Author: a.manzo

Thyssenkrupp Materials Services continues to drive digital transformation: Since early 2019 an artificial intelligence solution (AI), supported by Microsoft’s cloud platform Azure, has been integrated into the processes of the largest materials distribution and service provider in the Western world. “alfred” supports his colleagues at Materials Services in dynamically managing the global logistics network with 271 warehouse sites and more than 150,000 products and services. As with his namesake – Alfred Krupp – all information comes together at alfred. As a first step, alfred will help to optimize transport routes and thus save the transport of thousands of tons of material per year. In addition, materials will be available more quickly at the right locations in the future. In the medium term, Materials Services will be able to make all processes along the supply chain more flexible, for example, in order to better take into account specific customer requirements for delivery speed, pricing or material quality.

Klaus Keysberg, CEO of thyssenkrupp Materials Services, summarizes alfred’s strengths: “Artificial intelligence is one of the technologies that will make a decisive contribution to competitiveness in materials distribution in the future. With alfred we are taking an important step towards making our processes even more efficient and optimizing our value chain. At the same time, he gives us better insight into our customers’ needs so that we can align our offerings accordingly. In the medium term, this holistic approach will also open up new business opportunities for us”.

Using Big Data systematically

With the AI, the approximately 14 million order items received annually by Materials Services can be processed and analyzed much more efficiently. For the first time, the materials experts are also bringing all company data together on a single platform. Using self-learning algorithms based on Microsoft Azure Machine Learning, alfred analyzes all relevant information, generates important findings and supports employees with appropriate recommendations: Which materials have to be assigned to which industry? Where are materials processed? What would be the most intelligent transport route to supply the customers with materials in the best possible way? What are the needs of the individual locations? “The intention is very clear: With alfred we are improving our own processes so that we can serve our customers all over the world more efficiently,” says Axel Berger, Head of Digital Transformation Office at Materials Services.

The focus is on customer benefit

At Materials Services, the digital transformation is aligned along the value chain and consistently placed at the service of customer benefit – whether directly or indirectly. “From procurement through warehousing and logistics to sales, we rely on integrated digitalization concepts. While we simplify cooperation with our suppliers in the area of procurement by means of a cloud-supported platform, for example, we create possibilities for networking internal machinery with our self-developed IIoT platform toii. toii allows us to flexibly coordinate and optimize the processes of warehousing and logistics. In sales, we offer our customers access to 150,000 products and services at 271 warehouse sites sites in the world’s largest virtual materials warehouse,” says Klaus Keysberg. As a link between all these areas, alfred fits into the ecosystem and ensures continuous optimization of speed and service quality through intelligent data processing with corresponding recommendations.

Lifelong learning with Microsoft

In the company’s own Digital Transformation Office in Essen, all strands of digitalization flow together. Here, integrated teams of IT experts, engineers and business coordinators work under the direction of Axel Berger on various digitalization projects that arise directly from the core business of Materials Services – including alfred. The materials experts were supported by Microsoft and its global cloud platform Azure. “Joining forces with Microsoft allows us to use advanced technologies for our in-house developments. This enables us to ensure that the projects are very closely linked to our core business on the one hand, and that they are technologically state-of-the-art on the other,” says Axel Berger.

“At this point in history, manufacturers need to become digital companies to lead in their industries. thyssenkrupp Materials Services is not only adapting digital technologies, they are building their own digital capabilities and portfolio to elevate their logistics business with AI services to the next level. They unlock new business opportunities by merging their industry know-how with the core of AI: large volumes of relevant data as well as strong machine learning methods and algorithms”, said Çağlayan Arkan, Global Lead Manufacturing & Resources, Microsoft.

Klaus Keysberg is also convinced of the synergies of the partnership. “The collaboration with Microsoft makes the implementation of projects like alfred much more efficient. Ultimately, it will enable us to apply our in-house developments more quickly, gather important insights there and develop new business models from them.

