Manufacturing Newsletter 9
Manufacturing
Industrial Weighing and Measuring
Reduced Waste by Half
with Smart Weight Monitoring
The Swedish Company Sandvik manufacturers advanced products based on expensive
tungsten carbide. In order to eliminate costly waste, the consumption of tungsten carbide
needs to be precisely monitored and weighed. METTLER TOLEDO’s dosing and
counting solutions helped the company to optimize material flows and costs in production.
The Swedish Sandvik group plays an important role within numerous industrial
sectors in regard to the production of
various advanced products like hot rolling rollers, teeth for circular saws or gaskets. The group has different production
sites and manages the entire set of processes from producing the raw materials
to manufacturing the finished product.
The Sandvik site in Epinouze, France, focuses with more than 100 employees on
the following two activities: wearing
parts production for the aeronautics, automotive, and agri-food industries as well
as rotary knifes for markets associated
with hygiene products.
Complex raw material handling
All the Sandvik products that are manufactured in Epinouze are based on tung-
sten carbide, a material with numerous
mechanical properties and a price that
has risen significantly over recent years.
With several tons being consumed each
week, managing the material itself along
with the transformation of the material
and any rejects is a mammoth task.
“That’s why weight monitoring has a role
to play throughout the entire production
process,” explains Damien Gendron,
Head of Production at the Sandvik Epinouze site.
Material control by weight
It all starts when the barrels of tungsten
carbide powder arrive from the Sandvik
powder production site in Grenoble,
France. The barrels, which usually weigh
100 kg, are identified by bar codes and
are then sorted by grade and according
9
News
Smart Weight Monitoring
to batch number. An initial weight check
is then performed. After that, the powder
is sent to a mechanical or isostatic press.
When the powder comes back, a second
weight check is always carried out to determine the residual weight and monitor
the exact quantity of powder used. The
quantity of powder dispensed to the press
is also measured by weight to ensure the
correct amount. A brand new METTLER
TOLEDO station has just been installed.
“We have always had a METTLER TOLEDO
terminal and this has now been in use
for more than 25 years”, explains Mr.
Gendron. “Therefore, we decided to contact our regional commercial engineer
at METTLER ­TOLEDO, Jérôme Jarrier,
with a view to modernizing the existing
installation,” he adds.
Accurate dosing to the gram
Now an IND690dos terminal that allows
the powder to be dispensed in a feed hop-
Robotic press equipped
with a WMS high speed
precision weigh module.
Publisher / Production
Mettler-Toledo AG
MarCom Industrial
Heuwinkelstrasse
CH-8606 Nänikon
Switzerland
Subject to technical changes
© 02/2012 Mettler-Toledo AG
Printed in Switzerland
2
METTLER TOLEDO
Newsletters 1/2012
Inspection of the tungsten carbide barrels on arrival.
per for small parts production has been
introduced. “High-precision dispensing
when the powder arrives at its destination
is critical to avoid the problem of weight
dispersion, particularly in the case of
small parts. That’s why I ­proposed an
IND690dos terminal with a 12 kg platform that is accurate to the gram,” adds
Jérôme Jarrier. The compression phase
represents a crucial phase of the production process, as it involves a high level of
industrial risk. By introducing a system
for monitoring material consumption
and production times, the reject rate has
been halved in the space of two years. In
addition to this installation, weighing
also plays a role within the context of a
robotic press. The press features an integrated WMS weigh module that enables
highly precise and fast weighing of small
parts that are moved by an articulated
arm. If the weight is not within the set
tolerance limits, all you have to do is readjust the quantity of material being
used by the press.
Know-how
Avoid Waste and
Save Expensive
Material Costs
Learn how smart counting solutions help you to avoid waste
and optimize your material flow.
Rejects checking with a BBK high precision counting scale.
are located directly on the production
lines. “The performance of our site
depends on our ability to monitor
­
­production times and obtain a precise
picture of the material quantities consumed. For us, weighing is absolutely
crucial! That is why all the METTLER
TOLEDO weighing equipment is subjected to an annual inspection by the local
technician,” concludes Damien Gendron.
Register for the free “Best Practice in
Piece Counting” webinar and profit
from expert knowledge!
www.mt.com/ind-counting-webinars
Piece Counting
High performance thanks to
monitoring rejects
Following compression, the tungsten
carbide parts are then baked, which
­
causes linear shrinkage of around 20 %.
They then undergo surface machining
with a diamond grinding wheel. There
is now a dedicated weighing platform for
monitoring rejects. In due course, this
task will be handled by each operator.
