Devi aggiornare il tuo mescolatore e sei pieno di dubbi. Il che è comprensibile, perché si tratta di un’operazione delicata che richiede giorni di fermo impianto, con tutte le conseguenze del caso.
Per aiutarti a compiere le scelte giuste, ho stilato la mia personale lista di FAQ, nata da anni e anni di esperienza.
Puoi immaginare le decine di domande alle quali, nel corso di tutto questo tempo, ho dovuto rispondere; i dubbi leciti di chi deve decidere cosa fare e vuole essere sicuro di fare la migliore scelta per la propria azienda.
Di seguito riporto quelle principali, quelle più frequenti. Spero aiutino anche te a chiarire dubbi, perplessità, timori (se ne hai).
CONVIENE ASPETTARE QUALCHE ANNO E CAMBIARE IL MESCOLATORE O AGGIORNARE L’AUTOMAZIONE DI QUELLO ESISTENTE?
Dipende.
Questa è una domanda alla quale non c’è una risposta univoca che va sempre bene. La scelta dipende sostanzialmente dai seguenti fattori:
- se puoi sostenere un investimento di diverse centinaia di migliaia di euro
- se i tuoi clienti attuali e quelli che forse arriveranno con la nuova macchina ti consentiranno di ripagare l’investimento entro pochi anni
- se la tua macchina attuale è a fine vita o con una buona manutenzione puoi usarla ancora per diversi anni.
Se puoi sostenere l’investimento e se pensi di poterlo ripagare in un tempo medio corto (devi valutare il ROI), acquistare una nuova macchina ti garantisce un’elevata produzione di alta qualità per parecchi anni.
Ma se la macchina attuale è ancora in buone condizioni e ha bisogno solo di una buona manutenzione meccanica, aggiornare l’automazione (e magari montare un inverter se la macchina ne fosse sprovvista) ti garantisce parecchi anni di produzione, avendo tutti i controlli e le funzioni dei nuovi mescolatori ma investendo meno di un decimo del costo di una macchina nuova.
Se invece la meccanica è arrivata a fine vita, puoi anche considerare un mescolatore ricostruito (mi raccomando ricostruito bene, non semplicemente verniciato) dotato di un moderno software di controllo. La spesa è circa la metà di una nuova macchina.
HO UN VECCHIO MESCOLATORE CHE FUNZIONA ANCORA BENE MA E’ SENZA PLC, POTETE FARE QUALCOSA?
La nostra piattaforma software è stata creata per adattarsi ad ogni macchina presente sul mercato, anche molto vecchia.
Nel caso la macchina fosse completamente elettromeccanica o addirittura con comandi pneumatici, quindi non dotata già inizialmente di un PLC, i nostri tecnici provvederanno ad installarne uno moderno.
Per poterlo fare, a seconda del modello del mescolatore, viene fornito un quadretto con già cablato un PLC dotato di tutti gli ingressi e uscite necessarie. Analizzando il quadro elettrico esistente e la documentazione presente (anche se vecchissima), vengono create delle interfacce per poter fare con il PLC quello che adesso viene fatto dai relè.
Possiamo farlo perché sappiamo esattamente come funziona la macchina ed abbiamo una grande esperienza anche su macchine molto vecchie.
HO SOLO UNA MACCHINA CHE NON POSSO TENERE FERMA. QUANTO TEMPO CI VUOLE PER INSTALLARE IL VOSTRO SISTEMA?
Una volta completato lo studio sul mescolatore esistente e sulla documentazione in tuo possesso, siamo in grado di garantire i giorni per poter fare l’aggiornamento.
Ci sono tre discriminanti che incidono sui tempi:
- se la macchina ha già un PLC (anche se vecchio e limitato) che controlla i movimenti;
- se si vogliono fare delle migliorie, ad esempio installare un inverter;
- se è presente la documentazione elettrica-meccanica della macchina attuale.
Come indicazione di massima, puoi fare riferimento a questa tabella:
| Mescolatore già dotato di PLC e velocità variabile | 2 giorni di fermo completo
2 giorni per test con produzione limitata |
| Mescolatore già dotato di PLC ma senza velocità variabile (che si vuole aggiungere) | 4 giorni di fermo completo
2 giorni per test con produzione limitata |
| Mescolatore non dotato di PLC né di velocità variabile | 5 giorni di fermo completo
3 giorni per test con produzione limitata |
Possiamo garantire con certezza questi tempi di collaudo perché abbiamo realizzato diverse decine di interventi su varie macchine e perché tutti i componenti software sono già collaudati e pronti all’uso.
