimately leading to long-term improvements in performance and efficiency.
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