Innovative use of "golden batch" optimization in discrete manufacturing at Weber Metals

Guests: David Mitchell, Automation Engineer, Weber
Metals. 
Sean Upson, Systems Engineer, AVEVA. 


David Mitchell is an automation engineer at Weber Metals, a major
supplier of aluminum and titanium forgings to the aerospace
industry. Among the thousands of things Weber manages with
sensor-based data is a 60,000 ton forging press that is the
world’s largest private investment in aerospace metal forging.
When Weber installed the PI System it was to consolidate various
silos of sensor-based data into a single source to improve
situational awareness. Over time Mitchell found more valuable
uses for the data. For example by comparing each forging to other
forgings in a production campaign operators now have a "golden
batch" profile that helps them improve the quality of each
forging. Integration with their MES (manufacturing execution
system) further improves their ability to meet production targets
by having all pertinent information in a common data
infrastructure. Improved visualization tools allow Weber to
identify more easily anomalies and thus detect and troubleshoot
more effectively quality, compliance, and maintenance issues.


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