Manufacturers typically focus on improving process efficiency. In today’s highly competitive and inflationary environment, they are more focused than ever on enhancing process efficiency and reducing overall costs. As a result, an increasing number of manufacturers are adopting Industry 4.0 initiatives, incorporating further automation and digitization of processes, essentially doing more with less.
The primary focus of Industry 4.0 implementation is usually the main manufacturing systems—but what about the various supporting subsystems? These subsystems are often rudimentary and highly manual, making them prime candidates for improvements through digital automation and control. For example, in the production of automotive parts, a key process may involve die-casting a precisely shaped, high-quality engine block from molten aluminum. The overall efficiency of the die-casting process is heavily influenced by the use of lubricants, which facilitate metal flow, optimize wetting and spreading time, or maintain mold temperature within a narrow range. While the die-casting process itself is automated and controlled, it is common for the auxiliary system supplying essential process aids, such as die lubricants, to be entirely manual, lacking even the most basic forms of automation or control technology. This is quite ironic for a manufacturer striving for precision, quality, and efficiency, and spending significant money on process fluids to achieve these results.
The first step toward better understanding the potential for improvement begins with manufacturers generating data, even from auxiliary systems that monitor process fluids.
Why It Matters
Data can help manufacturers identify where fluid management processes can be improved, where unnecessary costs are being incurred, and where productivity is being hindered. When process fluids are managed manually, one or more of the following downstream manufacturing issues typically arise:
1. Accelerated tool wear – this leads to more machine maintenance, higher replacement costs for tools, and even longer downtimes.
2. Reduced quality of finished parts – this directly affects the manufacturer’s profit margin, as a product that does not meet certain quality targets is often downgraded for lower-value applications, reworked, or simply scrapped.
3. Poor fluid condition – unstable fluid concentration and pH levels can indicate poor fluid condition, leading to increased costs due to excessive consumption or the need for complete refills. The latter means that the fluid must be disposed of and replaced, increasing both disposal and replenishment costs.
Traditionally, manual fluid management has involved a lot of "guesswork." Many manufacturers simply monitor a fluid bath visually and do not record meaningful data. In these cases, fluids are manually replenished only when they appear low, or worse, when a downstream problem arises. This is essentially operating in the dark regarding fluid volume, concentration, and condition—a reactive approach to problem-solving, rather than a proactive approach to preventing issues in downstream processes. By employing automation technology to monitor fluid concentration and other critical parameters that contribute to determining fluid condition, manufacturers can step out of the dark and achieve predictable results. Through the use of automated control technology based on regular data collection and analysis, manufacturers can achieve more with less—less labor, less downtime, less fluid consumption, and overall lower operating costs.