Transcript
Manufacturing Industrial Weighing and Measuring
News
Efficient Order Picking Thanks to Mobile Database of 15 000 Articles Significant time savings were made due to short order picking routes with a mobile solution. With an optional, simple control method, errors occurring as a result of confusion between different parts are prevented.
Hermle Mechanische Uhrwerke & Drehteile GmbH, based in Reichenbach, Germany, specializes in precision turned parts. They also manufacture mechanical clockworks. Clockwork manufacturing orders are made out at the storage location. This means that traveling distances can be shortened if a variety of different parts need to be picked. The article IDs and piece weights of the 15 000 parts are saved in the mobile IND690sys weighing terminal. With the SysDataManager program, article data is edited on the computer efficiently and conveniently and data loss is prevented. An article can be called up using a keyboard or barcode reader, automatically making the correct individual piece weight available for counting. Thanks to this method,
determining the individual weight based on a reference quantity, which tends to be time-consuming and fault-prone, is eliminated. A plausibility check may be carried out to check whether the actual piece weight corresponds to the saved value. During this check, the selection of a wrong article number or a wrong part from a shelf will be detected. For the purposes of identifying the picked parts, a label is immediately printed with the article ID, quantity and individual weight. METTLER TOLEDO has met customer requirements with a freely-programmable IND690sys and a PBA330-B60 scale. The rechargeable battery means a guaranteed mains-independent power supply. The whole system is installed on one carriage.
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Component Manufacturing
Customer benefits • Mobility thanks to mains- independent power supply • Short routes during order picking • No time is lost or counting errors are made when determining the piece weight • Simple data management and • backup using the computer • Optional correct part check
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Thanks to the mobile solution from METTLER TOLEDO, Hermle GmbH has significantly increased the efficiency of its order picking procedures.
Publisher Mettler-Toledo AG Industrial Heuwinkelstrasse CH-8606 Nänikon Switzerland Production MarCom Industrial CH-8606 Nänikon Switzerland Subject to technical changes © 01/2009 Mettler-Toledo AG Printed in Switzerland
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SysDataManager The SysDataManager is PC software used to manage articles, tables and configuration data of the IND690Sys weighing terminals quickly and simply.
Solid and Accurate Floor Scales Made for Shipping Departments A wire manufacturer relies on Rocker Foot suspension for floor scales in his busy shipping department where there is a high volume of fork lift traffic.
KOS WIRE EUROPE s.r.o., a member of the South Korean KOS GROUP, built a new plant for the production of stainless-steel wire in Lovosice in the Czech Republic. The company has invested EUR 21.5 million and employs 90 people at its three sites. KOS produces several types of stainless steel wire, which is particularly suitable for use in the automobile industry.
ing the pallets onto the scale while they are still moving. The sliding applies sheer forces which can destroy the load cell if it does not have sufficient protection. PFA574 and PUA579 floor scales from METTLER TOLEDO are equipped with the Rocker Foot to protect the load cell from sheer forces.
The METTLER TOLEDO service team installed two PFA574-E3000 floors scales KOS needed 4 floor scales to weigh the with a capacity of 3000kg for the heavy wire reels. The tare weight of the emp- reels which are transported by fork lift ty reels had to be set numerically. Each trucks. For the less heavy reels, which scale had to be linked to the IT System are transported with pallet jacks, they with an automatic interface. The scales installed two PUA574s with an ultra low are to be used in the busy shipping de- profile. The ultra low profile allows the partment, where there is a large number pallet jacks easy access to the scale. of fork lift trucks and pallet jacks. In such a busy environment there is an increased For more information: risk of fork lift trucks or pallet jacks slidwww.koswire.com
KOS uses the solid IND445 Industrial Weighing Terminal, with a memory capacity for up to 99 tare weights. It has an optional Ethernet TCP/IP interface to communicate with the IT System.
The PFA574 floor scale with a capacity of 3000 kg is used to weigh wire reels up to 2000kg. The loading is performed by fork lift trucks.
The Rocker Foot ensures optimum force transmission into the load cell at all times. It allows the weighing platform to be moved laterally to its safety end stops. This prevents any damage to the load cell due to lateral shearing forces which might occur when loads are forcefully loaded onto the scale. Not all commercially available scales are protected from these shearing forces.
The PUA579 ultra low profile floor scales for 1500kg. The low profile allows easy access for pallet jacks. The solid construction can withstand the load from the wheels of pallet jacks.
