integrated material flow - epda · 2016-08-09 · the homag group development 04.07.2016 4 the...
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© HOMAG Group
Integrated Material Flow
HOMAG Automation GmbH
Presenter: Jan Ihde [email protected]
June 17th, 2016
© HOMAG Group
AGENDA
� Introduction of the HOMAG Group within the DÜRR Group of companies
� Integrated Material Flow � Successful concepts from woodworking to plastics industry
� Examples of intelligent sorting and collating solut ions for plastic panels� automatic and intelligent storage and retrieval solutions� other sorting and collating solutions
© HOMAG Group
Structure of the Dürr Group
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Paint and Final Assembly Systems
Paint shops, Final assemblysystems
3,400
1.4 billion
Application Technology
Paint applications, glueing and seam sealing technology; Products for industrial painting
1,900
0.6 billion
Measuring and Process Systems
Balancing, assembly, test, filling and cleaning technology
3,000
0.6 billion
Clean Technology Systems
Exhaust-air purificationsystems, energyefficiency technology
500
0.2 billion
Woodworking Machinery and Systems
Machinery and plants for woodworking
6,000
1.0 billion
Employees
Sales
© HOMAG Group
1960 – Foundation Hornberger Maschinebau OHG by Eugen Hornberger und Gerhard Schuler
2007 – Successful IPO
2014 – Takeover by DÜRR Group
The HOMAG Group development
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The HOMAG Group development
1976Integration
1977FoundationHOMAG MachinerySão Paulo
1980Integration
1985Integration
1986Integration
1987Integration
1990Integration
1994FoundationHOMAG MachineryShanghai
1998Integration
2002Integration
2009Integration
2004FoundationHOMAG MachineryŚroda
2011FoundationHOMAG MachineryBangalore
2014Integration
2014Takeoverby
Eugen Hornberger and Gerhard Schuler
2014Fusion of BARGSTEDT & LIGMATECH
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Worldwide production, sales and service network
HOMAG Group worldwide
Production
sales and service companies and sales partners
© HOMAG Group 6
Business areas HOMAG Automation
Storage & RetrievalTechnology
Automation & Robotics
Buffer and Collating Systems
Assembly Technology
Packaging Technology
HOMAG AUTOMATION - Products and services
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HOMAG AUTOMATION
Managing Director:
Production area:
Employees:
Christian Breyer,
Jochen Fischer
18.400 m²
383
HOMAG Automation GmbH Contact:
HOMAG Automation GmbH
Ligmatech Str. 1 | 09638 Lichtenberg
Tel: +49 37323 16-0 | Fax: +49 37323 16-170
GERMANY
© HOMAG Group
AGENDA
� Introduction of the HOMAG Group within the DÜRR Group of companies
� Integrated Material Flow � Successful concepts from woodworking to plastics industry
� Examples of intelligent sorting and collating solut ions for plastic panels� automatic and intelligent storage and retrieval solutions� sorting and collating solutions
© HOMAG Group
Integrated Material Flow
What do we mean by
INTEGRATED MATERIAL FLOW ?
© HOMAG Group
Integrated Material Flow
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Construction Datageneration Planning Format/
EdgeCutting AssemblyDrillingCollating/FeedingSale Storage Laminating Fittings-
mounting Packaging Service
Everything from a single source
© HOMAG Group
AGENDA
� Introduction of the HOMAG Group within the DÜRR Group of companies
� Integrated Material Flow Successful concepts from woodworking to plastics industry
� Examples of intelligent sorting and collating solut ions for plastic panels
� automatic and intelligent storage and retrieval solutions� sorting and collating solutions
© HOMAG Group
Intelligent sorting and collating solutions
Buffer and Collating Systems
Sorting and collating lines equalize part flows, arrange them as needed and flexibly align them to the actual production process.
Possible interfaces to:
© HOMAG Group
Intelligent sorting and collating solutions
Intelligent Storage & Retrieval for plastic panels
Horizontal storage & retrieval systems offer more leeway in combination with processing machines and with great panel varieties. They are the ideal solution for an effective production.
Possible interfaces to:
© HOMAG Group
Intelligent sorting and collating solutions
Conventional (plastic) panel storageby cantilever racking
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Intelligent sorting and collating solutions
� How much space do you require for storing material?
� How much time do you need for finding the right material?
BEFORE – narrow forklift paths, manual panel search AFTER – Save material flows, immediate material supply
PLENTY EMPTY / UNUSED SPACE!!!!
