Major IIoT project in the foundry sector: Grede introduces Monitizer
The implementation of the Monitizer® | DISCOVER IIoT solution at Grede demonstrated how digitalisation and modern technologies can help to optimise processes and reduce scrap rates.
As a partner to the automotive, heavy-duty and industrial sectors, Grede made the digitalisation of its manufacturing a central part of its strategy in 2020, with the aim of improving its operational processes and performance.
“We are moving from the art of foundry work to the science of Metalcasting™,” explains Cary Wood, CEO at Grede. “Our systems and innovation are key to our success. With the help of data and artificial intelligence, we will reduce process variability and produce high-quality castings at lower costs.”
Real-time digital overview of production
Monitizer is a modular IIoT platform designed to collect data from equipment from different manufacturers across multiple casting lines or global sites. It consolidates both real-time and historical data, storing and visualising it using customisable, user-friendly dashboards and Key Performance Indicators (KPIs).
“The developers of the standard dashboards really understand foundries,” says Matt Deyarmond, IoT Process and Control Lead at Grede. “They’ve probably reduced our set-up time by over 80 per cent. The system is easy to use and control, and we were able to make minor changes ourselves with ease.”
The real-time data and KPIs provide Grede with greater process transparency, as well as faster response times and the ability to resolve any issues immediately. This overarching process control has already contributed to significant improvements in production. Preventing scrap before it occurs
Monitizer | DISCOVER’s sophisticated alarm functions provide additional support for both production control and inexperienced users. In the event of a problem, the system notifies different groups of people in successive waves, depending on how the problem develops and whether the group notified first responds.
“If a machine is operating outside its ‘green’ operating range, the supervisor receives a notification,” explains Bart Hoemann, Managing Director of Grede’s St. Cloud foundry. “If a limit is exceeded, the issue is escalated to the next level – the quality manager. If the limit is exceeded five times, the next escalation level – plant management – is notified.”
Monitizer – developed by foundry experts for foundries
Grede opted for Norican’s Monitizer IIoT platform because the system was developed by foundry experts for foundries. Much of this expertise comes from the experienced specialists at the other Monitizer brands: DISA, Simpson, Wheelabrator, StrikoWestofen and ItalPresseGauss.
“The decision to go with Monitizer was an easy one for us,” says Susan Bear, Chief Technology Officer at Grede. “It is the only solution with an AI component, and Grede has a long-standing, trusting relationship with the Norican team and its equipment brands. The Monitizer team is practically an extension of our IT team, and we have complete confidence in its staff.”
Grede found the secure system to be user-friendly and easy to navigate. “I can log into the plant’s dashboards from anywhere – whether I’m in the office or on a plane,” explains Susan. “We gain insight into every single foundry and can, for example, check sand compatibility. Or we can take a step back and get an overview of the entire company to monitor the operation of all plants.”
Significant improvements thanks to process transparency
“One of our foundries was able to reduce its scrap by 50 per cent using data from Monitizer by minimising sand inclusions,” explains Susan. “And of the foundries using Monitizer, all of them – that is, 100 per cent – were able to reduce their scrap!”
Once all foundries are connected to the IIoT, the Grede team will move on to project phase 2. This also includes AI optimisation with Monitizer | PRESCRIBE.
“In a green sand foundry, there are up to 2,700 different variables. It’s not possible to control all of these using spreadsheets,” explains Mike Meyer, VP of Operational Excellence at Grede. “With PRESCRIBE’s AI, we can, on the one hand, understand how these variables interact and, on the other, control them much more effectively. Essentially, we will be digitising our experience gained over the last 30 years.”
Monitizer drives digital transformation at Grede
In foundries, revenue growth means being able to produce higher-quality castings at lower costs. Grede’s work with Monitizer is already proving that expertly implemented digital technology is precisely the right way to achieve this.
“This sort of project requires full commitment at board level,” explains CEO Cary. “First, you need to develop a corporate culture that highlights the benefits and gets everyone on board. And then you need the right technology and the right provider. We had a vision of how we wanted to provide business support. We now have Monitizer to make that happen.”