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Tag: industrial machines

How Industry 4.0 is giving ERP a new lease of life

There’s no question that the manufacturing industry is moving at a rapid pace. Assembly lines are becoming smarter, R&D becoming more innovative, and operations becoming slicker. Manufacturing businesses are embracing new technologies and utilising everything from the Internet of Things, to smart devices, in order to build a competitive advantage and stay ahead during highly competitive times.

But while new technologies are coming thick and fast, there is one application that has been a vital tool in the manufacturer’s arsenal for the last 50 years. There’s one application that streamlines efficiencies across entire supply chains and there’s one application that is continuing to grow in order to keep up with, and seamlessly integrate with new, more recent technologies. That technology is the humble Enterprise Resource Planning (ERP) system – a technology that has been around for decades, but which remains the next big thing in Industry 4.0.

Boosting factory efficiency

The smart factory of the future is one that is capable of delivering shorter product runs, manufacturing more complex products with more frequent material changes, resulting in quicker deliveries, different mixes of packaging and distribution, better change forecasting, supply chain management, and product traceability.

ERP has been helping businesses achieve all of this for many years. Yes, the stories of manufacturers saving time and money with ERP are everywhere – and they’re all true, but many of these document a single business process. Imagine the efficiencies that a business could achieve with seamless integration of planning, materials management and procurement, manufacturing, financial and business intelligence processes through one single system. ERP can deliver complete factory automation and unify multiple business processes, and disparate systems to better connect all facets of your supply chain. It can enable you to work smarter, faster, and spend more time focusing on product innovation and servitization, instead of operating manual tasks to try and plug the gaps left in your poorly automated supply chain processes.

Get a handle on those robots

Like it or not, the age of robotation is coming to manufacturing. Industry 4.0 is a period where manufacturing businesses are improving machine uptime, decreasing labour costs, consolidating factory space and saving on capital expenditure – robots facilitate all of these.

However, the introduction of robots to the factory floor means that a busy manufacturing manager now has yet another asset to manage. And what happens when one of them ultimately fails in a way that a human worker rarely does?

By linking robots to your ERP system, and integrating their data streams into your ERP data, you can better schedule robot maintenance and analyse their output to make them move orders forward more effectively. And by using ERP to adjust your product designs and held inventory, you can consistently change and modify your designs and materials to reap even more value from your robots.

Help your business leverage the Internet of Things

From product development to production control and after-sales, connected devices are providing manufacturing businesses with a higher level view of their supply chains and enabling them to make better informed decisions, more quickly. Add the Internet of Things into the mix, and the possibilities for a manufacturing business become endless.

Many manufacturing businesses are starting to fit sensors to their products to analyse their performance in terms of their effectiveness safety levels, durability and other critical values. By sending this information directly to your ERP solution, you can update Bills of Materials, adjust design specifications and adjust processes to continually improve your products through production. By leaving sensors on products post production, you can feed this information into ERP to track the lifecycle of a product and use this information to deliver a greater service to your customers by alerting them when a product may need maintenance, and to streamline or alter your production strategy for continuous product improvement. The use of sensors in manufacturing post production is nothing new, but ERP offers a way to route the masses of data collected by the sensors into your design and engineering processes to enable continuous improvement.

Greater productivity, improved efficiency and higher flexibility are the three traits of any competitive manufacturing business during Industry 4.0 and unsurprisingly, three benefits that ERP can deliver. The businesses that truly thrive during the fourth industrial revolution will be those that continue to use ERP as a mission critical supply chain tool, and continue to think up new and innovative purposes for their solution. After all, ERP has evolved throughout the last 50 years, just imagine where it will be in the next 50?

Industry 4.0 and the Drive in Productivity

Digitization, automation, and data collection has been driving the fourth industrial revolution in recent years, otherwise known as Industry 4.0. We’ve seen a phenomenal rise in the establishment of smart factories and smart data, but how has Industry 4.0 impacted the supply chain? The supply chain network is a complex and multi-faceted web. It is all too easy for one weak link to completely break down the chain. By digitizing the vital processes that make up the supply chain, manufacturers will not only future proof their business but will benefit from a significant rise in productivity and efficiency.¨

Building one transparent ecosystem

For any manufacturer, regardless of the size of the company, the supply chain is a hugely complicated and multifaceted eco-system. A lack of clarity can mean that processes and relationships can break down, disrupting the efficiency of the entire chain. Complete transparency enables businesses to not only respond to problems in real time but also to anticipate any issues and respond to them in advance.

