Providing Integrated Solutions
During the planning of a factory’s layout and manufacturing processes, the integration of process automation solutions and software at an early stage maximises cost and time savings for the customer. Rockwell Automation, a global leader in the supply of industrial automation power control and information solutions, is collaborating with German company TTC (Technical Tire Consulting) in order to do just that – deliver reduced integration costs, optimised capacity availability, safe product quality and ensured traceability. When Tyres & Accessories met with representatives from both companies during February’s Tire Technology Hamburg exhibition, they explained exactly how tyre industry customers stand to benefit.
“TTC offers strong tyre manufacturing and development expertise – the consultancy offers customers complete solutions for producing tyres, including support for developing new production lines,” says Claus Biernoth, EMEA Business Development Manager Industry Solutions, Tyre, Rockwell Automation “The consultancy’s entire team comes from a tyre industry background, covering all areas of tyre development and manufacturing. TTC is collaborating with Rockwell Automation in a pilot project, the building of a complete tyre factory for a customer. This project involves all stages including plant design, layout, designing processes, layout of machinery.”
This project is planned to be followed by others of a very similar nature. TTC business manager, Dr. Helmut Kreuser, points out that the solution TTC and Rockwell Automation have developed together can be applied the future projects. This is good news for the numerous industry newcomers, particularly in the growth area of China and Asia. Many of these companies, Claus Biernoth points out, have not had the time or experience to develop the bench strength they need. “Some new customers have no wealth of process knowledge, so they rely on OEMs. TTC supports this knowledge,” he says.
Everything from mixing to final finishing is contained within the Rockwell Automation/TTC package, including materials handling equipment. It is “almost a complete tyre production facility in a box”, notes Biernoth. The plus for a customer opting for such an arrangement, adds Kreuser, is obvious: “The clear benefit for customers is that the package we provide can be implemented more quickly and the final product is more efficient and powerful as everything is integrated. Efficiency and time to market are seen as a key for the future.”
Rockwell Automation’s strategy is to utilise integrated technology in its solutions, from the smallest to the largest. The advantage of this integrated approach is that items from the company’s product portfolio are designed to work with each other and are scalable. Scalability is vital, says Biernoth, as it permits a customer to operate everything from just a few units to a large setup. Such scalability is built into the pilot project.
On top of time savings, the collaboration between Rockwell Automation and TTC provide a second key benefit, that of energy saving and process improvement. An important role for TTC, says Dr. Kreuser, is to examine in depth the energy use at plants and make it measurable. “For example, TTC optimises the curing press cure cycle,” he explains. “Through this a potential 20 per cent cure cycle reduction for truck tyres is possible, providing an energy saving of up to 20 per cent.”
Continuing the curing press example, Dr. Kreuser explains that TTC will work to design an overall system, and Rockwell Automation then works with the customer on its implementation. This joint effort is conducted in a ‘holistic’ manner and covers all areas of factory layouts, the design of manufacturing processes and product technology. The service on offer also includes the support of machine selection to best meet the customer’s needs. “It is not just about changing individual aspects such as curing cycles, it is an integrated approach,” says Dr. Kreuser.
Providing Integrated Solutions
Rockwell Automation and TTC pool their expertise to save tyre industry customers time and money
During the planning of a factory’s layout and manufacturing processes, the integration of process automation solutions and software at an early stage maximises cost and time savings for the customer. Rockwell Automation, a global leader in the supply of industrial automation power control and information solutions, is collaborating with German company TTC (Technical Tire Consulting) in order to do just that – deliver reduced integration costs, optimised capacity availability, safe product quality and ensured traceability. When Tyres & Accessories met with representatives from both companies during February’s Tire Technology Hamburg exhibition, they explained exactly how tyre industry customers stand to benefit.
“TTC offers strong tyre manufacturing and development expertise – the consultancy offers customers complete solutions for producing tyres, including support for developing new production lines,” says Claus Biernoth, EMEA Business Development Manager Industry Solutions, Tyre, Rockwell Automation “The consultancy’s entire team comes from a tyre industry background, covering all areas of tyre development and manufacturing. TTC is collaborating with Rockwell Automation in a pilot project, the building of a complete tyre factory for a customer. This project involves all stages including plant design, layout, designing processes, layout of machinery.”
