Reducing scrap and generating growth.
ItalPresseGauss has established itself as a reliable partner in the die casting industry, especially in cooperation with customers who require high production capacity and quality. The customer, which has been working with ItalPresseGauss since its foundation in 2016, produces over 300,000 die-cast parts and assemblies per year for the global automotive industry. To continue this positive development, they were looking together for digital solutions to reduce the scrap rate and optimize the performance of the casting equipment.
Process optimization by AI
Working with IIoT experts from Monitizer, a sister company to ItalPresseGauss, they installed Monitizer®│PRESCRIBE on one of the customer’s 11 die casting cells.
With proven success in both high pressure and low pressure die casting environments, PRESCRIBE is an ‘AI-as-a-service’ solution powered by AI partners at DataProphet. PRESCRIBE works by analysing historic and live die casting data to learn which process settings deliver the best quality outcomes.
Using this knowledge, and accounting for real time production conditions, it proactively prescribes control adjustments that keep production stable for consistent quality.
Steven Li, Aluminum Project Director for ItalPresseGauss, said: “The customer already had their own Manufacturing Execution System (MES) for collecting basic machine data. As Monitizer is compatible with existing equipment and software solutions, this meant implementation was straightforward. We could add to their capabilities without them having to replace or update anything.”
A quality improvement that is ready for immediate use
In just one production batch, PRESCRIBE enabled the customer to reduce their average scrap rate by 52%, and is now helping them to maintain this impressive performance.
If the results achieved on this project - which involved specific dies on one cell - were to be replicated across all dies and products, the customer could expect to save almost 130,000 Euros a year in scrap reduction alone. Before factoring in additional energy savings and productivity gains.
Steven Li added: “This customer always tells us that they like our high pressure die casting machines for being easy to use. That they deliver reliable performance with minimal maintenance effort. I think they now feel the same about their digital solution! PRESCRIBE delivered great results, quickly, and will enable the customer to keep doing so. We’re already talking about expanding the project to include more dies with a view to wider roll out.”
