Closed loop for greater productivity

Mr. Staab, is the closed loop — i.e. using measurement and test results to optimize manufacturing processes — already a reality or still a vision of the future?

The closed loop is a proven and implemented reality in series production of all types for process control, process optimization and process control.

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In which areas/industries are you furthest here?

For large series and component manufacturers (e.g. automotive, powertrain). Pioneers included suppliers who determined the complete process, machining/tool data (offset data) and tolerance variances for workpieces, assigned them and stored and used them in a retrievable way.

In addition, a trend was determined from the actual values after surgery. Based on these findings, downtimes were optimized and event-related interventions were carried out (e.g. offset data correction after appropriate wear and tear or direct correction of the processing machines). These processes usually run fully automatically with standardized interfaces from the respective manufacturers of measuring and processing machines as well as CAQ, process monitoring and CAD software manufacturers.

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What hurdles still stand in the way of the closed loop? What are the biggest challenges for implementing a closed loop?

To define a common standard (interface and format) for corrections and initial data. In some cases, there are missing “infrastructure” process components. WENZEL Metrology is ready to fill this gap with its own standard components.

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When/in which cases is the closed loop a desirable goal? When not? Which technologies are required for this? What effort is behind this?

The closed loop is desirable for series production where consistent dimensional accuracy must be achieved. This is due, among other things, to the need to replace the parts of the same quality and class. It is not desirable when creating unique pieces or, if necessary, components to be paired.

The effort involved in carrying out online monitoring in series, for example, automatic corrections and process interventions as soon as features reach a warning line. This applies to upstream and subsequent processes.

A large part of the effort consists of connecting the corresponding devices and systems from the start to the finished product via interfaces and communication technology.

Furthermore, the nominal and current information and results of high quality must be traceable and reproducible. The possible different conditions of manufacturing processes and manufacturing environments and their influences must also be taken into account.

‍How does your company address the issue? What technologies does your company offer to enable a closed loop?

WENZEL Metrology offers its customers multiple process interfaces and integration options for all devices in its portfolio. In addition, the project teams address the entire process chain and integration, i.e. implementation, in accordance with customer requirements.

Thanks to this “know-how” and experience, the projects are then implemented using WENZEL standard tools, but these also allow them to be tailored to specific customer requirements.

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Are these always turnkey projects, i.e. individual projects? Will closed-loop solutions also be available “off the shelf” in the future? In which areas would that make sense?

No, they are not always individual projects; solutions can also be transferred, as interfaces and components that are implemented are also used in other projects. This is how projects become “series models.” Off the shelf, when the same environment can be implemented almost one-to-one at other locations and providers. In reality, it often happens that a proven closed-loop process is then mapped to other, different manufacturing processes.

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Are there practical examples in which the closed loop has already been implemented? What are the benefits for customers here?

Tools, processing machines and manufacturing processes are put together on the basis of values and specifications calculated theoretically during development.

As a result of the resulting tolerances, the process is monitored and monitored. If, for example, several production lines are linked in parallel or in succession, any necessary process optimizations can be initiated immediately or carried out automatically when results are obtained “online”.

By automatically assigning the parts to the processing machine, their tools and/or shapes, these individual operations/process stages can also be optimized or corrected or, if necessary, replaced (e.g. wear that can no longer be corrected).

After a corresponding series run time, findings from the process data results can also automatically flow back into development in order, if necessary, to adapt the theoretical requirements there in accordance with actual conditions, thus completing a closed loop.

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