industrial weighing and measuring - mettler toledo...that help improve profitability is to choose...

Don’t wait for Industry 4.0 to happen. Use your weighing equipment to improve your produc-

tion process today. We explain why you should speed up and integrate manual processes

into your existing systems, make use of weighing data for process optimization and enable

remote monitoring.

How to Boost Productivity with Industry 4.0 Discover the Potential of Weighing

status information about the manufac-turing process, collect measuring results and steer production equipment. Measur-ing devices, such as weigh modules, plat-forms and terminals, can be built into highly modular assembly lines and con-veyor belts. There they can be either auto-mated or operated manually. Despite in-creasing automation, manual work will not disappear in modern factories. As-sembly, quality checks and material han-dling is still done by operators on manual workplaces. Manufacturers are now look-ing for equipment that allows them to in-tegrate these workstations into their sys-tems. On the operational side, innovative interfaces, user guidance and intuitive handling features can enable productiv-ity potential in factories today.

Recent developments surrounding In-dustry 4.0 and the Internet of Things are facilitating a major paradigm shift in manufacturing. Traditional production hierarchy, with centralized control, is shifting toward a decentralized self-orga-nization, in which the product indepen-dently communicates with the production devices and actively intervenes in the pro-duction process.

Digitalization of weighing equipmentAs measuring technologies evolve, digiti-zation has become a core element of inno-vation. As a result, an intelligent measur-ing device or sensor provides more than just accurate measuring values. In addi-tion they can provide qualified real-time

17News

IndustrialIndustrial Weighing and Measuring

METTLER TOLEDO Industrial News 172

Packaging Logistics and ShippingQuality Control in ProductionProduction /WarehousingMaterial Receiving

Publisher / ProductionMettler-Toledo GmbHIndustrial DivisionHeuwinkelstrasseCH-8606 NänikonSwitzerland

Subject to technical changes© 02/2017 Mettler-Toledo GmbH

Intelligent Logistics

Start production supervision at your factory gates. Review the deliv-

eries from your suppliers with measuring equipment such as floor

and bench scales. Floor scales help to verify large quantities of in-

coming goods. Weighing devices feed weighing results to your net-

work and prevent over- or out-of-stock situations.

Use warehouse entry to gather data

Use bench scales in warehousing to perform picking tasks, cycle

counts and prepare exact deliveries for intra logistics. Get orders

from your ERP systems and send back the results of your opera-

tion. Weighing terminals feature advanced human-interface func-

tions, such as user prompting, for error-free handling and speedy

processing.

Preventative maintenance with Remote Equipment monitoring

Cloud-based remote monitoring of weigh modules, load cells and

scales prevents downtime. Remote support facilitates fast repairs

and reduces the need for on-site interventions. All data transfer is

protected with third-party accredited security measures.

Industry 4.0 and manual workplacesNot only automated production lines ben-efit from Industry 4.0; manual workplaces also can increase productivity when they can overcome the challenges of the novel interaction between people, machines and data. Workers have to manage faster processes, a higher degree of digitali-zation and a greater variety of applica-tions. In addition, they have to deliver continually high quality while product customization increases. That is why it is important to bring together efficiency, ergonomics and data integration.

www.mt.com/ind-4-0-in

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METTLER TOLEDO Industrial News 17 3

Collect+™Data Collection Software

Packaging Logistics and ShippingQuality Control in ProductionProduction /WarehousingMaterial Receiving

Innovative HMI’s increase handling speed by 30%

Reduce waste and quality cases with innovative piece-counting

and quality check solutions. Scale management software saves all

article records and makes recalling article data error-free and fast.

Together with the colorWeight® result indication this speeds up-up

quality checks even if the product variety increases significantly.

Monitor production flow and worker efficiency in real time

Collect+™ software captures production-weight and process data

from every scale on your shop floor and visualizes it in an easy to

understand dashboard. Use data for audits, quality initiatives and

process optimization.

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Testing of hazardous-area equipment is essential to ensure a safe weighing workplace.

No Compromises on SafetyPractical Tips from a Hazardous Areas Expert

Recent changes to hazardous-area standards and regulations raise questions about the im-

plications for chemical manufacturers. We sat down with Richard Schuller, lead assessor

and certification manager at DEKRA, a world-leading expert organization. He explains what

production managers and safety officers have to consider for a safe weighing workplace.

How do recent regulatory changes impact equipment users? Global standards organizations and na-tional authorities are harmonizing and tightening regulations to raise safety lev-els and simplify international trade and production. Some regulations are targeted at equipment users, such as the recently updated Canadian Electric Code (CEC), which now requires the use of the inter-national Three-Zone system for all new installations. Other regulations address equipment manufacturers, such as the new IECEx standards on non-electrical equipment (IEC 80079-36 and 80079-37). They close a gap that allowed equipment manufacturers to “self-certify” non-elec-trical devices.