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Intelligent sorting and collating solutions
Moving carriage on bridge with traverse
Control cabinet /Switchboard
Processing machinefor example saw and / or CNC Panel Infeed / Outfeed
Positions
Storage area(stacking area)
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Intelligent sorting and collating solutions
� Priority Management => Possible day and night operation
� Store and retrieval system operates 24h / 7 days (if required)
24 hours
� Infeeding of panels� Pre-Sorting of next days work� Leveling of stack heights
� Feeding of panels to processing machines or outfeed positions
� Infeeding of panels � Outfeeding of panels
� Pre-Sorting of next days work� Leveling of stack heights
0:00 – 08:00 hours 08:00 – 16:00 hours 16:00 – 00:00 hours
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Intelligent sorting and collating solutions
ST71 Traverse
Creation of vacuum byejector (no vacuum pump required)
Specially designed for more demanding panel types that require stronger vacuum flows due to the individual panel properties
Lift capacity: up to 350 Kg
Width: min. 400 – max. 2200mmLength: min. 800 – max. 5600mm
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Intelligent sorting and collating solutions
Example of a data flow of an integrated material flow:
WEEKECNC / Nesting machinefor plastics
HOLZMApanel saw for plastics
HOMAG AutomationStorage and retrievalsystem for plastics
HOLZMALabel printer
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Intelligent sorting and collating solutions
Explanatory animation for an integrated material flow- Intelligent manufacturing -
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Intelligent sorting and collating solutions
⇒ Remarkable storage capacity for plastic panels
Sample Calculation:
Store and retrieval system with approx. size of 50 x 12m
Various different sized panel stacks
In total approx. 70 stacks with an average stack height of 1.6m
⇒ 112m total stack height⇒ 4480 panels with 25mm
thickness
Approx. 50m
Approx. 12m
What is an Intelligent Storage & Retrieval system in a nutshell?
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Intelligent sorting and collating solutions
⇒ Inventory manager / full stock transparency Our self-developed software keeps track of any panels, panel movements over time and corresponding stock levels of each material
Software allows for:
� IntelliStore operation (statistical monitoring)
� panel rotation by age
� Control and administration also of external stock
� Offcut Management included
� Settings of min. and max. stock levels
� Statistical control and self analysis tool available
What is an Intelligent Storage & Retrieval system in a nutshell?
© HOMAG Group
Intelligent sorting and collating solutions
What is an Intelligent Storage & Retrieval system in a nutshell?
⇒ Material pre-sorting done over-night
Pre-sorting possible nearly anywhere
� Dedicated Pre-sorting positions� Infeed / outfeed positions� On top of existing stacks
Automatic generation of the pre-sorting orders from the running production
Automatic generation of the pre-sorting orders from the production order of the saw / nesting machines
No more waste of storage space for pre-removal plac es
© HOMAG Group
Intelligent sorting and collating solutions
⇒ Space saver resulting in a reduced footprint for storage area
What is an Intelligent Storage & Retrieval system in a nutshell?
No more forklift truck aisles required and therefore no ‘dead spaces’ between racks!
© HOMAG Group
Intelligent sorting and collating solutions
⇒ Feeder and stacker for processing machines (either directly attached or not)
What is an Intelligent Storage & Retrieval system in a nutshell?
Store & retrieval system withintegrated processing machine(s)
Store & retrieval system withintegrated processing machine(s) and external processing machines
Store & retrieval system withexternal processing machines only
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Intelligent sorting and collating solutions
⇒ Interface module with existing ERP Systems via open SQL- data base
What is an Intelligent Storage & Retrieval system in a nutshell?
� Connection to external optimization software or production planning systems directly at SQL data base level
� Flexible import and export interfaces (SQL data base, Excel, ASCII, BDX)
� Automatic insertion of master data from and to external systems and administration of master data from any interface
� Direct communication with external systems considering available and reserved stocks
� Intake of orders from PPS / ERP systems possible
� Supplier-, delivery- and storing data management (complete traceability acc. to ISO 9000)
ERP
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Intelligent sorting and collating solutions
Customer movie SK Scheidel- Plastics industry -
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Cut to Size – double bridge system
Large variety of panels (SKU’s) – Daily output up to 700 panels (incl. pre-sorted panels for processing machines)
Approx. 100m
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Panel trader – double bridge
Large varity of panels – Daily output approx. 400 panels (incl. pre-sorted panels for processing machines)
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Plastics Cutting Center – double bridge
Approx. 65m
Medium to large variety of plastic panels – Daily output approx. 600 panels (incl. pre-sorted panels for processing machines)
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Kitchen Manufacturer – twin-bridge
Storage System with 1 bridge and feeding position
Stand-Alone Storage System with 2 bridges
Approx. 86m
Approx.
16m
Large variety of panels – Daily output approx. 500 panels (Pre-sorting of panels over-night for processing machines)
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Intelligent sorting and collating solutions
Buffer and Collating Systems (extract)
Sorting and collating lines equalize part flows, arrange them as needed and flexibly align them to the actual production process.
Possible interfaces to:
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Explanatory movie Buffer and Collating System- Woodworking industry -
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Intelligent sorting and collating solutions
Double sided buffer and collatingsystem with center-wise movingcarriage
+ greater stocking capacity- Reduced cycle times comparedto rack system
One sided buffer and collating system withmultiple rake systems
+ fast access and cycle times- less stocking capacity
Moving Carriage vs. Rake system
© HOMAG Group
Intelligent sorting and collating solutions
THANK YOU FOR YOUR KIND ATTENTION!