Design & Realization
Our technical office manages the design construction and revamping of process tanks, automatic cranes, machines and systems for aluminum anodizing systems as well as creating automation and specific software for the production management and tracking. The machines and components are fully designed and manufactured internally following the highest quality standards
One of the most important point in extrusion and in surface treatment industry, is always trying to keep repeatability of the quality reducing the scraps. Quality of the process in most of the plant is based on the operator skill, have high level operators is very important and this cannot be substitute but because of the human factor, repeatability in the process cannot be assured. In order to achieve this result, we need the capability to analyze the process data and understand where the problems are made in order are to react and correct the process. The three main keys word are Tracking, Optimization, Repeatability. Alfa system is the software solution that can manage this information’s in easy way.
Tracking is one of the important features included in Alfa system, for example in the anodizing process, every load processed in the plant is recorded and monitored in the most critical parameters. we track process time in the tanks, temperature, pH., conductivity, oxidation current, levels, inclination, dropping time. All the data are stored in Alfa system database and can be easily retrieved using different index as job code or customer, day, lot of production. With all this information is easy, in case of non-conformity of the final products, generate detailed reports and found in the process the real reason and the precise fault position. Alfa system includes also a module that can manage production recipes in easy way, transferring directly to the plant the correct operation parameters and automatically recognizing if any parameters are changed by the operator. We also created a friendly interface where compose the working recipe is simple as to use any office tool as Excel or Word.
Errors retrieve and alarms dispatcher
Deep tracking tool allow us to collect a lot of information, but how we can understand where process is wrong without open end compare all the data? Alfa system integrate one visual toll that can make this easy too. In Fact, is possible for any important parameter, set a range where we expect the result should remain inside. In case of wrong parameters in any of the positions, just locking in the production list, is possible immediately find some of the production lines highlighted in red. This mean that the respective load, could have inside some working parameter not respected during the process. Clicking on the line, is possible to open a detailed list of the processed steps where in the faulted fields a bar graph allows us to immediately identify which parameter is wrong and the dimension of the error. For important alarms or out of range values, Alfa system integrate a configurable alarm dispatcher able to advise any interested person through email or message. In same way, Alfa system can be configured to send production reports or production statistic to any mobile device
One more Alfa Powerful tool is regarding the chemical analysis in the critical process tank. We have developed different mathematic models that allow Alfa system to provide a reliable prevision relating chemical quality in the tanks containing chemical mixture, controlling the correct analysis procedure. For any tank, a schedule for the chemical analysis procedure can be created, defining the time limits where the operators need to insert the results. If the results are not updated respecting the programmed time schedule, a supervisor is immediately advised trough the alarm dispatcher tool. Alfa system generate a chart showing guidelines were remain inside to keep the correct concentration. In the same time Alfa system generate a trend line projected in the future showing what can be the result if continuing with the actual behavior. Chemical engineers just need to keep the result inside the visual trend guidelines following the analysis schedule. This easy procedure assures to reach and keep the best results in easy and intuitive way. The trouble preventing module can be connected directly with the chemical laboratory making easy and fast to share all the necessary information’s.
Wastewater treatment and quality report
Water waste treatment and quality is in most countries a very important point that some time require more attention than the final product. Alfa system can monitor the correct parameters of the wastewater system, tracking all the chemical propriety that are available from the sensors inside the plant. Also, in this case we apply same concept of the quality tracking, if any parameter is outside a programmable range, in the main page we can be advised by a highlighted symbol and access to a detailed list of information’s. More fields allow to immediately identify which parameter is wrong and the dimension of the error. Personalized custom reports can be realized to accomplish any local rules.
Energy and chemical costs calculator
Normally, energy consumption is a parameter that is measured in global mode, we check the cost of gas, electricity, water, chemical product every month, we divide the cost for the tons or square meters that we are product and then we have the cost of the global production. In order to optimize the productivity and calculate the correct cost for the final products, is very important go one step forward and be able to calculate the real energy and chemical costs for any different order produced. Years ago, electronic sensors able to measure the different consumption was very expensive devices, today with affordable costs is possible to integrate any desired measure in the system. Alfa, together with the tracking, can calculate the real cost in energy and chemical products related to any order processed. This capability is important to have under control precise production costs and be able to calculate the correct single item sales value.
Alfa system is web based, mobile compliant and cloud ready. In addition to being able to share information with any server and databases, it will be possible access to all the important data directly from any device and any position where an internet connection is available. We can use our pc, pad, mobile phone without requires any physical server or Vpn system that generally can create problems with most IT policy. In this way it will be possible monitoring our plant having available all the interesting data at any time in any place.