Ultimately, digitization is the key to creating a transparent supply chain ecosystem. Through the installation of a digitized and fully integrated supply chain network, companies are able to respond to customer demands more effectively and efficiently, ultimately improving productivity.

Investing for the future

There is no quick fix to digitising an entire supply chain. This complete transition will take time and will be costly, but once completed manufacturers will reap the benefits for many years to come. In the last ten years, Essentra Components has invested in over £13.5 million in upgrading, future proofing and digitising the manufacturing operations at their Kidlington site in the UK.

Driving efficiencies

The creation of smart machines, linked to each other and to the cloud, ultimately speeds up set up times and installation processes, driving efficiencies in production whilst also reducing costs. By linking these smart machines to the cloud, process engineers are able to access machines remotely, diagnosing and resolving problems more quickly, ensuring the machines are back up and running in the shortest time possible. This quick exchange of information is revolutionary and boosts the agility and responsivity of the entire chain.

There is no quick fix to investing in the digitization of the supply chain network but, manufacturers wanting to compete on a global scale must begin implementing a digitized supply chain network now. By doing so, businesses can respond to customer demand in real time, ultimately improving the experience for both the manufacturers and the customers. Manufacturers must be reassured by the fact that this long term investment will pay dividends to the company for many years to come.

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How design changes with Industry 4.0

Based on the adoption of interconnected and intelligent technologies and solutions, the new paradigm of Industry 4.0 design is gradually changing production processes within Italian manufacturing companies.

However, the digital innovations of the Fourth Industrial Revolution not only affect the way factories produce, but also invest in the design and engineering techniques of the industrial product.

The 4.0 technologies allow a significant improvement in product design thanks to the integration of software components (sensors, GPS) that, connected to machinery or other physical objects, make it possible to collect data from the field. Making products intelligent through the Internet of Things has many advantages at every stage of the product life cycle, including design.

Access to data and information during the use of an industrial product enables designers to constantly monitor its performance and the way it is used. Thanks to real-time monitoring, for example, it is possible to effectively redesign the infrastructure of the digitized product in order to achieve high levels of energy savings, avoid downtime and consequently optimize production flows.

In the automotive sector, more and more companies are relying on IoT to automate various safety procedures for their vehicles. For example, the design of cars with vehicle proximity control sensors, stop-and-go assistance, emergency brakes or 3D maps enables the collection of information that can be used upstream by designers to improve the consumer driving experience and make it safer.

Once this scenario is outlined, it is quite clear to manufacturing companies that they need to rely on technologies based on data collection to improve not only the production of industrial goods, but also their design. In order for the potential benefits of Smart Manufacturing to become effective, the adoption of 4.0 technologies must therefore be accompanied by the implementation of management systems that make it possible to store, share and use data collected in the field and ensure proper management of information throughout the product lifecycle.
How do you evaluate the design activity in your company?

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Prototyping and testing

With an experienced, creative and multi-disciplinary team of engineers JOULEHUB supports companies in transforming an idea into an engineered concept, using the most advanced numerical codes and design tools.

Deliverables

We optimize product design by FEM (Finite Element Method), CFD (Computational Fluid Dynamics) analyses and virtual testing considering complex physical phenomena and advanced materials in the following fields:

  • structural mechanics (FEA)
  • vibrations and fatigue analysis
  • CFD
  • thermal management
  • impact and crash analyses
  • coupled multi-physics.

We use Life Cycle Thinking instruments to support you in strategic decisions including the assessment of economic and environmental impacts, paving the way for product certifications.

