Manufacturing Newsletter 9
Contents
1. Reduced Waste by Half with Smart Weight Monitoring The Swedish Company Sandvik manufacturers advanced products based on expensive A in tungsten carbide In order to eliminate costly waste the consumption of tungsten carbide v needs to be precisely monitored and weighed METTLER TOLEDO s dosing and J 05 j counting solutions helped the company to optimize material flows and costs in production The Swedish Sandvik group plays an im portant role within numerous industrial sectors in regard to the production of various advanced products like hot roll ing rollers teeth for circular saws or gas kets The group has different production sites and manages the entire set of pro cesses from producing the raw materials to manufacturing the finished product The Sandvik site in Epinouze France fo cuses with more than 100 employees on the following two activities wearing parts production for the aeronautics au tomotive and agri food industries as well as rotary knifes for markets associated with hygiene products Complex raw material handling All the Sandvik products that are manu factured in Epinouze are based on tung o Po o Oop Sog i i i oe sten carbide a material with numerous mechanical properties and a price ta has risen significantly over recent years a With several tons being consumed each week managing the material itself along with the transformation of the material and any reje2. Minimum Weight Certificate are two important quality documents that will preserve you from rejected lots customer complaints or failed ISO audits Recalibration and verification During operation the scale will be ex posed to dirt rough operators and all sorts of disturbances that will affect its performance over time So how will you know today that your production will meet all your quality standards For this purpose you will perform a series of sim ple routine tests that will confirm you that the scale you are going to use will effectively perform to the level expected However depending on the level of toler ance and risk of your process you will need to recalibrate your scale at a regu eeen METTLER TOLEDO Standard Calibration Certificate rer m aikoisi Sii Ba mii ee For more information on calibration Visit gt www mt com ind calibration lar basis A trained technician will then verify that the scale fulfills its factory performance and proceed to any adjust ment on an as need basis A combination of simple routine tests and regular recalibration will ensure that your daily production fulfills all your quality requirements For more information regarding the rou tine test and their frequency visit gt www mt com gwp and play the video on Good Weighing Practice ib am m F Mi a re ie DE eT Lee BH Lee ees arr fapleewee fee ee ged leone rt
3. able to put together orders that involve very small products which in some cases weigh less than 1 4 grams as well as much larger products where weight dispersion is a significant factor Some bags were being sent back to us because a tiny connector was missing a part without which the electrical unit could not be assembled properly he adds Integrated weighing solution to avoid errors Mr de Baudus who was already familiar with METTLER TOLEDO because of its counting scales decided to contact his regional commercial engineer Manuella Page about the problem In view of the low weight of some electrical compo nents the solution had to be able to IND690 weighing terminal connected with KA15s 15 kg x 0 01 g weighing platform under the conveyor belt ensure an optimum level of precision Naturally I proposed a KA15s platform with a weighing capacity of 15 kg and 0 01g resolution combined with an IND690 weighing terminal explains Manuella I also suggested that we add a barcode scanner to make it easier to identify the bags and improve the trace ability of operations she adds The weighing system which was perfectly integrated into a belt conveyor has been providing operators with 100 satisfac tion for more than a year Thanks to this installation only non standard bags need to be checked manu ally and this results in higher levels of productivity As a result complaints about incomplete bag del
