Goals and challenges
OneBase®: Material Flow and Production Control Perfectly United
The solution for this demanding project was the introduction of ABF’s control systems, which met all requirements for automatic material supply, production control, and process optimization. The combination of our OneBase®WORLD control systems now also controls one of Europe’s most modern 40 meganewton production lines, enabling an impressive degree of full automation.
To ensure smooth Manufacturing, material provision at the right time and the right place is absolutely essential. Upon delivery of raw material, aluminum rods are transferred by forklift operators to an intermediate storage facility with multiple levels. From this point on, all material movements of the automated racking system and manipulators are monitored and controlled by the ABF transport control system. OneBase®MFT specifies all necessary transport orders and handles the optimal storage in the bar stock warehouse’s stanchion slots and the supply to the production lines. This guarantees that the correct material is always available on time at both the P16 and P40 presses.
After the raw material is provided from the automated warehouse, further processing takes place on the production line. Here, ABF’s new Manufacturing Execution System takes control. It was specifically developed for the requirements of the P40 press and coordinates the individual units in the fully automated process flow. This includes, among other things, the control of the billet saw, induction furnaces, and the press itself. In addition, downstream areas such as pullers, stretchers, finish saws, stackers, and longitudinal and vertical conveyors are monitored by the system and controlled through the coordinated specification of order and process data.
The core of the ABF system is OneBase®CoRE. It ensures communication with the integrated controls of the various systems via the industry standard OPC (Open Platform Communications). Furthermore, ABF’s Communication Real-time Environment serves as a central communication platform for all processes. This includes, among others, production planning, system visualizations, and existing third-party systems. Every individual process has access to all relevant production data at all times – this guarantees optimal workflows.
With the establishment of the new production line, the tasks of the already existing basket manipulator became many times more complex. New strategies and optimizations were required for the simultaneous operation of the existing P16 press and the new P40. Now, after each transport, the status of the systems is checked, and the next transport order is optimally generated based on priorities and planned production steps. The basket manipulator now performs a variety of tasks: It transports empty baskets to the presses, moves full baskets into the basket storage, supplies the eight heat treatment furnaces with material, integrates the P22 line, and transports finished products to the packaging facilities.
Maximum Customer Benefit – The Advantages of the ABF Solution
The transport & Manufacturing control system (Manufacturing Execution System) introduced by ABF offers numerous advantages that enable efficient, transparent, and flexible Manufacturing. It monitors, controls, and optimizes all Manufacturing processes in real-time, ensuring that all material movements and Manufacturing steps are seamlessly documented and traceable. The system ensures that every movement, from raw material storage to billet heating, the pressing process, and cutting to length by profile saws, all the way to the finished goods warehouse, is precisely recorded and, above all, automatically controlled. Complete traceability and transparency improve quality assurance and, most importantly, increase productivity.
A key advantage of the Manufacturing control system is the continuous optimization of material usage (recovery process). By precisely recording actual data, such as profile length after the pressing process, deviations can be immediately identified and necessary adjustments made. The system enables precise control and adjustment of the input quantity, thereby minimizing material waste and maximizing Manufacturing efficiency. Residual materials or rod remnants are optimally integrated into Manufacturing planning, ensuring higher utilization and lower Manufacturing costs.
Another significant point is the automation of processes. In the event of changes in production status or an order cancellation, the system automatically carries out all necessary measures to minimize production downtimes. This functions entirely without human intervention, which simultaneously significantly improves the reaction speed to unforeseen events.
In summary, the Manufacturing control system not only contributes to optimizing efficiency and reducing Manufacturing costs but also significantly improves the flexibility, quality, and transparency of the entire Manufacturing process. The automation of processes and the seamless collection and evaluation of Manufacturing data enable continuous optimization.
The partnership between Hydro and ABF contributes to sustainably increasing the competitiveness of the site in Austria.