We support you by prototyping the developed design and testing it in a relevant environment, providing:

  • Rapid prototyping with 3D printing machines
  • Design of Experiment (DoE) to optimize test campaign
  • Material testing and prototyping (from laboratory scale to full scale)
  • Process development and validation (from laboratory scale to full scale)
  • Setup of demonstrator combining mechanical and mechatronic skills
  • Prototypes and small series production.

Contact us today to find out more.

Three Phases of prototyping

Prototyping involves more than just the creation of a tactile mockup. It’s both a proof of concept using off the shelf hardware mixed with DIY materials and a fully-functional product constructed of precision-crafted components.

For that reason, new product designs generally go through several prototype iterations before they are deemed ready for the production line. Whereas it’s common to think in terms of a single prototype, the process, in fact, typically results in the creation of multiple iterations.

Indeed, the design process can usually see as many as three to five different prototype phases, with a multitude of test units put through their paces.

To that end, we have partitioned the prototyping process into three classifications: what we’ll call the Alpha, Beta, and Pilot. While different product developers may use alternative terminology such as minimum viable product (MVP) and proof of concept (POC), these phases are fairly universal. Each phase represents a step forward along a product roadmap and corresponds to an increasing score along the Technology Readiness Level scale.

It should be noted, however, that the process itself is usually nonlinear in nature, as developers will occasionally use lessons learned in various test phases to go back and revisit earlier iterations. Depending on what stage along the process you are, the tools, methods, decisions and challenges will be different.

For the sake of clarity we’ve listed prototypes in succession; however, in some cases, prototypes may be developed anywhere along the product development timeline. It’s important to realize that developers design prototypes to match the manufacturing method, so depending on changes and differences it may be necessary to push forward prototypes concurrently.

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How Rapid prototyping helps you Design and Develop Products quickly

Product design failure in the development stage is a huge loss for the organization in terms of man-hours and the money invested in the development process. A tangible prototype of the product makes the complex product design looks simple. It helps product designer and engineers in visualizing and analyzing the actual part of the product before the development stage. This drastically reduces the chances of product failure to a great extent.

It helps you to develop every component of the complicated product in stages and compare every part of it with the prototype prepared. Any deviation from the prototype can give you a clear indication of the design failure of the part and it helps the development team to rectify the error immediately.

Why Rapid Prototyping?

  1. Clear understanding and visualization of the Design Concepts
    It acts like a POC for the client and it’s easier to understand the design rather than struggling to visualize by looking the design on the screen or paper. It helps the designer to understand the look and feel of the design rather than having a virtual design through CAD model.
  2. Quick changes or modification
    Having a visible and tangible model provides manufacturers with the better understanding of how the product may look like. It helps them analyze the actual design and suggest correction or modifications quickly which can be incorporated to make the product design perfect before advancing to the manufacturing stage.
  3. Reduction in monetary investment and time consumption for Designing
    Rapid prototyping creates a model very similar to what an actual product can look like. This eliminates a need for preparing molds and use of other software to create a model. The existing CAD software and printing equipment are sufficient to create a rapid prototype which gives you a feel of an actual model. This not only result in saving of time and cost invested in creating the actual models but also results in overall reduction of your time to market.
  4. Product Customizations
    Rapid prototyping empowers you in developing the customized products with ease. A small modification in CAD model is sufficient to create a modification in the existing design without the need for any special tool or process.
  5. Higher Accuracy level in designing
    The material used for the prototyping has similar properties of the actual product. This makes it easier to perform the physical tests and identify the flaws and errors prior to the actual manufacturing process. This helps manufacturers to avoid the risk of halting the manufacturing process at a later stage.

Nowadays, manufacturers are more inclined towards rapid prototyping while initiating their new product development and manufacturing process. These revolutionary techniques are making things easier for product development companies, and product manufacturers in developing innovative products cost-effectively.

If you are struggling to hold the market share due to continuous innovative products being pumped by the competitors, there is a time to look into your product design and development process. Probably you require an expert who can boost your product development team to enable them to develop products at a faster pace.

At JOULEHUB, we carry out a systematic study of your concept and existing product line to redesign of systems and components successfully. We can partner with you to innovate, design and develop products rapidly to gain the first mover advantage.