This project is planned to be followed by others of a very similar nature. TTC business manager, Dr. Helmut Kreuser, points out that the solution TTC and Rockwell Automation have developed together can be applied the future projects. This is good news for the numerous industry newcomers, particularly in the growth area of China and Asia. Many of these companies, Claus Biernoth points out, have not had the time or experience to develop the bench strength they need. “Some new customers have no wealth of process knowledge, so they rely on OEMs. TTC supports this knowledge,” he says.
Everything from mixing to final finishing is contained within the Rockwell Automation/TTC package, including materials handling equipment. It is “almost a complete tyre production facility in a box”, notes Biernoth. The plus for a customer opting for such an arrangement, adds Kreuser, is obvious: “The clear benefit for customers is that the package we provide can be implemented more quickly and the final product is more efficient and powerful as everything is integrated. Efficiency and time to market are seen as a key for the future.”
Rockwell Automation’s strategy is to utilise integrated technology in its solutions, from the smallest to the largest. The advantage of this integrated approach is that items from the company’s product portfolio are designed to work with each other and are scalable. Scalability is vital, says Biernoth, as it permits a customer to operate everything from just a few units to a large setup. Such scalability is built into the pilot project.
On top of time savings, the collaboration between Rockwell Automation and TTC provide a second key benefit, that of energy saving and process improvement. An important role for TTC, says Dr. Kreuser, is to examine in depth the energy use at plants and make it measurable. “For example, TTC optimises the curing press cure cycle,” he explains. “Through this a potential 20 per cent cure cycle reduction for truck tyres is possible, providing an energy saving of up to 20 per cent.”
Continuing the curing press example, Dr. Kreuser explains that TTC will work to design an overall system, and Rockwell Automation then works with the customer on its implementation. This joint effort is conducted in a ‘holistic’ manner and covers all areas of factory layouts, the design of manufacturing processes and product technology. The service on offer also includes the support of machine selection to best meet the customer’s needs. “It is not just about changing individual aspects such as curing cycles, it is an integrated approach,” says Dr. Kreuser.
Wind-up and Let-off Safety Solutions
Another focus at the Tire Technology expo was Rockwell Automation’s solution to what the Rubber Manufacturers Association has identified as one of the most dangerous stages of the tyre production process. In the last twelve months three fatalities involving wind-up and let-off spools and machinery have occurred in North America alone. Rubber is wound off onto the spools at nearly every stage of manufacturing, and then let off for the next stage, and this operation frequently require hands-on attention. Previous safety solutions were typically hardwired safety relays that required the stoppage of machinery whenever an operator was present. As is the case when given a choice between safety and productivity, one is always compromised.
Rockwell Automation’s solution to wind-up and let-off safety solutions eliminates this compromise. “Our wind-up and let-off safety solution can be operated in various modes so machinery can continue operation,” explains Biernoth. “Therefore, not only does the equipment meet new North American OSHA and European EC regulations, it also helps increase productivity.”
The wind-up and let-off solution has been implemented at Goodyear’s factory in Gadsden, Alabama, a plant that had a less than exemplary record in this area. Thanks to the solution provided by Rockwell Automation, says Biernoth, the Gadsden plant went from ‘worst to first’ in terms of safety within one year: “Goodyear identified the need for a safety solution. Rockwell created a solution and presented it to Goodyear. The company replied that it liked the look of it, and gave Rockwell the go ahead to start a pilot programme before the start of the following year.” Rockwell managed to deliver 65 units and have production underway within 20 weeks of receiving the nod from Goodyear, a remarkable achievement.
Each of the wind-up and let-off modules has a unique code and connection to different devices, giving them plug and play capability – each unit will automatically configure itself.
And according to Rockwell Automation, the safety equipment at Goodyear’s Gadsden plant paid for itself within four months. Mr. Biernoth explains how: “In the previous year, OSHA incidents and production shutdowns accounted for a costly loss of productivity. The elimination of these have been supplemented by enhancements to the plant’s machinery, which have in turn increased productivity.” A further benefit of the Rockwell Automation safety solution is that its meeting of safety regulations applicable in so many global marketplaces aids its rolling out by multinational companies. Bridgestone’s head office in Japan could, for example, choose Rockwell Automation for all world markets, knowing that all regulations have already been met.
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