In our industry also more and more customers are dealing with this issue. There is a fundamental interest in technical progress, because it is always a chance to realize an increase in efficiency in all sections. For this industry the so-called „Digitization“ is no exception.
On the following pages we would like to introduce two new modules. Firstly it is the module PCM (Production Control Module), on the other hand there is the module POM (Production Optimization Module).
It is our concern to make the know-how of LENNERTS & PARTNER that was put in these modules also accessible to you. Our support includes the conception regarding integration of the program systems to your company as well as the best care after installation by our support team.
PCM – PRODUCTION CONTROL MODULE
Back in 2017 we have already started a project with a customer in Australia to further automate the production processes in a rebar shop.
Therefore, the involved machine manufacturer developed a new concept of logistic handling to automize the bundling and tagging of the single bar marks and to enable an integrated master bundling over several machines. Based on this concept and in close cooperation the LENNERTS & PARTNER GmbH created a module which provides the necessary data for bundling and tagging on the one hand and consistently automizes the further production steps on the other.
The module PCM is permanently running in the background, supplements the manual production planning and replaces the manual downloading via barcode scan.
Machine allocation – For allocation all defined priorities will be checked and the production time for each production line will be calculated. When there is a machine breakdown or a maintenance, the bar mark items will automatically be reallocated to the next suitable production line. Also offcuts will be managed and suitable bar marks will be allocated to the respective offcut machine. An integrated machine utilization and the load distribution complete the assignment.
Prioritization – Delivery units released for production will be sorted by configurable parameters (loading date, delivery date, scheduled production date) and brought into the right order. Here also dependencies (cut and bend in two steps on different machines) will be considered. The process will be completed by a reverse calculation to find the latest production start and end for each single bar mark items.
Production units – Next the bar mark items to be produced will be combined to production units. With these production units a high flexibility can be reached and machine breakdown will be prevented. Here the size and number of production units is freely definable (e. g. 12 x 2 hours). Unlike with the prioritization here a forward calculation is made for determination of the earliest possible production start and end for each single bar mark.
Bar cutting optimization – In the module PCM the bar cutting optimization is made automatically. Here for each shearline different parameter sets (optimization parameters, bin system, stock lengths, sorting) will be used as well as different bar mark combinations will be passed. The single optimization processes can be started in parallel. To valuate the results a configurable scoring system will be used.
Master bundling – Bundles will be combined automatically from the single bar mark itmes with defined weight, cross-section and dimension. Here the logistic possibilities are considered and master bundling is made on the basis of steel diameter, machine, delivery unit and also over all machines. Features like handling of bar mark items to be bent can be specifically defined (e. g. in general single transfer, but combine parted and graduated bar mark items).
Machine downloading – In the module PCM the downloading of machine is made autonomously and continuously. So data will not be requested by barcode scan, but will be transferred automatically upon receipt of production feedback of the previous bar mark items. Of course, also in this case the cast number management integrated in the downloading is available.
POM – PRODUCTION OPTIMIZATION MODULE
Automatic master bundling – After start of the module first an automatic re-allocation of bar mark items which are allocated to inactive machines (breakdown or maintenance). Then bar mark items will be identified to be produced on a special machine. These bar mark items will be supplemented to big bundles by adding further bar mark items. Here the maximum number of bars, the maximum bundle weight and the cross section of the bundle will be considered. In the next step the remaining bar mark items will be combined in bundles.
To reduce the total number of bundles, bar mark items can be reallocated to other production lines on the basis of a possibility check made before. The maximum bundle weight depends on the settings in the subsidiary, the machine and other customer restrictions. For a homogeneous master bundling the bar mark items will be classified according to categories based on the geometry of the shape code.
Balanced work load – Based on the shift times and the individual performance of each machine an automatic balanced work load will be made. Here suitable bundles will be relocated to machines checked before. The rules for this balanced work load can be defined with separate priorities.
Bar cutting optimization – If the balanced work load is completed, the bar cutting automization will be started automatically for all shearlines. The optimization processes run parallel and use all predefined parameter sets in order to achieve the optimum result.
Bundle and machine allocation – The result of the automatic bundling will then be shown in an overview. In addition to the overview, the balanced work load will be presented in a work load diagram. Also for each shearline a summary of the bar cutting optimization will be shown and it is possible to look at the cutting lists.
Manual allocation – The user has the option to reallocate complete bundles or single bar mark items later. Here the master bundling process and possibly the bar cutting optimization for affected machines will be repeated.