Lübeck, July 1, 2019. Rosswag Engineering has announced the acquisition of its third selective laser melting system from SLM Solutions. The third SLM^®280 machine delivered to their facility in Pfinztal, Germany, expands their production and development capabilities with the metal additive manufacturing technology.

A division of Rosswag GmbH, one of the world’s leading providers of open die forged products with nearly 120 years of experience in the manufacturing of 400 different metal alloys, the company has built decades of know-how in material science and combines its production expertise on SLM^® machines with a complete in-house process chain from metal powder production, design, process simulation, and printing to CNC post-processing and heat treatment as well as metallurgical testing and quality control.

As a strategic partner of SLM Solutions in the advancement of the selective laser melting technology, Rosswag Engineering also qualifies new alloy powders and parameters by combining the capabilities of their simulation software package, powder atomizer and three SLM^®280 machines. With the ability to quickly produce special metal powders, simulate build results, print tests using SLM Solutions material development module, then post-process and inspect builds in-house, the time to market cycle for new materials is reduced from months to weeks.

Using the Material Development Module from SLM Solutions, Rosswag duplicates part positioning and uses rule-based parameter variation for an automated and systematic analysis of parameter sets. After completing the qualification process, comprehensive data for production, including metal powder characteristics, process parameters, mechanical values and chemical and metallurgical material properties are available.

“At Rosswag Engineering our goal isn’t only to provide our customers with quality products built on metal additive manufacturing machines, rather to help the technology gain acceptance and expand,” stated Gregor Graf, Head of Engineering at Rosswag. “By adding a third selective laser melting system we are able to increase our production capacities and gain more flexibility for demanding material and part qualification processes.”

Hendrik Schonefeld, Head of Sales EMEA at SLM Solutions said, “Our partnership with Rosswag allows us to help customers develop small-batch and exotic alloys to meet their unique needs. SLM Solutions is focused on production applications, and our machines reflect this, however many customers need quick parameter development to prove their process before they get to that step, and the experts at Rosswag allow us to meet their needs as well, creating a full-service selective laser melting partnership for all types of customers.”

So successful is the process developed by the experts at Rosswag that the company was recently the first company certified as metal powder manufacturer by TÜV SÜD Industrie Service GmbH through their audit based on the AD 2000 Code for pressure equipment and the European Pressure Equipment Directive (PED).

About SLM Solutions

SLM Solutions is an integrated solutions provider and metal additive manufacturing partner. The company takes a vested interest in customers’ long-term success with metal additive manufacturing. Robust Selective Laser Melting^® machines optimize fast, reliable and cost-efficient part production and SLM Solutions’ experts work with customers at each stage of the process to provide support and knowledge-sharing that elevate use of the technology and ensure their return on investment is maximized. A publicly traded company, SLM Solutions Group AG is headquartered in Germany with offices in France, Italy, the United States, Singapore, Russia, India and China.b

Automation, networking and robotics are rapidly gaining ground in metalworking – and in storage and sawing technology. Storage systems and sawing machines are increasingly being integrated into a uniformly controlled material flow in which all processes between incoming and outgoing goods are fully automated – from the storage of the long goods raw material to the dispatch of the palletized finished parts. This enables users to make their production processes much more flexible and efficient, improve working conditions and significantly reduce operating costs. At Kasto, these topics have long since ceased to be visions of the future.

Whether they are in the steel trade, the automotive and supplier industry or in mechanical and plant engineering, metalworking companies across all industries have been facing increasing demands for years. Customers expect ever greater production flexibility, from batch size one to mass production. The variety of materials and sizes is steadily increasing. At the same time, quality standards are rising and there is continuous pressure to cut costs. To hold their own against international competitors, companies need versatile and efficient solutions for a wide variety of production tasks.