Why is non-electrical equipment considered a hazardous-area risk?Non-electrical equipment was considered an ignition source already under ATEX. For example, rotating parts or movable parts, such as springs and drive belts, can generate heat or static electricity from friction. Devices based on a light metal (e.g. aluminum) construction can gener-ate sparks on impact, for example when tools are dropped.

What are the main causes of accidents in hazardous areas?The main cause, by far, of accidents in hazardous areas is human error. Most often it is lack of knowledge and training that leads to negligence and carelessness. All in all, it comes down to insufficient quality control. Proper training, such as IECEx 05 Personnel Competence, prevents many problems. Can you give an example of the most common problems?Typical problems we see at inspections in-clude flame-proof enclosures with miss-ing bolts, cable glands with missing

sealing, or the wrong combination of pro-tection types, such as flame-proof enclo-sures (Ex d) with increased safety cable glands (Ex e).Are such issues less common with intrinsically safe solutions? Each type of protection requires its own knowledge. Intrinsically safe solutions, for example, depend on the accurate use of barriers between hazardous and safe areas. That said, if an intrinsically safe system has been correctly installed, the incident risk during operation and main-tenance is lower compared to other pro-tection methods.


What are the responsibilities of equipment users to ensure safety?The equipment user has to fulfill four key aspects to ensure safety and regulatory compliance in hazardous areas: 1. Accurate classification of the hazard-

ous area into zones or divisions2. Correct installation of the equipment

by competent persons3. Implementation of safe operations

through training and standard oper-ating procedures and

4. Regular verification if the equipment and its components are functioning properly.

What are the responsibilities of the equipment manufacturer and DEKRA in the certification process?Initially, the manufacturer must design the equipment in accordance with stan-dards and regulations. When they apply for a certificate, the manufacturer must

provide technical documentation and a description that details the compliance with the protection types used.

At DEKRA, we verify if the analysis was done correctly and, if applicable, imple-ment test programs. For example, we test seals and perform impact and aging tests. When all tests have been completed satis-factorily, we conduct an internal review to ensure all processes were followed and no mistakes were made. Finally, we issue the certificate and the equipment can be re-leased to the market.

www.mt.com/ind-intrinsic-safety-in

The Most Common Errors in Hazardous-Area Installations

Wrong or poorly designed equip-ment is unsuitable for specific envi-ronmental conditions. 1. Poor or no maintenance on Ex d

enclosures facilitates corrosion of the protection.

2. Incorrect installation of Ex d cable glands enables flame propagation in case of an inter-nal explosion.

3. Missing separation of Ex i and non Ex i circuits or incorrect earthing jeopardize intrinsic safety of circuits.

4. Ingress of water in Ex e enclo-sures due to condensation can cause short circuits and gener-ate sparks or fires.

Richard SchullerLead Assessor /

Certification Manager

DEKRA Certification

B.V, Netherlands

Richard is an expert in hazardous areas. During the past 16 years, he worked in various roles. He has worked as an engineer of intrinsically safe and flame-proof equipment and as a project manager for intrinsically safe equipment. Those roles were followed by his position as Auditor for Quality Management Systems of Man-ufacturers and Certification Manager for Explosion-safe Equipment.

DEKRA is one of the world‘s leading expert organizations with more than 37 000 employees in 50 countries. DEKRA is Notified Body for the ATEX Directive, is ac-credited as a Certification Body and Test Laboratory for the IECEx Scheme and accredited by INMETRO/CGCRE Brazil. In addition, DEKRA has agreements with FM and QPS (North America), KGS, KTL, KOSHA (South Korea) and TIIS (Japan) to assess equipment according to local standards.

www.dekra-certification.com/explosion-safety


Calib

ratio

n How to Optimize Calibration Efforts With a Risk-based Approach

Regular calibration based on a thorough process-risk assessment helps stabilize produc-

tion while conserving time and resources. Testing too infrequently risks undetected accu-

racy problems, while testing too often interrupts production. Find out the right schedule for

you in just two minutes and comply with the new ISO 9001 risk-based thinking approach.

Optimize calibration effortsA systematic risk-based review of your weighing process may be the most im-portant step an organization has to take to optimize calibration effort and comply with the revised ISO 9001 standard.

METTLER TOLEDO has developed Good Weighing Practice™, a standardized sci-entific methodology for secure selection, calibration and operation of weighing equipment based on a thorough risk anal-ysis. During a consultation, our GWP® experts help you objectively assess risks related to your weighing equipment and develop the right risk-management pro-cess to prevent failures before they occur. Eliminate unnecessary testing when risks are low and ensure top performance when risks are high. We also provide the full documentation for a smooth transition to ISO 9001:2015.

