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Optimized Processes

Optimized Processes

Optimized and Productive Processes

The quality of the end product sets basis for process optimization. Accurately defined requirements for the weld quality result in best optimization. The aim is to avoid over-kill, which is waste in terms of lean-principles, and to provide solutions that are suited for the task, keeping the whole production chain and economical aspects in mind.

Before a certain process variant can be selected, a number of factors should be considered: How much welding in terms of weld wire volume the products require, what is the targeted cycle time, what are the metallurgical restrinctions related to the base material type, how does the heat input effect geometry during the welding, which are most productive welding positions, what is the required quality level of welds, what risks are related to each processes etc.

PLM integration

PEMA deliveries include in-house developed software solutions required for daily operations. PEMA systems can be integrated with your existing PLM-infrastructure for the following purposes, for example:

Manufacturing Process Management:

  • use of manufacturing BOM, (Receipt, Routing)
  • use of manufacturing process data
  • pruduction planning and scheduling
  • material resource planning
  • costs

Product Data Management

  • use of CAD data in 2D/3D formats
  • base material data
  • part numbers
  • cost

Product Design

  • Concurrent Engineering possibilities

Each PEMA delivery contains a user-friendly interface which can be extented to communicate with customers' existing PLM solutions. 

PEMA Provides In-House Solutions for Production Processes

Welding

Pema offers a wide selection of welding process for the mobile machinery industry that range from TIG and Plasma welding and from Ø1 mm solid wire, pulsed MIG/MAG with low heat input and root joint welding processes to tandem MIG/MAG and multiple wire SAW welding processes. The deposit rate and welding speed window being offered is huge and capable of fulfilling every requirement.

Cutting

In some cases, it makes sense to also provide cutting capabilities for the production chain after normal 2D-plate cutting stages. The 3D-thermal cutting can be applied in groove beveling for weld joints and also after welding or bending to ensure that the product achieves geometrical tolerances, despite heat distortions caused by welding or dimensional errors caused by bending. This way, the preparation works before welding do not necessary have to meet highest demands for accuracy, since the final dimensions can be made after welding.

Handling

The benefits of fast, reliable and safe workpiece handling are obvious: The handling equipment provides higher arc-on-time, which equals value-added time in terms of lean principles for the actual processes, since changes to the workpiece orientation are done by powerful motorized movements. Handling equipment enables the use of the most productive welding position as often as possible (PA/EN, 1F/AWS). Accessibility for welds is also increased and the automation level of the welding task therefore increases too.

Transportation

Considering the whole value stream, the times between the value-adding steps are critical. The first step is to minimize change over times and get rid of the need for manually operated cranes during the loading/unloading stages. We provide in-feed/out-feed conveyors with buffers and custom-designed pallet systems for quick loading and unloading of the workstations. These systems can easily be extended to handle whole material flow inside the production system. The cleverly designed, automated transport system reduces WIP drastically, shortens the lead times and provides a constant, up-to-date-view of the manufacturing system status.

 

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