vision systems and coil fed in line laser applications by andrea dallan

Vision systems and in-line laserapplications

Andrea Dallan, C.E.O. Dallan Spa – Italy

2016-04-07

© 2015 Dallan S.p.A. All right reserved.

How to introduce LEAN concepts in the manufacturing cyclevia coil-fed integrated punching and laser cutting systems

Dallan group established in northern Italy 1978

• Roll forming machines (1978)

• Coil fed punching machines (1989)

• Packaging systems (1995)

• Coil fed laser cutting systems (2014)

• 150 Employees

• 30M$ Sales

104 international patents

Dallan group


What we’ll cover

• 3 simple LEAN concepts

• Vision systems applied to manufacturing processes

• Punch/laser combo systems

• ELLECI case

• Laser cutting systems from sheets and coils

• UGUR case


Lean production concepts

• Value-driven analysis (analyzed from customer’s perspective)

• Analyzing the manufacturing steps that add value to the product

• Putting these steps as close together

1. Minimizing Work in Progress

2. Minimizing Waste

3. Analyzing hidden «waste»: setup times

• Optimized productivity by optimizing the setup of the presses


Classic manufacturing cycle

Raw material arri-val and storage

Blanking line Storage of BlanksPunching machines

Storage of punchedmaterial

Laser cuttingmachines

Storage of cutparts

Bending, Panel benders, Forming

Storage of bentparts

Paint line Storage of partsfor assembly

Assembly and packaging

line

Storage of finished products

M1M2

M3M4

M5

In-line manufacturing cycle1. Minimizing WIP

Raw material arri-val and storage

Storage of cutparts

Bending, Panel benders, Forming

Storage of bentparts

Paint line Storage of partsfor assembly

Assembly and packaging

line

Storage of finished products

M3M4

M5

In line punching and laser cutting from coils M1 and M2 are eliminated

2. Material optimization

Optimization of rectangular products on standard size sheet

Optimization on standard size coil On slit to size coil


3. Productivity and Flexibility Minimizing setup times

Productivity

High

Low

Low

Stamping with press

Coil fed punching and laser

Turrett punching

Flexibility

High


All the advantages of the in-line layout

• Storage of materials in coils

• Reduced number of formats to keep in stock

• Reduced WIP

• High Value operations are easily connected by the in-line layout

• The final storage of punched and cut parts occupies a small space as the products are flat

• Higher material utilization than standard technologies

• Minimum setup time thanks to the in line laser


Vision systems and software is the key

• Easy optimization in line processes

• High definition camera takes the picture of the part

• Confronts the «is» situation to the «should be»

• Produces an output

• Measured deviation

• Presence or absence of a specific hole


Vision system: pattern recognition


Application of Vision Systems

• Recognition of position of the side of the strip

• Possibility to re-position long sheets on the same working area

=> In line laser systems

40 in

D C B AFeeding dir. Exit of cut parts

Area in process


Application of Vision Systems for in line lasers

• Recognition of pre-punched holes to reference the laser cutting

• Recognition of the sheet edges

• Recognition of the integrity of punches

• Quality control of the part


Punch/laser combo

• Punching and laser are separated to maximise output

• Laser module with vision system can be applied after any punching machine, to create a combo system


Punch/laser combo application: Elleci Spa

• Italian producer of high quality fully assembled metal components

• 100 employees, 200,000 sqf covered production

• Standard punching, laser, punch+laser

• Coil fed punching, Coil fed laser

• Bending, panel bender

• Welding stations

• Powder coating lines

• http://www.ellecispa.net/


http://www.ellecispa.net/

Punch/laser combo application: Elleci Spa


Elleci system under construction

System installed at Elleci premises

Example of applications

Multiple holes are obtained in servo electric punching machine

Embossing and threading obtainedin punching machine

A

Lean concepts included in this system

• Just in time production

• Tool change is reduced to minimum

• Material optimized 100%

• No skeleton = reduced labor cost

• In line quality controls(on punches, for example)


In line laser cutting

• Continuous and automatic production


Autonomous production: Example

• 1 coil in 22ga = 0,7mm

• 10000lb = 4500kg

• 30inch = 750mm wide

• Length = 1100 meters

@ 4 meters per minute (simple parts) = 4,5 hrs production

@ 2 meters per minute (low complexity) = 9hrs production

@ 1 meter per minute (medium complexity) = 18 hours production

@ 0,5 meters per minute (high complexity parts) = 37 hours production

Sequential process

160 in

40 in

D C B AFeeding dir. Exit of cut parts

Area in process

• Sequential process

• 40 or 80 inches in length

• 40 or 60 inches in width


Total flexibility to process coils and sheets


In line laser application: Ugur

• Turkish producer of refrigerators http://www.ugur.com/

• 1,850 employees - 2,150,000 sqf covered production

• Supplier of major beverage producers

• Advanced application of Lean Production concepts(1 fridge every 12 seconds)

• Need for high productivity and flexibility on 0,3mm thick aluminiumand steel


http://www.ugur.com/

Ugur systems under construction

Systems installed at Ugur premises

No.2 1kW laser systems 1000x2000mm

Examples of produced parts

On these parts Ugur has reduced processtime from 90 seconds to 44 seconds

Lean concepts included in the in line laser

• Reduction of the waste

• Continuos production – all value-added operations

• Tooling time reduced to zero

• Working with no skeleton = reduced labor

• Automatic production


Conclusions: advantages of Combo lines

• Extremely high REAL productivity thanks to the simultaneous action of punching and laser

• Execution of deformation, embossing, threading

• Optimization of material to 100%


• Eliminating the skeletonReduced labor


Conclusions: advantages of Laser lines

• Versatility to work from sheet and from coils

• Extremely high flexibility

• Optimization of material to 100%


• Eliminating the skeletonreduced labor


THANK YOU!• Contact information:

www.dallan.com; [email protected]

www.dalcos.com; [email protected]


http://www.dallan.com/

mailto:[email protected]

http://www.dalcos.com/

mailto:[email protected]

vision systems and coil fed in line laser applications by andrea dallan

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