4. and external keyboards for quick data entry Versatile product portfolio The terminals are available with or with ICS449 terminal with full colored graphic display colorWeight colorWeignt METTLER TOLEDO Newsletters 1 2012 out numeric keypad and big graphic TFT or LCD display Select from a broad port folio of weighing platforms from 3kg x 0 01 g up to 12000 kg floor scales gt www imt com ics scales 10 Save Resources with the New IND78Qbatch Terminal With rising raw material prices reducing waste and eliminating mis takes becomes more and more essential The IND78Obatch terminal saves resources by controlling your batching processes automatically or by guiding the user through manual processes Batch processing requires a control solu tion that manages not only recipes but also weighing scales valves and order management The new IND780batch terminal offers a solution for all these requirements and improves your pro cesses Automatic control The IND780batch terminal is very flexi ble and supports 999 material paths and 28 automatic material feeds It can control automated processes material feeders or valves making sure that the material flow is constant as well as other auxiliary equipment Additionally the terminal provides conditional control tasks go to commands and timing functions Manual control If your application does not include inte erated automation the IND780batch supp
5. 2 9 Reduce Eyestrain and 2 Speed up Production Counting and checkweighing can be exhausting tasks as operators need to concentrate on working fast and weighing accurately The new ICS series of compact weighing terminals is designed to improve operator productivity Profit from a large bright color display QL with colorWeight functionality user friendly menus and various connectivity options The colorWeight functionality causes the display to appear in different colors METTLER TOLEDO according your specifications Green can be used to indicate that you are weighing within specification while red indicates under filling and yellow overfilling Or you can specify which color you want eS to allocate to which status The color Weight display technology reduces eyestrain as the human eye can respond to a color much faster than it can read and interpret a value on a screen The terminals are equipped with freely de finable softkeys providing quick access to the key functions speeding up the work ing process ICS669 terminal with bargraph showing the actual filling status Built for industrial environment The ICS terminals are dust proof and METTLER TOLEDO S440 built robustly for the use in harsh indus trial environments An integrated battery case makes the terminals mobile The various interface options allow the connection of barcode scanners for fast article call up printers for easy docu mentation
6. a readability of 0 0001 the X Platform offers range and accuracy optimal weighing 0 001 deviation can make a difference in quality In the production of parts for laptops even the smallest weight deviations of 0 001 can indicate shaping errors insufficient coating incompleteness or a wrong density In order to guarantee the quality of your products wrong parts can automatically be rejected with the help of integrated high precision weigh modules The weigh module capacities range from 120 g to 6100 g with a read ability from 0 1 mg to 0 01 g X204 X404 the Accurate Weighing Sensors 200 g 400 g x 0 0001 g METTLER TOLEDO Newsletters 1 2012 WMS High Precision Weigh Modules 120 gx0 0001 g 6100 gx0 01 g High performance demands quality equipment Golf balls golf club parts and tees need to be counted and their quality must be verified during production so the player can perform well during the game The BBK4 series of compact scales offer the unique high precision MonoBloc tech nology which maximizes the accuracy of results The capacity ranges from 0 61 kg up to 35 1 kg The scales have a readabil ity from 0 001 g up 0 1 g These compact scales offer simple weighing counting filling and checkweighing applications all in one BBK4 Series High Precision Compact Scale 0 61 kgx0 001 g 35 1 kgx0 1 g Continued good customer relationship Precisely controlling the completeness of modules is key
7. cts is a mammoth task That s why weight monitoring has a role to play throughout the entire production process explains Damien Gendron Head of Production at the Sandvik Epi nouze site Material control by weight It all starts when the barrels of tungsten Fi carbide powder arrive from the Sandvik powder production site in Grenoble France The barrels which usually weigh 100 kg are identified by bar codes and are then sorted by grade and according to batch number An initial weight check is then performed After that the powder is sent to a mechanical or isostatic press When the powder comes back a second weight check is always carried out to de termine the residual weight and monitor the exact quantity of powder used The quantity of powder dispensed to the press is also measured by weight to ensure the correct amount A brand new METTLER TOLEDO station has just been installed We have always had a METTLER TOLEDO terminal and this has now been in use for more than 25 years explains Mr Gendron Therefore we decided to con tact our regional commercial engineer at METTLER TOLEDO J rome Jarrier with a view to modernizing the existing installation he adds Accurate dosing to the gram Now an IND690form terminal that al lows the powder to be dispensed in a feed Robotic press equipped with a WMS high speed precision weigh module Publisher Production Mettler Toledo AG MarCom Industrial H
