integrated material flow - epda · 2016-08-09 · the homag group development 04.07.2016 4 the...

© HOMAG Group

Integrated Material Flow

HOMAG Automation GmbH

Presenter: Jan Ihde [email protected]

June 17th, 2016

© HOMAG Group

AGENDA

� Introduction of the HOMAG Group within the DÜRR Group of companies

� Integrated Material Flow � Successful concepts from woodworking to plastics industry

� Examples of intelligent sorting and collating solut ions for plastic panels� automatic and intelligent storage and retrieval solutions� other sorting and collating solutions

© HOMAG Group

Structure of the Dürr Group

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Paint and Final Assembly Systems

Paint shops, Final assemblysystems

3,400

1.4 billion

Application Technology

Paint applications, glueing and seam sealing technology; Products for industrial painting

1,900

0.6 billion

Measuring and Process Systems

Balancing, assembly, test, filling and cleaning technology

3,000

0.6 billion

Clean Technology Systems

Exhaust-air purificationsystems, energyefficiency technology

500

0.2 billion

Woodworking Machinery and Systems

Machinery and plants for woodworking

6,000

1.0 billion

Employees

Sales

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1960 – Foundation Hornberger Maschinebau OHG by Eugen Hornberger und Gerhard Schuler

2007 – Successful IPO

2014 – Takeover by DÜRR Group

The HOMAG Group development

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The HOMAG Group development

1976Integration

1977FoundationHOMAG MachinerySão Paulo

1980Integration

1985Integration

1986Integration

1987Integration

1990Integration

1994FoundationHOMAG MachineryShanghai

1998Integration

2002Integration

2009Integration

2004FoundationHOMAG MachineryŚroda

2011FoundationHOMAG MachineryBangalore

2014Integration

2014Takeoverby

Eugen Hornberger and Gerhard Schuler

2014Fusion of BARGSTEDT & LIGMATECH

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Worldwide production, sales and service network

HOMAG Group worldwide

Production

sales and service companies and sales partners

© HOMAG Group 6

Business areas HOMAG Automation

Storage & RetrievalTechnology

Automation & Robotics

Buffer and Collating Systems

Assembly Technology

Packaging Technology

HOMAG AUTOMATION - Products and services

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HOMAG AUTOMATION

Managing Director:

Production area:

Employees:

Christian Breyer,

Jochen Fischer

18.400 m²

383

HOMAG Automation GmbH Contact:

HOMAG Automation GmbH

Ligmatech Str. 1 | 09638 Lichtenberg

Tel: +49 37323 16-0 | Fax: +49 37323 16-170

GERMANY

© HOMAG Group

AGENDA


� Integrated Material Flow � Successful concepts from woodworking to plastics industry

� Examples of intelligent sorting and collating solut ions for plastic panels� automatic and intelligent storage and retrieval solutions� sorting and collating solutions

© HOMAG Group


What do we mean by

INTEGRATED MATERIAL FLOW ?

© HOMAG Group


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Construction Datageneration Planning Format/

EdgeCutting AssemblyDrillingCollating/FeedingSale Storage Laminating Fittings-

mounting Packaging Service

Everything from a single source

© HOMAG Group

AGENDA


� Integrated Material Flow Successful concepts from woodworking to plastics industry

� Examples of intelligent sorting and collating solut ions for plastic panels

� automatic and intelligent storage and retrieval solutions� sorting and collating solutions

© HOMAG Group

Intelligent sorting and collating solutions

Buffer and Collating Systems

Sorting and collating lines equalize part flows, arrange them as needed and flexibly align them to the actual production process.

Possible interfaces to:

© HOMAG Group


Intelligent Storage & Retrieval for plastic panels

Horizontal storage & retrieval systems offer more leeway in combination with processing machines and with great panel varieties. They are the ideal solution for an effective production.


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Conventional (plastic) panel storageby cantilever racking

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� How much space do you require for storing material?

� How much time do you need for finding the right material?

BEFORE – narrow forklift paths, manual panel search AFTER – Save material flows, immediate material supply

PLENTY EMPTY / UNUSED SPACE!!!!

