Leveraging Modern Electronic Controls for Continuous Improvement
Continuous improvement in production performance is significantly aided by the use of modern electronic controls. These systems provide substantial data for statistics (Statistical Process Control - SPC) and enable the visualization of various aspects of the production process.
Impact on Production Operations
Until only a few years ago, these electronic tools were not economically feasible. Their availability now has a considerable impact on how a production plant is run and influences the requirements for extruders and downstream equipment. These aspects are crucial for continuous improvement in production, extending beyond purely technical equipment construction and polymer processing aspects alone.
Visualizing Process Data
Scanners, for example, previously required an electrician to make their signal visible on a scope. Nowadays, the signal is visible directly on the control screen and can be adjusted by operators. This visualization capability removes much of the frustration previously associated with this type of equipment, empowering operators. Automatic Temperature Centring (ATC) and scanners are examples of process control systems that support the operator, freeing them from routine jobs while ensuring the pipe is produced optimally. Making things visual helps provide an automatic check.
Technical Specifications
Metric
Description
Data availability
Lots of data for statistics and visualization provided by modern controls.
Scanner Signal
Visible on control screen, adjustable by operators.
OEE Calculation Example
0.9 (Availability) x 0.9 (Performance) x 0.9 (Quality) = 73% of max. production
FAQ Section
What is the role of modern electronic controls in supporting continuous improvement in pipe extrusion?
Modern electronic controls are vital for continuous improvement by providing extensive data for statistics (SPC) and enabling process visualization. This helps in analyzing performance, identifying areas for optimization, and understanding process variations.
How does process visualization benefit operators on the production line?
Visualization tools, like scanner signals being visible on the control screen, make it easier for operators to monitor and adjust equipment. This removes frustration, makes them more capable, and allows systems like ATC and scanners to support them by handling routine tasks for optimal pipe production.
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Gerrit Jan Wilpshaar
