Sacmi Imola – an Industry 4.0 Applied to Can Production
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AN INDUSTRY 4.0 APPLIED TO CAN PRODUCTION From the metal sheet to the terminated can, the Can 4.0 Stefano Severi Vision Systems Sales Area Manager SACMI IMOLA Emilio Chiesi General Manager PARMACONTROLS 1 About us… 2 . SACMI was founded in 1919 . SACMI is an Italian Cooperative: it designs, produces and sells manufacturing systems for the ceramic and packaging industries. SACMI is one of the leading Italian companies in terms of Billing in this worldwide sector. 3 SACMI, a major group International development, enthusiasm for innovation, a solidity that allows ambitious, wide-ranging planning: these factors have made SACMI a worldwide success and the leading provider of cutting-edge technology for the ceramic and packaging industries. Thanks to constant commitment, SACMI is a partner customers can count on, capable of identifying and developing optimal solutions to ensure the highest standards. 4 Company Profile TODAY: 270,000 M2 5 MAIN STRENGTHS provider of plants to st provider of 1 the global ceramics st st 1st machines for cap industry 1 1 manufacturing in the world 1 476 million euros 4 341-strong of sales workforce INDUSTRY 4.0 6 Our Vision is Your Quality Revenues from sales and services 1 476 1 394 in millions of Euro 1 354 1 303 1 243 1 227 1 196 12 14.6 13% 15% 15% 11 11 % % % % Italy 2011 2012 2013 2014 2015 2016 FORECAST 2017 7 4.341 . More than 80 companies with SACMI EMPLOYEES employees, sales and support services, including 30 production facilities in Italy, in the World 1,335 Germany, Egypt, Iran, USA, Mexico, Outside Italy Brazil, India, Indonesia, China Germany Italy 237 2870 Russia 28 China North & Korea Europe America 454 México 201 155 Middle East Far East 31 Índia 71 South 64 America Africa 8 61 8 Our Vision is Your Quality Group investments 65 47 40 40 38 35 2012 2013 2014 2015 2016 FORECAST 2017 In millions of euros 9 Business Divisions Ceramics Packaging Food Automation . Tiles . Caps . Cocoa . Vision Systems . Sanitaryware . PET preforms . Chocolate . Line supervisors . Plates and cutlery . Packaging . Wrapping . Automation . Heavy clay . Beverage lines machines . Special pressure . Technical ceramics 10 Our Vision is Your Quality Ceramics Packaging Food Automation 11 Food and Beverage Industry Vision Systems Ceramic industry 12 INDUSTRY 4.0 Applied to the Canmaking Industry 13 Our Vision is Your Quality Interconnectivity • Interconnectivity is the heart of 4.0 approach and the way that SACMI MVS Vision Systems communicate and operate with your plant. • MVS can be easily interconnected thanks to the support of communication protocols such as: • OPC – UA • MODBUS • HTTP • Data such as counters, alarms, machine status and other information become visible remotely, without being in front of the equipment. • Interconnectivity permits to operate MVS remotely, avoiding any direct interaction of the operator 14 Our Vision is Your Quality Remote connection, Home Page The Home Page provides real-time information about the Vision System 15 Our Vision is Your Quality Remote connection, Charts of statistic data 16 Our Vision is Your Quality Charts of statistic data by tool number The system allows visualization of specific statistical chart by tool number, informing the defects number of defects by tool. The darker the color, the higher the number of defects 17 Our Vision is Your Quality OEE – Overall Equipment Effectiveness 18 Our Vision is Your Quality Panorama Supervisor • PANORAMA supervisor allows the visualization in a window of all SACMI MVS vision systems installed in a production plant, providing in real time the main information such as alarms, main statistical data, active inspection recipe and OEE. • PANORAMA allows to interact directly and remotely with a specific vision system. • PANORAMA can interchange information with your ERP system 19 Enterprise Resource Planning system 20 Our Vision is Your Quality Panorama supervisor Enterprise Resource Planning system 21 Our Vision is Your Quality We Close The Loop! An Application Example 22 Our Vision is Your Quality We close the loop! Enterprise New SKU Resource Planning system 23 Our Vision is Your Quality We close the loop! • Help to maintenance Defects by tool number 24 Our Vision is Your Quality We close the loop! • Help to maintenance Defects by tool number 25 Our Vision is Your Quality We close the loop! 26 Our Vision is Your Quality We close the loop! Enterprise Production Data Resource Planning system 27 Our Vision is Your Quality Outstanding Advantages • Reduces line down-time • Improves line efficiency • Reduces ejectionsSAVE MONEY! • Increases productivity • Helps Maintenance • Helps Quality Control 28 SACMI MVS Vision Systems Our Team for the Canmaking Industry 29 Our Vision is Your Quality Vision Systems for the Canmaking Industry • Eclipsim-COAT – Coating inspection in metal sheets • Eclipsim-DECO – Decoration inspection in metal sheets • iCanEnd – multi-line inspection of can-ends • Ulysse – “All-in-One” system for can ends and lugged caps • iCan – Inside Can Inspection • LabelCheck-360 –Seaming or Labelling inspection • ElioSCan – Decoration inspection in beverage cans • DecoCap360-3D – Decoration inspection in lugged caps 30 Our Vision is Your Quality Eclipsim-COAT - Coating inspection Main features: • Line scan color camera • Precision down to 0.15 mm/pixel • Patented Chrometriq Illuminator, for "Chromatic" and "3D" defects • 100% FULL production inspection. • 100% control of sheet • Up to 6,000 sheets / hour. • Max sheet size (mm): 1200x1200. 31 Our Vision is Your Quality Patented Chrometriq illumination Target: Achieve maximum visual evidence of the defect by using Real different geometric and colorimetric components of light. R G B Results Acquired image 2 Diffused light 1 Direct light SMART RGB FILTER 32 Our Vision is Your Quality Eclipsim-COAT - Detectable defects • Oxidations • Grease strips • Dirty inkwell • Drops • Water Marks from the inkwell • Grid marks • Lack of coating • Drops of varnish • Soot • Smears • Smudges • Scratches • Dirt and contaminations • Hickeys • …others… 33 Our Vision is Your Quality Some detectable defects BUBBLES 34 Our Vision is Your Quality Eclipsim-DECO - Lithographed sheet inspection Main features: • Line scan color camera • Precision down to 0.15 mm/pixel • LED Illuminator for Matte colors • LED Illuminator for Bright colors (Gold, Silver) • 100% FULL production inspection. • 100% control of each sheet • Up to 6,000 sheets / hour. • Max Sheet Size (mm x mm): 1200 x 1200 35 Our Vision is Your Quality Eclipsim-DECO – Detected defects Diffused defects Color plane presence/absence Color registration Wrong colors Color variations - E (Warning / Alarm) Position (with respect to the edges) Double print Punctual defects Smears Smudges Scratches Dirt and contaminations Hickeys …others… 36 Our Vision is Your Quality Some detected defects Double print 37 Our Vision is Your Quality iCanEnd – Multi-line Can End Inspection iCanEnd family is based on SACMI patented Chrometriq illuminator, available in three different sizes • iCanEnd-70 for beverage ends and aerosols • iCanEnd-100 for ends having any shape and a maximum size < 100 mm • iCanEnd-200 for ends having any shape and a maximum size > 100 mm 38 Our Vision is Your Quality Ulysse – «All-In-One» Vision System for can end inspection Main features • Compact “All-in-One” unit • Computer integrated inside the illuminator • Based on Chrometriq illuminator • Easy installation • No electrical wiring (shorter installation time required) • 5M pixels colour camera • Also available in UV (ultraviolet) and IR (infrared) versions 39 Our Vision is Your Quality Range of applications 40 Our Vision is Your Quality iCan – Inside Can Inspection iCan family of Vision System are dedicated to the ICI – Inside Can Inspection. Main features: • Two different size of illuminators • iCan-100: Ø < 100 mm, H < 240 mm • iCan-200: Ø < 200 mm, H < 240 mm • 1, 2 or 3 cameras, depending on the can height • An additional camera dedicated to the neck inspection is available for beverage cans • It can inspect both round and shaped cans 41 Our Vision is Your Quality Some detectable defects 42 Our Vision is Your Quality LABELCHECK-360 – Seaming inspection View 1 – 0° View 2 – 90° View 4 – 270° View 3 – 180° 43 Our Vision is Your Quality LABELCHECK-360 - Seaming inspection 44 Our Vision is Your Quality LABELCHECK-360 - Decoration or labelling inspection Main features • Real 3D inspection through 4 side cameras and CVS360 inspection module • High protection grade to allow easy cleaning 45 Our Vision is Your Quality ElioSCan – Decoration inspection in beverage cans Main features • 4 high resolution colour cameras (5M pixel) • 1 top camera • CVS360 inspection module • Real 3D inspection of decoration • Up to 2500 cans/minute • No changeover required 46 Our Vision is Your Quality 47 Our Vision is Your Quality Some detectable defects 48 Our Vision is Your Quality DecoCap360-3D – Decoration inspection in lugged caps Main features • CVS360 inspection module • 4 side cameras • 1 top camera • Precise inspection of the decoration on top and sidewall 49 Our Vision is Your Quality Some detectable defects 50 Thank you very much for your kind attention For any request please contact: Parmacontrols SRL Mr. Emilio Chiesi General Manager [email protected] Phone +39 0521 1797270 www.parmacontrols.it 51.