JOULEHUB offers custom engineering design solutions and services to our global clients leveraging a team of experienced engineers and designers. Our diverse services span all aspects of engineering from legacy conversions, to designing and detailing, to FEA/CFD analysis. JOULEHUB has domain expertise in many industry verticals including automotive, off-highway vehicles, heavy machinery, consumer equipment, packaging and medical devices.

Contact us today to find out more.

We are hiring!!!! Business Development

Location: Luzern Switzerland, Remote work possible

Start date: December 2018

What we do:

JOULEHUB is a R&D laboratory specialized in electronics, robotics and mechanics. We project, create prototype and if the customers need, we can produce also. Our business core is based on:

  • Project
  • Feasibility study
  • Prototype
  • Production

What you are going to do:

  • Responsible for the acquisition of new leads
  • Support us in the development and implementation of the growth strategy
  • Execute and improve daily operations
  • Finalize of the interviews

Contact us today to find out more.

Key Differences Between Production and Prototype Tooling

In product development, testing is a critical factor. In some cases engineers need to demonstrate how a new design will perform as part of management approval for investment into production. In other cases, regulatory requirements require testing of products from representative materials and processes that correspond to those intended. As part of its prototyping methodology, manufacturers often use different strategies for executing prototypes depending on the purpose of the parts. When injection molding is involved in the final product, the use of specially engineered polymers in the product specification may result in the need to injection mold the parts being used in testing in order to get reliable results. Depending on the circumstances, the final production injection molds may be used or separate prototype tooling may be utilized. The goal is to ensure a superior prototype and timely testing, which helps identify design changes before taking a product into full production.

There are a number of key decisions, which go into the prototype tooling process, which enables a design team to select the appropriate build strategy. A key element to consider is the degree of uncertainty or uniqueness of a particular design. The more unique a given design is from a company’s previous manufacturing experience, the more critical it is to test process and product early. Likewise, overall program schedule plays a big factor. The component in need of testing may just be one part of an overall system being developed. Final production tooling timing may be aligned more with the overall system’s development schedule. If so, waiting for production tooling may be a costly risk delaying valuable testing time. In those cases, a simple prototype tool to allow early evaluation of the component or sub-system may be a great investment. Finally, the likelihood a product may change should also be a factor in considering if separate prototype tooling should be used. If a design change is likely or probable, it is better to identify this early rather than executing the change to final production tooling which could require welding on the tool steel or other changes which might compromise the integrity of the mold for long run use.

For both production and prototyping, every tool is different. Two factors, which strongly influence the distinction between the two, are as follows:

  • Production Quantity – The degree of automation in a tool is often correlated with the production quantity intended. High production molds often are highly automated with wear maintenance provisions, sensing and process control capability built into the design. These factors add to the time and cost of the tooling but provide cost and processing efficiencies in the actual volume molding itself. Likewise high production molds are often multi-cavity allowing several parts of the same design to be molded simultaneously. Prototype molds by contrast, typically have limited automation and cavities, saving time and cost in fabrication and thus are suited to low volume molding with quicker development time.
  • Hard vs. Soft Tooling – Another difference between the prototype tooling process and production tooling process has to do with tooling materials. Production tooling is often made from hardened P20, H13 or other tool steel suitable for repeated use and long tool life. Heat-treating and surface hardening or plating are also often utilized. Prototype tools are often called soft tools based on the fact that aluminum and or mild steel are often used. This tooling material can be cut quicker in the machining process allowing for faster and more cost effective prototype tools. The tradeoff however is that tool life may be limited depending on the plastic intended to be molded and processing is not optimized for shortest cycle time. Soft tooling can offer affordability for both production and prototyping. However, because it allows for quick turnarounds of samples, it is often the preferred choice for prototypes.

Tooling is a big investment and cost is always an important deciding factor. Therefore, a manufacturing company will determine which type of tooling makes the most sense from a financial perspective and any product based factors necessary to make the right choice.

Innovative Prototyping and Production Services

The JouleHub team of experts can assist your team in the process of making critical decisions about machines, material, and tooling and providing the support services needed regardless of choice. For a superior quality prototype or product, we would love the opportunity to help. Visit us online or call to speak with a company representative regarding your project.