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Moving carriage on bridge with traverse

Control cabinet /Switchboard

Processing machinefor example saw and / or CNC Panel Infeed / Outfeed

Positions

Storage area(stacking area)

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� Priority Management => Possible day and night operation

� Store and retrieval system operates 24h / 7 days (if required)

24 hours

� Infeeding of panels� Pre-Sorting of next days work� Leveling of stack heights

� Feeding of panels to processing machines or outfeed positions

� Infeeding of panels � Outfeeding of panels

� Pre-Sorting of next days work� Leveling of stack heights

0:00 – 08:00 hours 08:00 – 16:00 hours 16:00 – 00:00 hours

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ST71 Traverse

Creation of vacuum byejector (no vacuum pump required)

Specially designed for more demanding panel types that require stronger vacuum flows due to the individual panel properties

Lift capacity: up to 350 Kg

Width: min. 400 – max. 2200mmLength: min. 800 – max. 5600mm

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Example of a data flow of an integrated material flow:

WEEKECNC / Nesting machinefor plastics

HOLZMApanel saw for plastics

HOMAG AutomationStorage and retrievalsystem for plastics

HOLZMALabel printer

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Explanatory animation for an integrated material flow- Intelligent manufacturing -

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⇒ Remarkable storage capacity for plastic panels

Sample Calculation:

Store and retrieval system with approx. size of 50 x 12m

Various different sized panel stacks

In total approx. 70 stacks with an average stack height of 1.6m

⇒ 112m total stack height⇒ 4480 panels with 25mm

thickness

Approx. 50m

Approx. 12m

What is an Intelligent Storage & Retrieval system in a nutshell?

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⇒ Inventory manager / full stock transparency Our self-developed software keeps track of any panels, panel movements over time and corresponding stock levels of each material

Software allows for:

� IntelliStore operation (statistical monitoring)

� panel rotation by age

� Control and administration also of external stock

� Offcut Management included

� Settings of min. and max. stock levels

� Statistical control and self analysis tool available


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⇒ Material pre-sorting done over-night

Pre-sorting possible nearly anywhere

� Dedicated Pre-sorting positions� Infeed / outfeed positions� On top of existing stacks

Automatic generation of the pre-sorting orders from the running production

Automatic generation of the pre-sorting orders from the production order of the saw / nesting machines

No more waste of storage space for pre-removal plac es

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⇒ Space saver resulting in a reduced footprint for storage area


No more forklift truck aisles required and therefore no ‘dead spaces’ between racks!

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⇒ Feeder and stacker for processing machines (either directly attached or not)


Store & retrieval system withintegrated processing machine(s)

Store & retrieval system withintegrated processing machine(s) and external processing machines

Store & retrieval system withexternal processing machines only

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⇒ Interface module with existing ERP Systems via open SQL- data base


� Connection to external optimization software or production planning systems directly at SQL data base level

� Flexible import and export interfaces (SQL data base, Excel, ASCII, BDX)

� Automatic insertion of master data from and to external systems and administration of master data from any interface

� Direct communication with external systems considering available and reserved stocks

� Intake of orders from PPS / ERP systems possible

� Supplier-, delivery- and storing data management (complete traceability acc. to ISO 9000)

ERP

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Cut to Size – double bridge system

Large variety of panels (SKU’s) – Daily output up to 700 panels (incl. pre-sorted panels for processing machines)

Approx. 100m

© HOMAG Group

Panel trader – double bridge

Large varity of panels – Daily output approx. 400 panels (incl. pre-sorted panels for processing machines)

© HOMAG Group

Plastics Cutting Center – double bridge

Approx. 65m

Medium to large variety of plastic panels – Daily output approx. 600 panels (incl. pre-sorted panels for processing machines)

© HOMAG Group

Kitchen Manufacturer – twin-bridge

Storage System with 1 bridge and feeding position

Stand-Alone Storage System with 2 bridges

Approx. 86m

Approx.

16m

Large variety of panels – Daily output approx. 500 panels (Pre-sorting of panels over-night for processing machines)

© HOMAG Group


Buffer and Collating Systems (extract)

Sorting and collating lines equalize part flows, arrange them as needed and flexibly align them to the actual production process.


© HOMAG Group


Double sided buffer and collatingsystem with center-wise movingcarriage

+ greater stocking capacity- Reduced cycle times comparedto rack system

One sided buffer and collating system withmultiple rake systems

+ fast access and cycle times- less stocking capacity

Moving Carriage vs. Rake system

integrated material flow - epda · 2016-08-09 · the homag group development 04.07.2016 4 the...

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