8. duction through weighing e Explore how weighing helps you to comply with industry standards e Learn about the system inte gration options provided by METTLER TOLEDO scales Get your own free Automotive Weighing Guide now gt www mt com ind automotive guide www mt com ind manufacturing s USA USA USA Mettler Toledo LLC Mettler Toledo Hi Speed Mettler Toledo Safeline 1900 Polaris Parkway 5 Barr Road 6005 Benjamin Road Columbus OH 43240 Ithaca NY 14850 Tampa Florida 33634 Tel 1 800 523 5123 Tel 1 800 836 0836 Tel 1 800 447 4439 For more information Canada Mettler Toledo Inc 2915 Argentia Road Unit 6 Mississauga Ontario LN 8G6 Tel 1 905 821 4200
9. e METTLER TOLEDO fags Lol eee eed ed ee ee ee ae ee r eg hoon Ga ee ee ee ee ee ee ee ee ars wns ee ee L Lorin mnr a ee ee epa eee ee ee ee BL IJ Se Be es ae Fi ee ee See Se ee ee ee a a commen Tne Geen econo emetic coo iMenion onc moe Gomes comm loom emcee Gimli oni om Kiem NER eT ee ee ee A ee eee F ee ee boim ee bry e i For more information on the Minimum Weight Certificate visit gt www mt com minweigh METTLER TOLEDO Newsletters 1 2012 7 Smooth Goods Flow with Smart Warehouse and Logistics Solutions To ensure quality products goods need to be checked before during and after production Errors can occur over the whole supply chain Whether the raw materials you receive have deficiencies or the deficiencies are created during production any type of out of spec end product will decrease your productivity Regular weight checks throughout production can help to minimize errors and improve production Fast Goods Receiving Fast accurate weighing Ensure that your suppliers are meeting all of your specifications Using a floor or bench scale to verify incoming goods received you can count or weigh your raw materials to verify inventory No matter how big or heavy the incoming goods are the right weighing systems can weigh almost everything in a split of a second According to your needs and environment different compact scales terminals and platforms can be combined g
10. erations scales keep track of stock movement and assure flawless storage of goods Article data can be stored in the scale s internal database or exter nally on a PC Product article information e g average piece weight tare weight can be easily called up with an integrated barcode scanner The database can be imported from or exported to Excel Various interface options such as Ethernet RS232 Bluetooth WLAN Profibus DP or DeviceNet allow communication with other IT systems e g SAP warehouse systems or directly with a conveyor belt or alarm lamp Stock under control Smart inventory scale solutions survey inventory level remotely Integrated shelf scales transfer data to warehousing systems for efficient and transparent ati atl i bi i goods control gt www mt com remote inventory 5 ee ig Reliable Packing systems Save time with automation Parts required for assembly can be precisely counted or rapidly checkweighed for quality control Semi automated counting solutions ensure flawless packaging during production Efficient counting at the end of a production machine requires a high degree of automation Using digital 1 0 METTLER TOLEDO scales can control conveyor belts sound or light alarms and redirects material flows Right parts fall automatically in a box or container a light alarm goes off when the target count is reached informing staff to remove full containers METTLER TOLEDO Newsletters 1 201
11. euwinkelstrasse CH 8606 Nadnikon Switzerland Subject to technical changes 02 2012 Mettler Toledo AG Printed in the USA METTLER TOLEDO Newsletters 1 2012 Inspection of the tungsten carbide barrels on arrival hopper for small parts production has been introduced High precision dis pensing when the powder arrives at its destination is critical to avoid the prob lem of weight dispersion particularly in the case of small parts That s why I proposed an IND690form terminal with a 12 kg platform that is accurate to the gram adds J r me Jarrier The com pression phase represents a crucial phase of the production process as it involves a high level of industrial risk By introduc ing a system for monitoring material verry F p consumption and production times the reject rate has been halved in the space of two years In addition to this installa tion weighing also plays a role within the context of a robotic press The press features an integrated WMS weigh mod ule that enables highly precise and fast weighing of small parts that are moved by an articulated arm If the weight is not within the set tolerance limits all you have to do is readjust the quantity of material being used by the press High performance thanks to monitoring rejects Following compression the tungsten carbide parts are then baked which causes linear shrinkage of around 20 They then undergo surface machining wi