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Component Manufacturing
Batching of Composite Sinter Material Traceable according to TS16949 The FormWeigh.Net® batching software makes management of recipes, raw material and dosing of different components more efficient and more accurate. It guides operators, with instructions, through the process and helps to reduce mixing errors. All process steps are documented in the IT system and on a print-out for uninterrupted tracking and tracing.
A composite sinter metal manufacturer in Germany manufactures bearings with layers of self-lubricating material that require either no lubrication or lubrication only during the initial installation, and no further lubrication for more than 30 years. These bearings are used for shock absorbers, hinges, gears, pumps, valves, car seats, vibration dampers and other equipment requiring bearing materials. The customer’s commitment to the environment extends not only to lead-free dry bearing material, but also to solvent-free manufacturing processes. The innovative technologies are applied in sophisticated, state-of-the-art manufacturing and development facilities. Customer Requirements The customer was looking for a solution to make the batching process for composite sinter material more efficient. The creation of batch protocols for traceability to comply with TS16949 had to be automated. The entire recipe management process should be performed on a computer. Operators needed to be guided through the batching process with instructions on the screen of the weighing terminal in order to avoid bad batches. Each step of the process had to be confirmed after completion. The protocol of each batch had to include raw material identification, net weight of all components, date, time and identification of operator and
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all operator confirmations. A particular requirement was the extraction of a part of a liquid component at the end of the mixing procedure. This extraction also had to be fully documented. Finally, the system had to be open for future connectivity to the already existing SAP system. Solution: METTLER TOLEDO in Germany fulfilled the customer’s need for recipe management, raw material management, user guidance, tracking and tracing with the FormWeigh.Net® software. This batching software runs on the MS Windows XP® operating system. Data is stored and managed on the MS SQL Server 2005 database system. The FormWeigh.Net® software is installed on an ID30 weighing PC, designed for industrial use. The stainless steel housing meets the IP69k protection standard. This protection standard is needed, since powders and liquid components that can produce dust are mixed directly next to the ID30. The batch is weighed on a KCC150 scale made of stainless steel. It has a full capacity of 150kg with a readability of 1g. The versatile scale meets the IP67 protection standard.
FormWeigh.Net® Features and Benefits – Perfect and reliably documented mixtures (traceability) – Fast and secure processes – Ready for 21CFR Part11 compliance – Automatic potency calculation – Recording and verification of batch information – Clear, user-friendly representation of the weighing process – Prevents the loss of valuable materials Options FormWeigh.Net ® has a modular structure. The software can be adapted to the customer‘s needs. A whole line of well-coordinated modules can be individually combined.
Conclusion: The customer is confident that the company can reduce the amount of waste raw material and increase batch quality. The documentation for tracking and tracing is available, as all relevant data is stored in the SQL database. During batching, the operators are guided through the process by the clearly visible instructions on the weighing terminal.
The following FormWeigh.Net ® modules are available: – Master data management – Dispensing – Production – 21 CFR Part11 – Batch control – Active substance control – Warehouse ERP integration
FormWeigh.Net ®: Human – Machine – Interface
For more information: www.mt.com/formweighnet
The weighing screen displays the actual weight in digits on the upper part of the screen. The target weight and its tolerances are clearly displayed together with the actual weight as growing bars at the lower part the screen. The upper growing bar is the fine range for accurate dosing to the target weight. The lower bar displays the fast dosing range for efficient, yet well-controlled filling. The large orange symbol on the right hand side stands for “health risks”. It can be replaced by any other warning symbol. The blue field displays the operator’s instructions.
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Component Manufacturing
Start as you mean to go on! Our experts make it possible Immediately following commissioning, you can rely on the measurement results from your new scales. Professional installation and training by METTLER TOLEDO Service guarantees the expected measuring accuracy right from the start.
The core businesses of the ISO9001:2000 certified, Swiss-based WKK Kaltbrunn AG are punching, shaping, bonding and assembling. In each of the four areas quality, adherence to deadlines and customer benefits are the top priority. WKK Kaltbrunn AG also supports customers with engineering for punching and bending technology, meaning that the entire development process is covered from the idea, to feasibility, through to serial production. Precise delivery For the order picking of outgoing goods, WKK Kaltbrunn AG was looking for a solution to quickly count several thousand small and large parts without risk of error. METTLER TOLEDO fulfilled their requirement with a counting system consisting of an IND690 terminal, a PFA330 35kg reference scale and a PFA574 1500kg volume-measuring scale. For weighing and piece counting during production, the customer opted for a high-resolution BBK432 6kg and two PTA455-1500T palette scales with a maximum weighing range of 1500kg.
