Improving quality in sheet extrusion manufacturing

JMC Motion, a Vention Automation Partner, is a system integrator that provides full turn-key automation systems to its clients.
 
JMC’s client found themselves spending a large number of resources, both financial and labor, on scrap and rework efforts. They tasked JMC with finding a creative solution to automate scrap reduction and process verification within a short timeframe and with a strict budget.

The solution consisted of multi-station thickness scanners for process control of continuously extruded sheets. With five linear actuators, five HMIs, seven remote operator panels, and data logging for traceability, the solution integrates seamlessly with the client’s existing extrusion lines. In addition, it has upstream data for process adjustments and downstream finished product thickness verification.

JMC Motion successfully created an end-to-end solution to reduce scrap and meet the customer’s needs. Showing the operators real-time thickness data of the extruded sheet allows them to adjust flow bolts and immediately see the results of those changes.
 
Having this real-time ability greatly reduced the scrap rate from before when defective material would make it all the way through the process and be caught at general quality control checks (or worse by the customer). All along, a constant flow of scrap material was being extruded until the issue was detected.
 
The modular design and Vention platform facilitate easy future modifications, retrofits, and expansion. Plans include integrating a part marking system to highlight defects for straightforward operator identification.