12. iveries have fallen dramatically Reliable detection of missing items from bags thanks to the KA15s high precision weighing platform Calibrated Trusted It is common wisdom that any instrument and particularly a scale shall be calibrated before its first use But is this sufficient Shall recalibrate my scale How frequently How And why If you are working in a regulated indus try you may have asked yourself these questions a thousand times You may have heard some of the usual answers But do you really believe what you heard Here is more information for a con scious user The benefits of calibration When leaving the factory a scale has been verified and adjusted for an imme diate use in an optimal environment However it is impossible to anticipate the conditions in which the scale will oper ate Think of a working environment with large temperature changes wind draft vibration from rotating equipment etc An initial calibration will document the effective performance of a scale with in its effective operating environment At that time a calibration certificate is is sued Sometimes a Minimum Weight certificate is issued as well This certifi cate will document for which weighing range from minimum to maximum the scale will deliver results in the accu racy corresponding to the tolerance re quired by your process and taking into account all the process risks The cali bration certificate and the
13. n feature Interfaces RS232 RS422 and Digital Input and Output DeviceNet Profibus Profinet IO and EtherNet IP with accessory Power Supply 10 to 29V DC lt 4W in operation Accessories Fieldbus modules DIN rail connection modules for control cabinet cables Communication Direct connection to PLC or control system METTLER TOLEDO Newsletters 1 2012 3 i R Accurate Weighing and Counting from Img up to 300 Tons Ee i N Ul fr C Whether you are producing the smallest gears of a clock or products as large as an airplane high quality N A i production demands reliability and accuracy A chain is only as strong as its weakest link therefore it is important to verify that all of the items that you manufacture are correct and complete every time METTLER TOLEDO s weighing solutions help you to sort out improperly manufactured products accurately count or verify end product quantities and efficiently determine weight for quality reasons Benefit from accurate weighing and counting from Img up to 300 tons Tiny parts accurately counted Even the smallest pieces such as gears in a watch can be measured and counted exactly These tiny pieces can barely be seen with your eye but can be counted exactly with high performance X Plat forms Used as a sample scale even parts with a 0 lmg weight are counted with high reliability With capacities from 200 g or 400 g and
14. orts processes where an operator can add material manually The IND 780batch will guide the operator with instructions on the display through the manual batching process eliminating human errors and costly re work Specifications Up to 1000 recipes can be stored in the terminal The terminal then precisely controls the mixing process according to the stored recipes Both vertical and horizontal applications can be managed The IND780batch does not need a PLC or DCS connection as it provides a fully integrated batch control solution itself For easy article recall and when track ing and tracing matters a barcode scan ner can be connected to the terminal An included PC configuration tool al lows easy management of batching data on the computer It can be used for as many IND780batch terminals as you like gt www mt com ind780batch IND780batch Terminal METTLER TOLEDO Newsletters 1 2012 11 Race Car Drivers Aren t the Only Ones Who Focus on speed To be productive and guarantee high quality products your operation needs fo be both fast and precise like mechanics in a pit stop Discover smart weighing applications used in manufacturing automotive parts and increase your production performance Read the free Automotive Weighing Guide and profit from expert knowledge e Discover different weighing applications used in manufac turing automotive parts e Learn how to improve quality and productivity in pro
15. precise documentation fo reduce the risk of non compliance gt www mt com service METTLER TOLEDO Newsletters 1 2012 5 Precise Packaging of Orders The Alombard site produces all kinds of electrical components Pictured here flush mounted boxes Error free Order Packaging of Light and Heavy Components Schneider Schneider Electric Alombard produces both very light weight products as well as large heavy electric components When packaging orders the challenge was to accurately count heavy and small components at the same time To avoid missing parts or overfilling METTLER TOLEDO suggested a reliable weighing system integrated into the conveyor system The France based company Alombard established in 1929 in Saint Pryv Saint Mesmin has been part of the Schneider electric group for around a decade Around 150 employees develop a whole host of electrical equipment electrical connectors flush mounted boxes and devices for the connection of luminaries etc The site is mainly responsible for supplying the group s logistics platform which supplies its French customers Giv en that almost 1200 parts are produced per hour product deliveries have to be very precisely controlled Prompt order fulfillment We wanted a solution that would im prove our packaging station for bags of electrical components explains Marc de Baudus Methodology Engineer at METTLER TOLEDO Newsletters 1 2012 Alombard We have to be