Il tempo maggiore solitamente si impiega a controllare che la macchina risponda ai nostri comandi (che i sensori funzionino, che il pistone si muova correttamente, ecc.).
I MIEI OPERAI SONO ABITUATI A LAVORARE IN MANUALE E NON HANNO DIMESTICHEZZA CON I COMPUTER. COME SI TROVERANNO?
L’interfaccia utente del software è stata sviluppata sulla base dei suggerimenti e segnalazioni di decine di operatori al mixer. Per questo motivo è molto intuitiva e semplice pur garantendo un controllo completo della macchina.
Questa è la schermata che avrà l’operatore addetto al mescolatore:
La pagina è molto semplice ma indica velocemente tutti i dati e parametri del mescolatore.
Quando si saranno abituati ad usarla e le ricette di mescolazione saranno affinate, difficilmente vorranno tornare indietro e l’azienda avrà guadagnato in ripetibilità e tracciabilità della produzione.
Se vuoi vedere un demo del programma, vai a questo indirizzo.
NOI FACCIAMO PICCOLE PRODUZIONI E CAMBIAMO FORMULA OGNI 2-3 CICLI. VA BENE ANCHE PER NOI?
Se sei in un settore di nicchia e cambi spesso le formulazioni, un software di controllo ti può aiutare perché se adesso lavori in manuale e l’operatore deve conoscere ogni singola formula e ricordarsi come gestirla, è più facile che commetta errori di cui ti accorgerai solo alla fine della lavorazione quando farai il controllo in laboratorio.
Tramite il video del nostro programma l’operatore viene aiutato a non commettere errori, deve solo seguire le indicazioni per sapere quali componenti caricare. Inoltre, un lettore bar code verifica che i componenti siano quelli impostati nella produzione.
Tutte le altre operazioni sulla porta di carico, il pistone ed i controlli di tempo, temperatura ed energia sono gestiti in automatico dal programma.
Anche il raffreddamento della camera e dei rotori è controllato dal nostro programma (se la macchina ne è dotata), evitando i problemi di surriscaldamento della mescola quando si passa da una formula ad alto Shore ad una con basso valore.
Questo garantisce una maggiore ripetibilità, meno errori e, quindi, meno scarti (con evidenti vantaggi economici).
TUTTO BELLO, MA QUANTO COSTA? ADESSO NON E’ IL MOMENTO DI INVESTIRE
Nel mercato ci saranno sempre minacce che ti faranno dire che non è il momento di investire, ma ci saranno sempre anche grandi opportunità per chi le saprà cogliere.
Ogni buon imprenditore non dovrebbe investire mai un euro più del necessario ma anche mai un euro meno del necessario.
Aggiornare l’automazione del mescolatore, ovvero dell’elemento chiave per produrre mescole di qualità, ti consentirà di avere una vera gestione dei tempi di produzione e dei costi (di energia e del personale); di avere produzioni più ripetitive; e di non dover più dipendere dall’operatore al mescolatore.
Inoltre, grazie alla tracciabilità ed alla reportistica, potrai dimostrare ai tuoi clienti la qualità della tua produzione e convincere anche il tecnico più scettico.
Non è possibile dare un’indicazione univoca di costo, ci sono molti fattori da considerare: dallo stato della macchina alle opzioni accessorie che vuoi installare (controllare i nastri, leggere i bar code della materia prima, aggiungere un inverter, ecc).
Per poter valutare un primo livello di investimento, l’installazione del nostro sistema completo su un mescolatore già dotato di PLC (anche se vecchio e da sostituire) parte da 30.000 euro chiavi in mano e comprende:
- un PC industriale per vedere lo stato del mescolatore;
- un PLC Siemens S7-1500 ultimo modello;
- il nostro modulo software PC e PLC;
- le attività per sostituire il vecchio PLC ed il collaudo.
Non hai trovato la risposta che cerchi? Fai la tua domanda in un commento nel post. Se invece vuoi una consulenza più specifica, manda una mail a: claudio.tosi@multidata.it.
Buona vita
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