Client: Techno Brazing, S.L.
Location: LLiçà de Vall, Barcelona, Spain
Sector: Metallurgy
Application: IIoT
TechnoBrazing offers ultra resistant welding using brazing oven welding technology. In this process it was necessary to control 2 key aspects:
- Quality: Temperature and speed of the brazing tape.
- Cost: Power consumption.
In depth analysis:
Initial situation:
A company dedicated to brazing with a 4-stage furnace needed to optimize electrical and gas consumption, increase productivity by reducing the cost per part, and increase production quality by monitoring the temperature, guaranteeing its customers the process by adding traceability. Productivity gains were achieved by addressing two key factors. Firstly, to reduce sudden temperature changes, and secondly, to reduce downtime due to maintenance.
Solution proposed:
A three-phase project is proposed to the client.
- Fase 1: Monitorización de las temperaturas de soldadura, velocidad de la cinta transportadora y monitorización general de errores. En esta fase se genera un dashboard que permite a través de gráficos dinámicos ver la información obtenida en tiempo real, pudiendo acceder a esta información desde cualquier parte con acceso a internet.
- Phase 2: Monitoring of electrical consumption. In this second phase, energy consumption is monitored to initiate consumption optimization, generating KPIs such as kW/ºC, information that also allows monitoring anomalies in the behavior of the oven.
- Phase 3: Generation of Business Intelligence and automatic quality reports. In this third phase, a set of automatic reports are generated to guarantee the quality of the manufactured parts, as well as to obtain information that allows optimizing production cycles and minimizing maintenance downtime.
- Phase 4: With the data collection, it is proposed to initiate a predictive maintenance system with Artificial Intelligence to perform the improvements automatically.
Results:
Unplanned maintenance downtime has been reduced by 70%.
Optimized energy consumption by 6%.
Manufacturing sequencing has been optimized, resulting in an 8% increase in productivity.
Preventive maintenance costs have been reduced by 30%.
- The quality standard required by customers has been achieved, with objective reports generated automatically and independently from the company, guaranteeing production traceability.