Professional installation Professional installation and commissioning has been successfully performed by METTLER TOLEDO Service. Calibration and tests for sensitivity, linearity and cornerload have been performed in accordance with DKD specifications. The service engineer has calculated the minimum weight “MinWeigh®” based on the permitted process tolerances, a risk analysis and environmental influences at the installation site of the weighing system. Maintenance of the specified precision of the scale has been confirmed at 1500kg and documented in the DKD certificate. The operators were subsequently trained to correctly and efficiently handle the weighing and counting system.
The production manager at WKK Kaltbrunn AG, Mr. Emil Diethelm, can rely on the new weighing systems as soon as commissioning is completed. He knows that the system is installed correctly. His colleagues can work with the system quickly and flawlessly from day one.
After successful commissioning, the future operators are trained by METTLER TOLEDO service engineers. The significance of the minimum weight is also explained during training, ensuring that employees, who work with the scale on a day-to-day basis, know how process tolerances are maintained.
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What is a MinWeigh® DKD calibration certificate from METTLER TOLEDO? The DKD calibration certificate documents the testing of all the important scale features (sensitivity, repeatability, linearity and cornerload) at the installation site. With the application of the ISO17025 guideline, a DKD calibration certificate from METTLER TOLEDO guarantees 100% reliable traceability to national standards and documents application-oriented measurement results and measurement uncertainties. In the MinWeigh® DKD, the minimum weight is also documented for measurement uncertainty. The MinWeigh® DKD calibration certificate is created by a fully qualified service engineer using software at the installation site.
Linearity test with ascending weights of the high-resolution BBK432 scale
The DKD certificate is a calibration certificate recognized throughout Europe. It corresponds to the UKAS in Great Britain, ENAC in Spain and COFRAC in France. These calibration certificates refer to the European EURAMET Standard (European Association of National Metrology Institutes), which governs the mutual recognition of national standards. So what is measurement uncertainty? Each measured result is met with a degree of measurement uncertainty – even if it is a high precision scale. Measurement uncertainty includes the following influential variables: Environmental conditions, temperature, operator, out-of-center load, rounding or graduation of the scale and repeatability.
Linearization with ¼ load of 475kg with calibrated and certified weights
So what is the minimum weight “MinWeigh®”? METTLER TOLEDO determines the practical minimum weight “MinWeigh®”, taking the respective measurement uncertainty, environmental conditions, risks and the process tolerances specified by the customer into account. These tolerances are defined and checked using quality management and customer requirements as a basis. Why do you need to know the minimum weight? Compliance with the minimum weight guarantees safe and reliable weighing results in the lowest weighing range. Falling below the minimum weight violates the process tolerances specified by the customer. Depending on the weighing task, this has a negative impact on product quality and safety.
Calibration with full load of 1500kg with calibrated and certified weights
The service engineer calculates the measurement uncertainty on-site using software
The easily accessible electrical installation unit enables efficient installation. The electrical installation unit has IP69k protection. This means that delicate parts are protected against any water leakages
The full load test with 1500 kg is successfully passed after installation. The scale is ready for operation. METTLER TOLEDO
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Customer benefits from a METTLER TOLEDO installation • Full load test up to 1500kg with certified weights guarantees correct and traceable measurement up to the maxi- mum weight. • Determining the lowest permitted initial weight MinWeigh® based on the required process tolerances, environmental conditions and a risk analysis prevents errors from occurring when weighing low weights. • The MinWeigh® DKD calibration certificate from METTLER TOLEDO guar-
antees 100% reliable traceability to national standards by using recognized guidelines during quality audits. • Operator training led by the METTLER TOLEDO service engineer ensures that the customer achieves the expected measurement quality from the start. CEO Michael Wenk stated: “We were looking for a solution to simplify processes for counting punched parts. When it comes to delivery quantities, our customers expect the highest degree accuracy, which we need to ensure. The installed technical solution and the installation service from METTLER TOLEDO have completely fulfilled our expectations in all aspects.“ For more information: www.wkk.ch
Do you know the minimum weight for your scale? Are you sure that your scale is measuring reliably from day one? If you have any doubts, please contact the METTLER TOLEDO service: www.mt.com/service
M ettler-Toledo AG CH-8606 Greifensee Switzerland Tel. + 41 44 944 22 11 Fax + 41 44 944 30 60
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