Revamping as a sustainable solution in Industry 4.0 system
The TFS example of rubber co-molding presses
As reported in a previous article of our blog, the technological revolution that goes by the name of Industry 4.0 has led many companies to rethink their business. The numerous transformation processes, triggered by digital automation, have favoured the spread of organizational and operational models in which the information produced is sent, collected, contextualized and shared in real time.
For at least 10 years, the interconnection required by operators of different economic sectors, with regard to hydraulic systems, has brought out the need to implement solutions that were capable of combining:
- flexible and tailor-made solutions for the company;
- the search for efficiency, without suffering the risk of obsolescence;
- a sustainable return on investments, due to ever shorter amortization periods.
In this way, the decision-making dilemma that emerges for many companies is based on the compromise between the allocation of financial resources for the purchase of new plants, against the hypothesis of revamping, i.e. the activation and maintenance of machines and existing industrial plants that have a useful life sufficient to maintain an optimal level of productivity.
Leaving aside the logic of investments in innovation projects, revamping can be an optimal solution and recommended when the spare parts for the PLC (Processing Logic Control) or the SCADA (Supervisory Control And Data Acquisition) installed have become unavailable or with a premium price based on scarcity.
From the attached photos, you can see the revamping intervention carried out by TFS on a rubber co-molding press. Specifically, the previous Siemens S5 PLC was replaced by a Siemens S7, Model 1200 microprocessor, saving the final use, as well as the original physical structure.
These interventions are recommended whenever one or some of the following cases occur:
- Business and production control requires data and aggregation of data provided by machines and plants in real time;
- The time devoted to scheduled maintenance increases exponentially;
- Breakages and related machine stops are frequent and less and less manageable by the internal maintenance team;
- The software implemented on PLCs or SCADAs are out of production and no longer maintained;
- Production and setup times do not allow adequate production.