Customer application 20 July 2021
Integrated MES for Greater Productivity and Efficiency

These days, almost nothing runs without energy. Plastics processor Ruch Novaplast has demonstrated that electricity can do more than just run the machines: Energy be used to optimize manufacturing with an integrated manufacturing execution system (MES).

With introduction of the HYDRA manufacturing execution system from MPDV, the fog has begun to lift for Mathias Schmälze, Comptroller at Ruch Novaplast and the man responsible for the roll-out. The acquisition of real-time data in manufacturing has enabled calculation of key performance indicators like OEE (overall equipment effectiveness) and ensures greater transparency and efficiency at production facilities in Germany and the Czech Republic. Ruch Novaplast, a mid-sized plastics company, has produced molded parts from EPS and EPP particle foams since 1960; with 180 employees, it is one of the market leaders in Europe.

Energy Management – Here’s How WAGO Supports You:

The HYDRA MES from MPDV records real-time data in production.
WAGO technology records energy consumption at every machine and forwards it to the HYDRA MES from MPDV.
This approach optimizes production at Ruch Novaplast and lowers energy costs.

The Range of Functions in the Integrated MES Solution

The basic manufacturing process is simple: Particle foam granulate is blown into the hollow cavity of a closed tool using compressed air and injector fillers. Hot water steam flows across the steam chambers and the tool to weld the raw material. The beads expand and fuse at their surfaces to form a homogeneous foam part. This is followed by additional steps for stabilizing the molded part until the finished part is finally removed from the mold by means of ejection, compressed air or handling systems.

The HYDRA MES supports Ruch Novaplast along the entire value-added chain. The incoming raw material is inspected and provided with a unique batch number in receiving. The data generated here is available later in production thanks to the central production database. Order planning is done in the ERP system, which is linked to the MES via a bidirectional interface. Through this interface, the orders are downloaded, while data recorded on the shop floor is reported back in compressed format. The operators use MES module functions, operating data and machine data for this purpose.

Integrated Monitoring and Control

Like all automotive industry suppliers, Ruch Novaplast is required to document the entire manufacturing process, including the material batches, machines and tools used. The tracking & tracing module in the MES supports them in this. Automated inspection during production is also useful; this function stores the results from the linked scale system in the MES. Faulty parts are immediately dealt with in a standardized process by the integrated complaint management. To minimize the number of IT systems on the shop floor, the parts manufacturer also uses HYDRA functions for staff time tracking, time management and physical access control. Asked about his experiences over the last few years, Schmälze explains: “The MES system is as natural and indispensable for our colleagues in manufacturing as the ERP system is for management. The HYDRA MES offers all the functions we need in order to monitor and control our production. The key productivity data is automatically generated by the MES. In just the first 24 months after introducing the MES, we were able to significantly improve our OEE index. This corresponds to a savings potential in the high six-figure euro range. The investment in HYDRA has already paid for itself several times over.”

Easy Data Acquisition in the Field

Extending the existing MES installation by adding the energy management module was a quantum leap forward. Ruch Novaplast requires both compressed air and steam during production. While compressed air is generated using a compressor, as in most factories, the steam results from water heated by a gas burner. The amount of steam and compressed consumed varies according to the shape of the item to be manufactured. In total, the energy costs account for up to 15 percent of total expenditures. Using numerous evaluations and operating figures, the HYDRA energy management system provides the foundation for recording and optimizing energy consumption.

Detecting System Errors

The less time that the employees on the shop floor have to spend learning a new software solution, the more willing they are to accept it. Therefore, a system that records energy consumption in a highly automated fashion is recommended. Ruch Novaplast met these challenges using WAGO automation technology. On each machine, an Ethernet controller, to which an I/O module with signal inputs is connected, records the steam consumption in kilograms and compressed air consumption in cubic meters. In addition, the gas consumption for steam generation and electricity consumption for air compression are recorded centrally. To simplify things, euro values are also calculated for all parameters. The steam and compressed air consumption varies depending on the item; however, a consistent level develops over several consecutive cycles, so excess consumption can be taken to signal a system fault. So, for example, a leaky valve or a crack in a line can be not just detected visually, but also recorded in the MES system, so that service can occur promptly.

Comparison, Optimization, Visualization

HYDRA uses evaluations to correlate the specific energy consumption with the machines, the job registered to the machines and the machine status. Conclusions can then be drawn as to which machine manufactures an item most efficiently and when a machine should be switched off. In particular, energy consumption in standby mode may offer significant potential for savings. Evaluations of this type are, however, only possible because Ruch Novaplast records their energy consumption in the integrated MES system. Connections between the data obtained, which enable subsequent visualization and evaluation, are already identified during the recording process.

As in other sectors, key performance indicators simplify the overview of complex connections. For example, the energy consumption per part provides information about the efficiency of a manufacturing step – assuming a target value exists. Machines can also be compared in terms of the consumption per machine hour or consumption in standby mode. However, even meaningful operating data is useless if no one is aware of it. This is why Ruch Novaplast uses context-dependent data visualization directly on the machine on the shop floor terminal, as well as general data visualization on large flat screens placed in clearly visible locations around the production hall. The transparency gained in this way increases employee awareness about their work and provides extra motivation. Ultimately, it comes down to improving a little bit every day, recognizing errors a little earlier and taking countermeasures a little more quickly.

Electrical Energy – More Than Just a Consumable Resource

Ultimately, electrical energy is not merely a necessity for a business like Ruch Novaplast, or even just a very expensive consumable resource – it is also a means to an end for optimizing production processes. As Schmälze confirms: “HYDRA energy management has brought a fresh outlook to our production halls and enables us to continue offering our customers functional solutions with added value. In addition, we are not only increasing our potential savings – we are also expanding our environmental management abilities.” Therefore, three aspects of energy management are now relevant to optimization: economical, ecological and organizational aspects.

Text: Markus Diesner | MPDV Mikrolab

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Customer application 20 July 2021 Integrated MES for Greater Productivity and Efficiency