Kasto offers efficient raw material management through fully automated storage systems

More and more users are relying on the automation and intelligent networking of individual workflows in production and logistics. This begins with the storage of the delivered raw material – instead of the previously widespread floor or cantilever storage, companies are increasingly relying on fully automatic long goods storage systems. These automated software-controlled systems have completely convinced users with their significantly higher storage density, fast access times and maximum stock transparency.

Cassettes are usually used as load handling devices for the storage of long goods. A storage and retrieval machine automatically transports these to one or more transfer stations in line with the “goods to the next process” principle. These can be designed differently for the respective requirements, as fixed stations, for example, or in movable form as longitudinal or transverse transfer carriages. Automatic storage and retrieval is not only much faster than by hand, it also protects employees from accidents and injuries as the heavy and bulky goods do not have to be moved manually. Orders are processed at the push of a button via the warehouse control system – or directly via a higher-level ERP system to which the control system is connected via an interface.

Optimized added value thanks to the linking of the storage systems with fully automatic sawing machines

The sawing of the articles removed from storage is often the first step in processing or manufacturing. Here too, all processes are increasingly organized without any human participation. The modern Kasto sawing machines can be seamlessly connected to the raw material warehouse by means of manipulators and conveyor technology and are supplied with the required materials. Depending on how it is equipped, the sawing machine can also run by itself. Material is fed to it automatically, and an intelligent machine control system sets all parameters, such as cutting length and cutting speed, based on the job data. State-of-the-art production saws can thus carry out a variety of jobs in succession with different materials and diameters, and operate autonomously for long periods.

High performance and perfection thanks to the integration of intelligent robots

Industrial robots also have considerable potential when it comes to handling and processing finished cut parts. Depending on the production cycle, for example they can remove the sawn parts from the machine at maximum speed, so employees no longer have to carry out this repetitive task. In addition, the robots can be used with the appropriate tools to add value for deburring, chamfering, marking, centering, cleaning or measuring and testing the workpieces. The sections can be weighed, sorted by size or order, and stacked on pallets or in tightly packed containers. For complex processes with different work steps, combinations of several robots and clamping devices can also be realized with Kasto systems. Further connection to driverless transport systems (AGVs) is also common practice nowadays.

Downstream processes are relatively easy to automate with volume saws that process only a few different component geometries. The situation is somewhat different with individualized job saws, however; they have to flexibly process numerous materials and dimensions, and the greater the diversity, the more challenging it is to fully handle all the tasks. For example, the optimal selection of robot tools is important, because the robot should be able to manipulate all the objects to be handled with as few aids as possible. This reduces procurement costs, minimizes idle times and increases productivity. Users can choose from mechanical, magnetic or vacuum-driven grippers. The grippers should be as compact as possible to give the robot easy access to the cut parts. Kasto supports users in defining the optimal tools for the upcoming tasks. In regular operation, the robot then independently decides which tool is best suited for the current task. The decision criteria may be the accessibility of the workpiece or the optimization of the stacking pattern.

Industry 4.0 has long since arrived in the world of storage and sawing technology

With the right components, storage, sawing, automation and robotics technologies can be combined to form decentralized and highly integrated systems that are seamlessly integrated into one continuous material flow. The manufacturer Kasto realizes combined storage-sawing-robot systems for its customers, in which all storage, handling, sawing, marking, palletizing and bundling processes run fully automatically, from the storage of the raw materials to the picking of the sections. The big advantage here is that the entire system functions with a uniform control software, which can be connected to existing Erp systems such as Sap with only one interface. This significantly increases transparency and efficiency. With additional production machines, such as for turning or milling, the storage, sawing and robotic systems can be linked to form a fully digitalized and automatic production system that organizes itself decentrally and independently, in line with industry 4.0.

Automation and robotic support offer significant advantages for the user, who can significantly increase productivity with less personnel, since many processes are not only unmanned, but also run much faster. It is easier to compensate for staff absences due to illness, and production simply continues even during breaks or after shifts. The result is lower personnel costs and a high degree of flexibility in terms of capacity utilization. For example, companies can process order peaks much better and drastically reduce non-productive times. This also quickly becomes noticeable from a profitability point of view.