16. t Www mft com compact scales gt www mt com bench scales Smart piece counting Counting scales determine the number of pieces in a box or container and allow reliable inventory checks in no time gt www mt com count shipping of Final Products Correct order fulfillment METTLER TOLEDO weighing solutions help to ensure that your customer orders are accurately filled with exactly the right number of pieces and products on time and with the required labels and documentation METTLER TOLEDO Newsletters 1 2012 Easy pallet weighing Heavy loads can be quickly weighed with rugged METTLER TOLEDO floor pallet or low profile scales Platforms are avail able in various designs and capacities up to 12 tons For more comfort ramps can be added mobile platforms are available and various terminals can be attached Benefit from easy to use applications such as piece counting accumulation of weights or counts checkweighing or filling gt www mt com floor scales Proper labeling according to your needs Correct industry standard labeling is important when shipping goods METTLER TOLEDO provides tailored printing solu tions meeting the demands and standards of your customers Design your own custom printouts e g with pictures barcodes cus tomer logos with the help of our system specialist gt www mt com industrial printers Efficient Warehousing Fast and secure connectivity In warehouse op
17. th a diamond grinding wheel There is now a dedicated weighing platform for monitoring rejects In due course this task will be handled by each operator These operators will be able to deter mine the number of rejects thanks to METTLER TOLEDO counting scales that Rejects checking with a BBK high precision counting scale are located directly on the production lines The performance of our site depends on our ability to monitor production times and obtain a precise picture of the material quantities con sumed For us weighing is absolutely crucial That is why all the METTLER TOLEDO weighing equipment is subject ed to an annual inspection by the local technician concludes Damien Gendron WMS High Precision Weigh Module SANDVIK Las Know how Free Webinars Register for the free Best Practice in Piece Counting webinar and profit from expert knowledge gt www mt com us counting webinars Piece Counting What Counts for You Solutions from the Expert MET E i Get your own free copy of the piece counting brochure and profit from industry know how gt www mt com ind counting brochure Easy to integrate due to very slim design and off center position of load plote Available with and without internal calibration Capacity 120g 6200g Readability 0 0001 g to 0 01 g G Scale Material Stainless steel Load Plate Material Aluminum Chrome plated Protection IP54 IP66 with wash dow
18. to maintaining quality Shipping the right quantity of parts is critical to continue the good customer re lationship within the broadly networked supply chain of the automotive industry K line high precision platforms offer a weighing range from 3 3000 kg and a wide variety of platform sizes and termi nal options which can be tailored to meet individual application needs i a K Line High Accuracy Bench and Floor Scales 3 kg x 0 01 g 8000 kg x 10g Fly and drive in comfort and safety Weight compliance of vehicles such as a car or an airplane can be crucial to drive or fly in comfort and safety METTLER TOLEDO provides weighing solutions for even the largest and heaviest products For example if you needed to weigh an entire airplane METTLER TOLEDO could produce a custom solution using heavy duty weigh modules Reliable load cells and weigh modules are available in various sizes capacities and resolutions Reliable Weigh Modules and Load Cells 110 kg 300 t up to 10000d resolution depending on model Best Practice METTLER TOLEDO Service includes e Precise installation and set up e Equipment qualification e Calibration according to Standards e Preventative maintenance Our global service organization delivers the following key benefits e Properly maintained equipment ensuring uptime and performance e Simplified compliance with industry specific standards and regulations e Clear and
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