Industry 4.0

Today, Industry 4.0 is generally understood to mean the interlocking of industrial production with modern IT and communications technology. Applied to the window manufacturing industry, this means: integrated production with a high degree of automation and digitalization as well as technical assistance and information transparency.

A good data basis is indispensable

The basic prerequisite for increasing automation is digital interaction on the basis of a good data basis. The employed software must make digital processes transparent and assume the role of a higher-level control center. Only a higher-level software solution is able to generate the appropriate machine data from the recorded orders - the basis for any automation. But, of course, the possibilities of modern software solutions with regard to digitalization and integration go much further, because there are almost inexhaustible digital integration variants. Examples include integrated delivery logistics or production and material logistics.

In today's paperless production, the necessary production data is made available on monitors at every workstation as a matter of course. In the production line, the work and target times can be displayed digitally at each processing station. The factory production control can also be integrated into this process. At the same time, all processes are digitally documented.

Focus on production

The software solution also makes an important contribution to technical assistance, because it maps the entire spectrum of window technology. It provides all information relevant to production monitoring such as production statuses, feedback on production progress, target/actual deviations or statistics.

This so-called control center technology reliably integrates workstations with machining centers. This does not only improve the information flow in all directions, but also makes processes transparent and shortens reaction times.

The right materials at the right time

At the same time, the use of an ERP software solution creates the prerequisites for integrating production with materials procurement and for ensuring just-in-time deliveries and replacement purchases. Dealers can digitally transmit their production orders, which are then automatically taken over into the system. The production status can thus be tracked in real time.

Last but not least, digitalization leads to an increase in productivity and, at the same time, makes processes transparent. Digitalization offers enormous opportunities to companies to open up new fields of business or services. One example is the integrated chip, which automatically signals maintenance and setting intervals.

"Today, it is important not to miss the opportunity to get into this technology. Once you have started implementing Industry 4.0 and digitaliization, you can develop this topic further according to your company's requirements through the rapid return on investment (ROI)," explains Gerhard Ebert, founder and CEO of 3E Datentechnik.

3E-LOOK in practice

A practical example: The continous path controls of the established machine manufacturers can be easily controlled via 3E-LOOK. In this case, all elements are categorized and distributed automatically by the system to the various workstations for further processing. At the workstations, a scan is performed to determine which tasks are to be carried out. This feedback can trigger completion reports, shortfalls or defects, which can be transmitted within the entire IT organization.

As soon as the work at a workstation has been completed, the element is scanned back into the path control system. The feedback messages (they can be sent in the form of an e-mail, a comment, in a live chat or as an automatic message) always provide information about which order is currently at which station.

This information can even be viewed for individual positions and workstations. When combining sashes and frames, for example, the 3E-LOOK buffer management, by simply scanning, can display the sash compartments. This makes work easier, as there is no need to search for the sashes and to lose precious time.

Full automation

If a glass sorting system is used, the glass can be stored in the sorting system via the production controlling. Possible glass defects can thus be detected at an early stage. Of course, it is possible to immediately generate a glass order by making use of the functionalities in production controlling. Stored glasses are requested by a simple scan at the glazing line and automatically transported. The automatic glazing takes place automatically after activation. Finally, the finished elements are transferred to the order picking system and managed and dispatched via the shipping logistics.

Another practical example: The automatic order management for a customer's glass warehouse is handled completely with 3E-LOOK. The customer is now able to operate his warehouse fully automatically without personnel. This technology reduces the glass breakage rate to almost zero.

Glasses are ordered online via the FTP server. After the order has been placed, storage is announced in the incoming goods department. Once the glass manufacturer has delivered the ordered goods, storage takes place fully automatically and without personnel. The process is completed by signaling "Glass cart stored". When the material is needed for production, the goods issue announces the delivery of the desired quantity. Again, transportation from the warehouse to the next workstation, where further manual processing takes place, is fully automatic.

(Source: Glaswelt 11/2017)