Why Choose CNC Rapid Prototyping

When it comes to rapid prototyping, there are several different options. These include 3-D printing, sand casting, selective laser sintering, investment casting, fabrication, and CNC rapid prototyping. While they all offer unique advantages, there are some unique advantages to CNC prototype machining.

What Is CNC Prototype Machining?

CNC prototyping involves utilization of 3D solid model CAD designs as the input, and correspondingly fabricating the part directly from solid material through a computer controlled cutting and milling process. Some have used the term, “subtractive” rapid prototyping to describe this process, to contrast it with 3D printing, which is sometimes referred to as “additive” manufacturing. The subtractive aspect is that the CNC machine removes material from a starting material block to create the final part precisely to the CAD model specifications. With modern CNC machines, this material removal process is efficient, quick, and accurate to demanding specifications. Because of this subtractive nature, CNC prototyping allows for parts made from literally any material that is machinable and commercially available in cast or extruded stock. This provides material versatility and permits prototyping in materials that are often identical or very similar to those specified in production use. CNC prototyping suppliers offer an outstanding option for low volume customized products and prototypes with precision results!

While prototyping offers many benefits, two stand out. First, by creating a model before producing hundreds or thousands of finished products, engineering teams can identify potential problems, often times minor geometry or functional issues that by human nature are inherently difficult to catch in a computer model alone. This can allow the manufacturer to make the necessary corrections before going into full production, which saves a significant amount of money. Secondly, human factors, or how humans interact with the product are most often best assessed on the prototype. Issues such as color, texture, feel, light, shadows, temperature to touch, resistance to motion, etc. can be assessed with prototypes made to high craftsmanship, quality, and proper materials.

A Broad Reach

Prototyping and CNC Prototyping in particular can benefit any industry, whether aviation, automotive, architecture, aerospace, construction, medical, or something else that requires a finished product with precision and detail. Investing in the prototype process with CNC machining reduces the risk of time-consuming and costly mistakes.

Likewise, CNC is a viable option for many lower volume production projects. Depending on the geometry and material, whether a customer needs 100 or 1,000 units, CNC machining may be an excellent option as it eliminates the need for upfront tooling and molds due to its “on-demand” manufacturing methodology. Whenever a customer needs a plastic or metal prototype or multiple pieces in low volume manufacturing, CNC machining can be an outstanding process.

Enjoy Stellar Results

If you need a rapid-prototyped part or component, our team at JouleHub can help. As a leader in the industry, we maintain state-of-the-art CNC machines and have a dedicated team of professionals eager to assist you. Visit our website or call for more information.

Mechspire is on Kickstarter

We have some exciting news here at JOULEHUB! For those of you who don’t already know, we have created a new machineries sharing portal called Mechspire. Mechspire is your go-to place for sharing industrial machines with your fellow businesses. You can list your own machines that you don’t use anymore or you can rent a machine you only need to use one time. We are very excited to share this portal with you! Here’s the catch- we’re still trying to get it off the ground.

We are only 85% complete so, we decided to launch a Kickstarter project! We need help finishing up all the technical aspects of our virtual portal so you can start taking advantage of renting machines without any complications.

Mechspire will help you save money. No more buying large, new machines that you only need for one project. Save your money and rent it from someone who lists it on Mechspire. Or, make the money back you spent on buying new machines by renting out yours! Our portal is already up if you want to get a gist for how it will work, but we need to reach our Kickstarter goal before people can start listing their machines.

So, if you are ready to start using Mechspire to save money and increase your industrial productivity, back our project today! We have some awesome rewards:

  • Pledge CHF 1 or more = Public thank you on the Mechspire website
  • Pledge CHF 5 or more = Public thank you on the Mechspire website and Facebook page
  • Pledge CHF 100 or more = Free registration and your first month of listings are free on our portal
  • Pledge CHF 5,000 or more = Dinner with the Mechspire founders team

Stay tuned and keep checking back on our Kickstarter page and all our social media accounts for weekly updates on how our Kickstarter is coming along!