• Address: 9603 Neuens St,
    Houston, Texas 77080

  • Call Us: +1 (713) 935 0900
    sales@parijat.com

Extrusion Process Optimization System

  • 1) A Visual Extrusion and Process Optimization tool which will increase gross pounds per hour and press availability up to 10%. Focusing on:
  • 2) Consistency
  • 3) Process optimization
  • 4) Reduction of both production and maintenance downtime.

Expected results 5 to 10%. Improvement



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Major Elements / Tools

  • 1)Press Heart Beat- Production optimization through clear graphic visuals
  • 2)Visual system at the press as well as any computer on the network
  • 3)Downtime Tracking both production and equipment
  • 4)Downtime summary and pareto's
  • 5)Production Tracking and Statistics
  • 6)Billet logs
  • 7)Recipe System (consistency and conformance)
  • 8)Easily understood variance reports
  • 9)Management by exception
  • 10)Integration of Business Systems


Benefits of Downtime Management and Production History Module

  • 1) Accurate real time production and maintenance downtime tracking and analysis tool
  • 2) Focus on correcting the things which are creating the most problems (Pareto Charts)
  • 3) Accurate Real time production data
  • 4)Detailed production Data – trouble shoot problems – quality (billet exit temp, quench ) – billet logs

These Screens can be seen at the press and remotely throughout the plant and offices. Many operations have a monitor in the lobby and management offices as a visual tool to monitor production. (Hawthorne affect)



DOWNTIME IDENTIFICATION THROUGH HMI POP UP WINDOW AT PRESS

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PRODUCTION STATISTICS

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DETAILED PRODUCTION STATISTICS

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DOWNTIME SUMMARY DETAIL AND PARETOS

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BILLET LOGS

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HISTORICAL HEART BEAT AND PRODUCTION BILLET GRAPHS

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RECIPE SYSTEM

  • 1)Recipes are starting points; Operators are expected to challenge the recipe and increase productivity and quality when possible
  • 2) Consistency shift to shift with all operators running by recipe – maximizing the productivity of the press
  • 3)Increase productivity - operations have seen up to 5-10% increase in IPM, and corresponding gross pounds per hour

Unless we have the tools to measure, we cannot manage the outcome

RECIPE SYSTEM - HOW IT WORKS

At Die Change or Order Change - recipe and order information is transferred to the press PLC’s to control the press functions - examples

  • 1)When the last billet of the previous run is on the loader – the billet furnace and log shear information is pushed to the furnace and log shear PLC
  • 2) When the press stops extruding the last billet from present order, the recipe for the next order will be pushed the press PLC.
  • 3)After the puller has released the job, the quench and puller recipe information are sent to these pieces of equipment


RECIPE SYSTEM - HOW IT WORKS

Recipes saved in data base by – Press – Die – Copy – Alloy – Holes – Vendor

  • 1)Recipe search based on job (order) sent to EPOS from your ERP system
  • 2) If no recipe found:
    •   -EPOS allows operator to clone an existing recipe and then use the cloned recipe to run the order
    •   -Run the order in manual and save recipe after run


Recipe Module input Screen

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Recipe Module input Screen

Each major piece of equipment has its own recipe screen and control variables

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Recipe compliance

Main screen – left hand current and previous data - green highlight of present data point means the order is being run to recipe (both ISO Thermal and Ram Speed), Red identifies when the order is not being run to recipe

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RECIPE SYSTEM COMPLIANCE

Color coded compliance

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Business System Integration

Integration with ERP-Business System (ExtStar, EPICS, ERP)

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Business System Integration

The first table to the right Demonstrates by “Action” the steps which the operator must take to start an order today (present) compared to the ERP / SCADA system. Yellow = Manual Input by operator, Green Means Automatic from recipe system

The second table shows the steps which are required to report production in the ERP.

OPERATOR CAN FOCUS ON QUALITY & PRODUCTIVITY

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