These operators will be able to determine the number of rejects thanks to
­METTLER TOLEDO counting scales that
Free!
What Counts for You?
Solutions from the Expert
Get your own free copy of the
piece counting brochure and
profit from ­industry know-how!
WMS High Precision Weigh Module
www.mt.com/ind-counting-brochure
Easy to integrate due to very slim design and off-center position of load plate.
Available with and without internal calibration.
Capacity
120 g – 6200 g
Readability
0.0001 g to 0.01 g
Scale Material
Stainless steel
Load Plate Material
Aluminum, Chrome plated
Protection
IP54, IP66 dust proof with wash down feature
Interfaces
RS232, RS422 and Digital Input and Output.
DeviceNet™, Profibus®, Profinet IO® and EtherNet / IP™ with accessory.
Power Supply
10 to 29V DC; < 4W in operation
Accessories
Fieldbus modules, DIN-rail connection modules for control cabinet, cables
Communication
Direct connection to PLC or control system
METTLER TOLEDO
Newsletters 1/2012
3
Accuracy
Accurate Weighing and Counting
from 1mg up to 300 Tons
Whether you are producing the smallest gears of a clock or products as large as an airplane, high quality
production demands reliability and accuracy. “A chain is only as strong as its weakest link,” therefore it
is important to verify that all of the items that you manufacture are correct and complete every time. ­
METTLER TOLEDO’s weighing solutions help you to sort out improperly manufactured products, accurately
count or verify end product quantities and efficiently determine weight for quality reasons. Benefit from
accurate weighing and counting from 1mg up to 300 tons.
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METTLER TOLEDO
Tiny parts –
accurately counted
Even the smallest pieces, such as gears in
a watch, can be measured and counted
exactly. These tiny pieces can barely be
seen with your eye but can be counted
exactly with high-performance X-Plat­
forms. Used as a sample scale even parts
with a 0.1mg weight are counted with
high reliability. With capacities from 200 g
or 400 g and a readability of 0.0001g, the
X-Platform offers optimal weighing
range and accuracy.
0.001 % deviation can make a
difference in quality
In the production of parts for laptops
even the smallest weight deviations of
0.001 % can indicate shaping errors,
­insufficient coating, incompleteness or a
wrong density. In order to guarantee the
quality of your products, wrong parts
can automatically be rejected with the
help of integrated, high-precision weigh
­modules. The weigh module capacities
range from 120 g to 6100 g with a readability from 0.1 mg to 0.01 g.
High performance
demands quality equipment
Golf balls, golf club parts and tees need
to be counted and their quality must be
verified during production so the player
can perform well during the game. The
BBK4 series of compact scales offer the
unique high precision MonoBloc® technology which maximizes the accuracy of
­results. The capacity ranges from 0.61 kg
up to 35.1 kg. The scales have a readability from 0.001 g up 0.1 g. These compact
scales ­
offer simple weighing, counting,
filling and checkweighing applications all
in one.
X204 / X404: the Accurate Weighing Sensors
200 g / 400 g x 0.0001 g
WMS High Precision Weigh Modules:
120 g x 0.0001 g – 6100 g x 0.01 g
BBK4 Series High Precision Compact Scale:
0.61 kg x 0.001 g – 35.1 kg x 0.1 g
Newsletters 1/2012
Best Practice
Accuracy Achieved
and Maintained
An out of specification scale can
­diminish quality, reduce profits
and increase liability. Because each
use and installation environment
of a weighing system is unique, choosing the optimal scale in the very
­beginning, setting it up correctly and
documenting its accuracy is crucial.
METTLER TOLEDO Service includes:
• Precise installation and set-up
• Equipment qualification
• Calibration according to Standards
• Preventative maintenance
Continued good customer
­relationship
Precisely controlling the completeness of
modules is key to maintaining quality.
Shipping the right quantity of parts is
critical to continue the good ­customer relationship within the broadly networked
supply chain of the auto­motive industry.
K line high-precision platforms offer a
weighing range from 3 - 3000 kg and a
wide variety of platform sizes and terminal options which can be tailored to meet
­individual application needs.
Fly and drive in comfort
and safety
Weight compliance of vehicles such as a
car or an airplane can be crucial to drive
or fly in comfort and safety. M
­ ETTLER
TOLEDO provides weighing solutions for
even the largest and heaviest products.
For example, if you needed to weigh an
entire airplane, METTLER TOLEDO
could produce a ­custom solution using
heavy duty weigh modules. Reliable load
cells and weigh modules are available in
various sizes, capacities and resolutions.