Learn more about Good Weighing Practice (GWP) and calibration:

www.mt.com/gwp-verification-in

www.mt.com/calibration-in

The 2015 revision of ISO 9001 has brought a major change regarding the risk-based thinking approach that is found through-out the entire standard. It also impacts the calibration process. The only way to ensure that measurements deliver the kind of cost, quality and revenue results that help improve profitability is to choose the right procedure and schedule to peri-odically re-calibrate your scale. However, industrial environments are tough on weighing equipment. If scales fail or de-liver inaccurate measurements, you risk production downtime, poor product qual-ity, regulatory non-compliance, increased liability and potential profit losses.

Risk-based thinkingMany companies are already familiar with risk-based thinking from other stan-dards, such as Good Manufacturing Prac-

tice or safety standards. Risk is usually analyzed in two parts: The likelihood (probability) that it happens and the se-verity (impact) if something happens.

Impacts on calibrationTranslating risk-based thinking into the calibration process starts with evaluating the impact of inaccurate weighing results on your business process. Examples are loss of material and time, out-of-specifi-cation results, production stops, product recall and reputational damage. Addition-ally, the impact of wrong measurements on people and the environment has to be assessed. Finally, you must estimate how probable the detection of the faulty mea-surement is. The more accurate a weigh-ing process has to be, and the higher the negative impact of faulty measurement, the more testing is required.

The higher the required weighing accuracy and business impact of faulty measurements, the more testing is needed.

Accu

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(+/-) 0.01% Medium Serious High High

0.1% Medium Medium Serious High

1% Low Medium Medium Serious

10% Low Low Medium Medium

Weighing

Risk

Minor Moderate Significant Severe

Business impact of inaccurate measurements

Weighing Risk Assessment Matrix


New Requirements: ISO 9001:2015

The most relevant update is the introduction of risk man-agement in the quality man-agement process. Risk iden-tification, assessment and management are key activ-ities to maintain quality. To maintain their ISO 9001 cer-tification, companies need to adapt to the new standard by September 2018.

www.mt.com/ind-iso9001-in

Recommended Performance Verification ActivitiesService ContractMaintenance and repair YearlyTestsCalibration (by service) YearlyMinimum weight certificate YearlyLinearity YearlyEccentricity (by user) –Repeatability (by user) QuarterlySensitivity (by user) WeeklyWeightsWeight 1 1 000 kg Class M2 or betterWeight 2 100 kg Class M2 or betterRecalibration interval of weights Every two yearsTest TolerancesSensitivityWeight 1 Warning limit 1.66 kg

Control limit 5 kgRepeatabilityWeight 2 Warning limit 0.25 kg

Control limit 0.75 kg

Risk Assessment UnitWeighing accuracy 1%Impact of wrong measurements on business process MediumImpact of wrong measurements on humans, animals and on the environment LowWrong measurements can be discovered easily No

Example of a GWP® Verification for a scale including the risk assessment and recom-mended testing activities.


Doubling ProductivityWeighing Solutions are the Key

Cándido Muñoz now has more eficient workplaces to speed up portioning tasks.

has helped to create a great improvement in efficiency and productivity,” says David Muñoz Pascual, Cándido Muñoz.

Reliability in a harsh environmentCándido Muñoz deployed scales designed to withstand wet and harsh environments. Thanks to the scales’ reliability under those difficult conditions, Cándido Muñoz personnel note a lack of technical prob-lems both with the scales and scale con-nectivity. That is in stark contrast to the company’s previous scales, which con-stantly needed replacement parts.

The food processor now uses the ICS469 scales, with colorWeight® functionality. This feature speeds up the process by using colored lights on the terminal dis-play to indicate when weights are within accepted tolerance. The ease of putting a carrot tray on a scale, adding produce until the light turns green, then moving

Cándido Muñoz was founded more than 40 years ago when Cándido, a greengrocer in Madrid, relocated to Segovia and began sending fresh country fruits back to the family stall. From those humble begin-nings, Cándido Muñoz has grown to sup-ply markets, supermarkets and intermedi-ary produce distributors with fresh carrots and leeks across Europe.

Today, the company has its own produc-tion facilities in Segovia and outsources some of its processing to both Segovia and Andalucia. Forty operators that handle orders work demanding shifts in humid conditions. Loads are particularly tough on Mondays and Fridays.

To keep pace with rising demand for its products and to ensure ongoing prod-uct quality, 33 METTLER TOLEDO scales and two Signature metal detectors were placed along three production lines. That helps ensure both weighing accuracy and that there is no contamination in com-pany processes. Scales are connected to network PCs stationed outside the humid production floor to gauge operator perfor-mance, determine a day’s pay and provide traceability.

