At GIFA 2019, DISA will reveal three radical new digitally driven innovations that move foundries closer to Zero Defect Manufacturing (ZDM).
Inspired by DISA’s unmatched experience in helping customers continuously improve casting quality, these cutting-edge ZDM solutions – the novel Trace and Guidance (TAG) concept, the patent-pending Mould Accuracy Controller (MAC) and the upgraded Monitizer – open the door to a new era of scrap elimination.
Visitors to the DISA section of the Norican Group stand (Hall 11, stand A74 – A78) will have hands-on access to both hardware and digital models so they can see for themselves how process data, real-time analysis and forensic quality control combine to help trace and eliminate scrap.
Trace and Guidance: 100% traceability for scrap elimination
“Finding the root cause of scrap can be extremely difficult,” says Per Larsen, Portfolio and Innovation Manager at DISA. “The total quality-related costs across foundries and casting users can represent up to 10% of the casting price.”
For the first time ever, foundries can gain full traceability with DISA’s ingenious new Trace and Guidance (TAG) concept. TAG adds a unique ID number to each casting to provide the missing link between individual scrapped castings and their process parameters like sand compressibility, shot pressure and pouring temperature. TAG tracking also paves the way for advanced machine-learning-based analysis of scrap causes.
“TAG tracking promises to be a major game changer for our industry, helping drive down quality-related costs to previously unseen levels,” says Larsen. “GIFA visitors will be able to explore the patent-pending TAG design for themselves in the demonstration area on our stand and sign up for exclusive news as this exciting concept is developed further.”
The groundbreaking, scrap-busting MAC
The trailblazing Mold Accuracy Controller (MAC) forms the second plank of DISA’s ZDM strategy. The MAC alerts operators to mold mismatches and gaps – causing scrap, rework and damaging melt run-through – before the mold is poured. At GIFA 2019, visitors to the DISA stand can test drive the MAC using a DISAMATIC Digital Twin (a digital simulation of a molding machine). They can change the virtual machine’s settings via a DISAMATIC D3 control panel and immediately see how those changes affect mold quality.
“Delegates can inspect a full-size MAC on the stand, then use the Digital Twin to virtually test how the MAC monitors the moulding machine’s output and helps spot any developing problems,” explains Larsen. “They will get a real feel for how operators are kept fully informed and can react to quality issues seconds after they first appear and, most importantly, before pouring the moulds.”
The MAC will be released at GIFA as a retrofit option for DISAMATIC machines with Automatic Mould Conveyors, helping more customers wave goodbye to scrap.
Turning data into value with Monitizer, the new Industry 4.0 solution
GIFA also sees the release of Monitizer | CIM, DISA’s third ZDM solution. This is the next generation of DISA CIM (Computer Integrated Modules), featuring a completely new suite of data analysis and alerting tools.
As the digital platform which collects and shares data between your foundry equipment, Monitizer keeps processes synchronised and delivers a full digital view of real-time and historic foundry data. Monitizer | CLOUD from Norican Group extends the platform, using IIo-T technology to collect, monitor, and analyse complete foundry data from one or multiple global foundry sites.
“With the DISAMATIC Digital Twin, MAC, TAG, and Monitizer, visitors can see how DISA’s disruptive digital innovations make it possible to “dive into the data” to troubleshoot problems, optimise critical foundry processes and take major steps towards zero scrap,” states Larsen.
During on-stand sessions and within the official GIFA lecture program, DISA experts will discuss how its ZDM solutions enable the data-driven foundry and help improve productivity, quality and resource utilization.