Simple Solutions That Work! Issue 6

Foundry managers are constantly challenged to do more with less; do it faster and cheaper, and improve quality – all the while doing it safely. Oh, and these requests are normally accompanied with fewer staff and decreasing budgets. This article will explore how implementing advanced control techniques can help foundry managers meet their process optimization goals. Using advanced control techniques has been proven to be an effective tool in optimizing operations, reliability, and quality. Even newer techniques that integrate predictive analytics can provide higher uptime reliability and reduce operating costs. When foundry equipment breaks, the result is clear; production comes to a grinding halt and the personnel necessary to resolve the issue might not be readily on hand. As a result, companies are faced with unplanned downtime until the problem is resolved, potential overtime wages for the necessary personnel, along with the increased costs of rushing critical part shipments and more. When considering any new production equipment, automation and control techniques should be thoroughly examined. The foundry operations team should identify goals and work with your equipment manufacturer to implement effective control techniques that work to meet and measure your goals. Implementing a well thought out automation and control platform early in design will help the foundry meet the obvious optimization goals with nominal additional cost. Consideration to adding advanced control features to existing equipment should be looked at closely too, but realize this may come with higher costs and downtime that may not meet certain goals. The process control in modern foundry equipment is most commonly provided in programmable logic controller (PLC’s). Furthermore, the maintenance departments in many foundries have electrical specialist’s that are fully trained in programming and operating PLC’s. In most cases, standardized control packages are included by the OEM that offers simple interface with the machine. The programmed logic normally operates the machine without any input from the operator. This provides a high JERRY SENK President EQUIPMENT MANUFACTURERS INTERNATIONAL, Inc. ARTICLE TAKEAWAYS: 1. Understand your vendors’ standard and optional supply for advanced control features 2. Nominal increase in capital cost will be quickly realized in lowering on-going cost of ownership and improved profitability 3. Next generation ‘predictive analytics’ maximize profitability, satisfaction, and safety SYSTEMS INTEGRATION 20 PROCESS OPTIMIZATION WITH ADVANCED CONTROL TECHNIQUES