K-Line High Accuracy Bench and Floor Scales:
3 kg x 0.01 g – 3000 kg x 10 g
Reliable Weigh Modules and Load Cells:
110 kg – 300 t, up to 10 000d resolution
­depending on model
Our global service organization
­delivers the following key benefits:
• Properly maintained equipment
­ensuring uptime and performance
• Simplified compliance with industry
specific standards and regulations
• Clear and precise documentation to
reduce the risk of non-compliance
www.mt.com/service
METTLER TOLEDO
Newsletters 1/2012
5
Precise Packaging of Orders
Error-free Order Packaging
of Light and Heavy Components
Schneider Electric Alombard produces very light weight as well as large, heavy electric
components. When packaging orders the challenge was to accurately count heavy and
small components at the same time. To avoid missing parts or overfilling, METTLER TOLEDO
suggested a reliable weighing system integrated into the conveyor system.
The France based company Alombard,
established in 1929 in Saint Pryvé Saint
Mesmin, has been part of the Schneider
electric group for around a decade.
Around 150 employees develop a whole
host of electrical equipment: electrical
connectors, flush-mounted boxes, and
devices for the connection of luminaries,
etc. The site is mainly responsible for
supplying the group’s logistics platform
which supplies its French customers. Given that almost 1200 parts are produced
per hour, product deliveries have to be
very precisely controlled.
Prompt order fulfillment
“We wanted a solution that would improve our packaging station for bags
of electrical components,” explains Marc
de Baudus, Methodology Engineer at
The Alombard site produces all kinds of electrical
components. Pictured here: flush-mounted boxes.
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METTLER TOLEDO
Newsletters 1/2012
Alombard. “We have to be able to put
­together orders that involve very small
products, which in some cases weigh less
than 1.4 grams, as well as much larger
products where weight dispersion is a
­significant factor. Some bags were being
sent back to us because a tiny connector
was missing, a part without which the
electrical unit could not be assembled
properly,” he adds.
Integrated weighing solution
to avoid errors
Mr. de Baudus, who was already familiar
with METTLER TOLEDO because of its
counting scales, decided to contact his
regional commercial engineer, Manuella
Page, about the problem. “In view of the
low weight of some electrical components, the solution had to be able to
IND690 weighing terminal connected with KA15s (15 kg x 0.01g)
weighing platform under the conveyor belt.
e­nsure an optimum level of precision.
Naturally, I proposed a KA15s platform
with a weighing capacity of 15 kg and
0.01g resolution combined with an
IND690 weighing terminal,” explains
Manuella. “I also suggested that we add
a barcode scanner to make it easier to
identify the bags and improve the traceability of operations”, she adds. The
weighing system, which was perfectly
­integrated into a belt conveyor, has been
providing operators with 100 % satisfaction for more than a year.
Thanks to this installation, only nonstandard bags need to be checked manually and this results in higher levels of
productivity. As a result, complaints
about incomplete bag deliveries, have
fallen dramatically.
Reliable detection of missing items from bags
thanks to the, KA15s high precision ­weighing
platform.
Calibrated
Trusted
It is common wisdom that any instrument and particularly a scale
shall be calibrated before its first use. But is this sufficient? Shall I
recalibrate my scale? How frequently? How? And why?
If you are working in a regulated industry, you may have asked yourself these
questions a thousand times. You may
have heard some of the usual answers.
But do you really believe what you heard?
Here is more information for a conscious user.
The benefits of calibration
When leaving the factory, a scale has
been verified and adjusted for an immediate use in an optimal environment.
However, it is impossible to anticipate the
conditions in which the scale will operate. Think of a working environment
with large temperature changes, wind
draft, vibration from rotating equipment,
etc. An initial calibration will document
the effective performance of a scale within its effective operating environment. At
that time a calibration certificate is issued. Sometimes, a Minimum Weight
certificate is issued as well. This certificate will document for which weighing
range (from minimum to maximum)
the scale will deliver results in the accuracy corresponding to the tolerance required by your process and taking into
account all the process risks. The calibration certificate and the Minimum
Weight Certificate are two important
quality documents that will preserve you
from rejected lots, customer complaints
or failed ISO audits.
Recalibration and verification
During operation, the scale will be exposed to dirt, rough operators and all
sorts of disturbances that will affect its
performance over time. So how will you
know today that your production will
meet all your quality standards? For this
purpose you will perform a series of simple routine tests that will confirm you
that the scale you are going to use will
effectively perform to the level expected.
lar basis. A trained technician will then
verify that the scale fulfills its factory
performance and proceed to any adjustment on an as need basis.