Users and their customers benefit equally

Working conditions are also improved by the automated technology, because employees are relieved of heavy, tiring and monotonous work, reducing the risk of accidents and injuries. The quality of the sawn sections is also enhanced, because the robot processes all the parts uniformly and precisely, sorts them reliably and stacks them cleanly. This ultimately benefits not only the plant operators, but also their customers.

Manufacturers of steel tubes and bars are increasingly confronted with the fact that their products must meet higher quality requirements. Tight specifications for precise outer diameters are established in the market for many years, but demands for product straightness are now increasing.

In the past, a few off-line samples were used to analyze the entire production. Important process information was lost and a complete quality control across the entire production could not be guaranteed.

With the new Bendcheck system from Zumbach, straightness, diameter and ovality can be measured directly in the production process. With an extension of the number of measuring points, head and tail bend of the product can be determined in addition to the straightness. Each pipe or bar is therefore completely recorded, measured and logged. Deviations are indicated in real time, so that the production process can be optimized quickly and profitably and unsatisfactory products can be sorted.

A customer-friendly display and control unit visualizes all important and relevant data at a glance. Measured values, statistics, trend charts and process data can be displayed clearly and conveniently. Thus, the new Bendcheck system offers a complete measuring solution for the increasing demands of the market.

As part of the fourth industrial revolution, Industry 4.0; in-line measuring systems are taking over increasingly more important roles. Also in this area the new Bendcheck system can fulfill the high expectations. The seamless acquisition and processing of measured data enables exchange with higher-level systems via communication protocols such as OPC UA and therefore making an important contribution to the digitalization of production processes.

With the Bendcheck system from Zumbach an industrial solution is now available which records and makes available all important data of a modern production.

Collaboration with Warwick Manufacturing Group Yields Synergy Effects

The recently opened Solutions Centre on the campus of the University of Warwick/UK is equipped with the latest systems for sample preparation and material characterisation. 

Buehler ITW Test & Measurement, a leading manufacturer of instruments, consumables and accessories for metallography and materials analysis, has opened a new European Solutions Centre in a collaborative venture with Warwick Manufacturing Group (WMG) with over 600 staff and a strong relation with over 1000 global companies, offering support to over 1800 SMEs through dedicated programmes. Part of WMG’s Materials Engineering Centre at the University of Warwick campus, Buehler’s new Solutions Centre aims to support academic and industrial research on various technologies ranging from additive manufacturing, energy storage, machining and processing of metallic and composite materials to joining technologies.

The new laboratory is equipped with latest metallographic sample preparation equipment, including several abrasive and precision sectioning machines, high-end grinder-polishers and a spectral analysis system for chemical characterisation of materials. Available equipment also includes Buehler’s latest hardness testers in varying degrees of automation and testing capabilities, and Nikon optical microscopes interfaced with Buehler’s own image analysis software for ideal metallographic analysis.

Dr. Evans Mogire, European Technical and Laboratory Manager at Buehler, comments: “The new Solutions Centre allows us to better address complex customer applications and/or technical requests relating to metallography and provides exceptional facilities for conducting and hosting seminars in the metallographic sector. The collaboration with WMG is a win-win relationship, offering both resident material scientists and Buehler access to latest characterization technologies for metallic, polymer, ceramic and composite materials.”

Paul Johnson, Technical Services Manager at WMG, adds: “This well-equipped microscopy, metallographic and materials preparation laboratory provides a valuable resource for the entire group. It offers us the opportunity to work side by side with a leading developer, producer and supplier providing us with leading-edge, perfectly maintained metallographic preparation and characterisation equipment, whilst Buehler can benefit by working with the very latest materials that we are developing and gain valuable insights for the further development of its product range.”

Written by:

Dr.-Ing. Jörg Wolters, Konsens PR GmbH & Co.