The METTLER TOLEDO scales have more than doubled production. “The fact that they are able to monitor what is being weighed and processed by every operator

Spanish company that specializes in growing and handling carrots and leeks has long

sought how to improve their process to get its products faster to market. Today, 33

PC-connected scales stand up to humidity and heavy loads to provide fast, traceable

weighing at its processing facilities.

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onto the next tray takes a lot of work out of the process, reducing operator fatigue and improving productivity.

The way loads are weighed depends on whether it is a bulk order for a produce stand or packaged goods for a supermar-ket. Some scales must stand up to bulk boxes of machine washed produce that are checkweighed. Operators also prepare individual vegetables for plastic bagging, sometimes cutting off ends, then adding them to tared trays.

Worry-free weighing for yearsCándido Muñoz operators are very pleased with the way the scales stand up to all their processes while offering pristine connectivity to their PC-based tracking system. The company expects that their scales will provide them with worry-free weighing for many more years to come.

www.mt.com/ics-scales-in

Classic

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Method 1

Basic weighingOperator places the item on the scale and checks if the displayed result is within the expected tolerance range.

Which Method is Best for Your Process?

Download White Paper to speed up your process www.mt.com/ind-fast-portioning-in

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Method 2

Portioning from bulk container beside the scaleOperator puts an empty container on the scale, tares it and starts portioning.Once the defined tolerance range is reached, he tares the scale and starts working on the next portion.

Method 3

Portioning from bulk container on the scale (take-away mode)Operator portions, with the bulk product placed in tray, directly out of the tray intocontainers beside the scale, tares the scale and starts to fill the next portion.


Fork

lift S

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s Keeps WorkingWhen Other Scales Break Down

Forklift trucks operate in tough, fast-paced environments. Your forklift scale should be rug-

ged, robust and built to last. Use a forklift scale that will stand the test of time, providing

continued high performance while keeping costs low.

www.mt.com/VFS120

Robustness Put to the TestTo test the robustness and reliability of the VFS120 forklift scale, it was subject to a series of durabil-ity tests. One of these tests involved driving the fork-lift truck into a wall at speed. The impact caused the wheel of the forklift mast to break. The scale, on the other hand, survived the crash unharmed.

Holds Calibration for 12 MonthsEven if your forklift crashes into something, its pat-ented three-point suspension helps the VFS120 forklift scale to maintain its calibration. Where scales using a four-point suspension can be thrown out of calibration by vibration or knocks and bumps, the VFS120 pro-vides consistent results without the need for frequent readjustment.


150% Overload ProtectionThe VFS120 can withstand an overload of up to 150% of the forklift’s capacity rating. The forklift will typically tip with an overload of 125%, meaning there is almost no chance of the scale breaking from an overload.

Solid ProtectionAll sensitive components – loadcells and electronics – are incased within the solid steel carriage, protecting them from damage from any angle.

Designed for SafetyA large safety window makes it easy for the operator to see out for safe positioning, lifting and transport – avoiding accidents, damage and associated costs.

Example SavingsWith each forklift scale you save:

1 minute of weighing time per pallet

300 meters of transport distance per pallet

5 square meters of space

$ 1 167 in labor per year

$ 7 875 in energy per year

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For more informationwww.mt.com

No SurprisesReal-time Equipment Monitoring

Don’t wait for Industry 4.0 to happen. Start monitoring the performance of your weighing equipment today with InTouchSM Remote Services. Connected scales send proactive alerts that enable you to immediately respond to performance issues.

Increase uptime and ensure consistent measurement quality.

For more information about Real-time Equipment Monitoring visit:

www.mt.com/ind-intouch-remote-in

Security without Compromise• ISO27001-2013 certification• User authentication and

access control• No changes to existing IT or

security infrastructure

Efficient Equipment Management• Real-time equipment status

information• Fact-based timing of preventive

maintenance activities

Improved Performance Control• On-going monitoring of

measuring performance• Periodic asset status reports

to optimize processes

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Local contact: www.mt.com/contacts

Mettler-Toledo, LLC1900 Polaris ParkwayColumbus, OH 43240

Mettler-Toledo Hi-Speed5 Barr RoadIthaca, NY 14850

Mettler-Toledo Safeline6005 Benjamin RoadTampa, FL 33634

Mettler-Toledo CI-Vision2640 White Oak Circle, Unit AAurora, IL 60502

Mettler-Toledo, Inc.2915 Argentia Road, Unit 6Mississauga, Ontario L5N 8G6

industrial weighing and measuring - mettler toledo...that help improve profitability is to choose...

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