However, depending on the level of tolerance and risk of your process, you will
need to recalibrate your scale at a regu-
www.mt.com/gwp
and play the video on Good Weighing
Practice™.
For more information on calibration
visit:
For more information on the Minimum
Weight Certificate visit:
www.mt.com/ind-calibration
www.mt.com/minweigh
A combination of simple routine tests and
regular recalibration will ensure that
your daily production fulfills all your
quality requirements.
For more information regarding the routine test and their frequency visit:
METTLER TOLEDO
Newsletters 1/2012
7
Logistics & Warehouse Solutions
Smooth Goods Flow with
Smart Warehouse and Logistics Solutions
To ensure quality products, goods need to be checked before, during and after production. Errors can occur
over the whole supply chain. Whether the raw materials you receive have deficiencies, or the deficiencies
are created during production, any type of out-of-spec end product will decrease your productivity. Regular
weight checks throughout production can help to minimize errors and improve production.
Fast Goods Receiving
Fast accurate weighing
Ensure that your suppliers are meeting all
of your specifications. Using a floor or
bench scale to verify incoming goods
­received, you can count or weigh your raw
materials to verify inventory. No matter
how big or heavy the incoming goods are,
the right weighing systems can weigh
­almost everything in a split of a second.
According to your needs and environment
different compact scales, terminals and
platforms can be combined.
Easy pallet weighing
Heavy loads can be quickly weighed with
rugged METTLER ­TOLEDO floor, pallet
or low-profile scales. Platforms are available in various designs and capacities up
to 12 tons. For more comfort ramps can
be added, mobile platforms are available
and various terminals can be attached.
Benefit from easy to use applications
such as piece counting, accumulation of
weights or counts, checkweighing or ­filling.
www.mt.com/floor-scales
www.mt.com/compact-scales
www.mt.com/bench-scales
Smart piece counting
Counting scales determine the number
of pieces in a box or container and allow
reliable inventory checks in no time.
www.mt.com/count
Shipping of Final Products
Correct order fulfillment
METTLER TOLEDO weighing solutions
help to ensure that your customer orders
are accurately filled with exactly the
right number of pieces and products, on
time and with the required labels and
documentation.
Proper labeling according to
your needs
Correct, industry standard l­abeling is
important when shipping goods. METTLER
TOLEDO provides t­ailored printing solutions meeting the ­demands and standards
of your c­ ustomers. Design your own custom
printouts (e.g. with pictures, barcodes, customer logos) with the help of
our system specialist.
www.mt.com/industrial-printers
8
METTLER TOLEDO
Newsletters 1/2012
Efficient Warehousing
Fast and secure connectivity
In warehouse operations scales keep track of stock movement and assure flawless
­storage of goods. Article data can be stored in the scale’s internal database or externally on a PC. Product article information (e.g. average piece weight, tare weight, …)
can be easily called up with an integrated barcode scanner. The database can be
­imported from or exported to Excel. Various interface options such as Ethernet, RS232,
Bluetooth, WLAN, P­rofibus DP or DeviceNet allow communication with other­
IT s­ystems (e.g. SAP), warehouse systems or directly with a ­conveyor belt or alarm
lamp.
Stock under control
Smart inventory scale solutions survey
inventory level remotely. Integrated shelf
scales transfer data to warehousing
systems for efficient and transparent
­
goods control.
www.mt.com/remote-inventory
Reliable Packing Systems
Save time with automation
Parts required for assembly can be precisely counted or rapidly checkweighed for
­quality control. Semi-automated counting solutions ensure flawless packaging during
production. Efficient counting at the end of a production machine requires a high
­degree of automation. Using digital I/O, METTLER TOLEDO scales can control
­conveyor belts, sound or light alarms and redirects material flows. Right parts fall
­automatically in a box or container, a light alarm goes off when the target count is
reached informing staff to remove full containers.
METTLER TOLEDO
Newsletters 1/2012
9
Product News
Reduce Eyestrain and
Speed up Production
Counting and checkweighing can be exhausting tasks as operators need to concentrate
on working fast and weighing accurately. The new ICS series of compact weighing terminals
is designed to improve operator productivity. Profit from a large, bright color display
with colorWeight® functionality, user-friendly menus and various connectivity options.
