ets, evaluate on a statistical basis the corresponding status reports of the diecasting machine and allow the provision of key information to a team of experts for analysis.

Downtime Increases the Energy Consumption per Good Part

Even if the machine is idling temporarily, the molten

product must continue to be kept warm and all required subassemblies must be kept in standby mode. Currently, up to 60 percent of the power consumption accrues dur- ing regular production even though the machine is not producing. As a result, all of the good parts manufactured have to help bear the costs of these “stand-by losses.” In other words: higher overall equipment effectiveness reduces the energy consumption per good part. It becomes clear that improving the OEE has an unequal effect on part costs than exclusively optimizing the energy efficiency of the producing diecasting cell itself. A simplified calculation model shows the percentage of influence an improved OEE has on the energy consump- tion or manufacturing costs, respectively (Fig. 5a). By comparison, the identical calculation can be redone for improving energy efficiency.

Modelling Provides the Basis of Decision-Making Starting with an hourly rate of the machine, that takes

into account the fixed costs to be expected and the actual energy costs, the model shows how the total costs to be borne for a good part are reduced by increased availability of the system: a 15 percent improvement of the OEE shown in this example affects the manufacturing costs ten times more than simply reducing the energy consumption by 15 percent. By varying the parameters of the model, the influence of a clear reduction of the stand-by energy con- sumption can be simulated (Fig. 5b). Tis decreases the influence of increased system availability on the reduced energy consumption. However, the ratio of the cost sav- ings remains the same. Using this kind of modeling provides an answer to the question of whether the goal of reducing costs means an investment in new, lower energy consuming system components or, alternatively, in measures to increase the availability of an existing installation.

Availability and Energy Efficiency The ever increasing cost pressure continuously

calls for innovation, including for diecasting. The use of more energy efficient diecasting machines plays an important role in lowering costs. The VDMA standard cycle for diecasting machines has made them comparable. Furthermore, the improved overall equipment effectiveness has an even more signifi- cant impact on the balance sheet for total costs per manufactured good part. A significant increase in productivity and decrease in costs can be achieved with an appropriately matched, preventative package of services. 

52 | FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION June 2015

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