The colorWeight® functionality causes
the display to appear in different colors
according your specifications. Green can
be used to indicate that you are weighing
within specification, while red indicates
under filling and yellow overfilling.­
Or, you can specify which color you want
to allocate to which status. The colorWeight® display technology reduces
­eyestrain as the human eye can respond
to a color much faster than it can read
and interpret a value on a screen. The
terminals are equipped with freely definable softkeys providing quick access to
the key functions, speeding up the working process.
ICS669 terminal with bargraph showing the actual filling status.
Built for industrial environment
The ICS terminals are dust proof and
built robustly for the use in harsh industrial environments. An integrated battery
case makes the terminals mobile. The
various interface options allow the
­connection of barcode scanners for fast
article call up, printers for easy documentation and external keyboards for
quick data entry.
ICS449 terminal with full colored graphic display colorWeight ®.
Versatile product portfolio
The terminals are available with or without numeric keypad and big graphic TFT
or LCD display. Select from a broad portfolio of weighing platforms from 3 kg x
0.01 g up to 12 000 kg floor scales.
www.mt.com/ics-scales
10
METTLER TOLEDO
Newsletters 1/2012
Save Resources with the
New IND780batch Terminal
With rising raw material prices, reducing waste and eliminating mistakes becomes more and more essential. The IND780batch terminal
saves resources by controlling your ­batching processes automatically
IND780batch Terminal.
or by guiding the user through manual processes.
Batch processing requires a control solution that manages not only recipes but
also weighing scales, valves and order
management. The new IND780batch
­terminal offers a solution for all these
­requirements and improves your processes.
Automatic control
The IND780batch terminal is very flexible and supports 999 material paths and
28 automatic material feeds. It can
control automated processes, material
­
feeders or valves making sure that the
material flow is constant as well as other
auxiliary equipment. Additionally the
terminal provides conditional control tasks,
go-to commands and timing functions.
Manual control
If your application does not include integrated automation, the IND780batch
supports processes where an operator
can add material manually. The IND780batch will guide the operator with
­instructions on the display through the
manual batching process, eliminating
human errors and costly re-work.
Specifications
Up to 1000 recipes can be stored in the
terminal. The terminal then precisely
controls the mixing process according
to the stored recipes. Both vertical
and horizontal applications can be
managed.
The IND780batch does not need a PLC
or DCS connection as it provides a fully
integrated batch control solution itself.
For easy article recall and when tracking and tracing matters a barcode scanner can be connected to the terminal.
An included PC configuration tool allows easy management of batching data
on the computer. It can be used for as
many IND780batch terminals as you like.
www.mt.com/ind780batch
Enjoy Working with the
New IND890 PC-Application-Terminal
Modern design does not just look good but can also facilitate working life. The new IND890 PC-application terminal uses design to combine uncomplicated, fast operation with flexibility and perfect readability.
The IND890 is designed to be ergonomic
and extremely user-friendly. It offers a
high resolution touch screen. The display
is available as 10” or 15”. Self-explaining
icons and the operator guidance feature
simplify the operator’s life. Clarity is ­given
by only displaying relevant information.
Flexible and customized weighing
The IND890 terminal offers many weighing applications and can be connected to
up to four scales. The scales can then be
displayed simultaneously on the terminal
screen. The terminal also provides captivating graphical possibilities and free
programming with visual studio. A shock
and vibration resistant compact flash
card makes the terminal perfect for the
use in the industrial environment. With a
capacity of 1GB Ram Standard an easy
integration possibilities in all kind of
­external systems the IND890 is an excellent weighing solution.
www.mt.com/IND890
IND890 PC-Application-Terminal.
METTLER TOLEDO
Newsletters 1/2012
11
Prepare Your Production
Performance for a Race!
Race Car Drivers Aren’t the Only
Ones Who Focus on Speed…
To be productive and guarantee high quality products, your operation
needs to be both fast and precise – like mechanics in a pit stop.
Automotive Weighing Guide
Discover smart weighing applications used in manufacturing automotive
parts and increase your production performance.
Increase Your Productivity
with Solutions from the Weighing Expert
Read the free Automotive
Weighing Guide and profit from
­expert knowledge:
• Discover different weighing
­applications used in manufacturing ­auto­motive parts
• L earn how to improve quality
and productivity in production
through weighing
• Explore how weighing helps you
to comply with industry standards
• Learn about the system inte­
gration options provided
by ­METTLER ­TOLEDO scales.
Get your own free Automotive Weighing Guide now:
www.mt.com/ind-automotive-guide
www.mt.com/ind-manufacturing
For more information
Mettler-Toledo AG
CH-8606 Greifensee
Switzerland
Tel. + 41 44 944 22 11
Fax + 41 44 944 30 60
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