Vision systems and coil fed in line laser applications by andrea dallan

Vision systems and in-line laser
applications
Andrea Dallan, C.E.O. Dallan Spa – Italy
2016-04-07
© 2015 Dallan S.p.A. All right reserved.
How to introduce LEAN concepts in the manufacturing cycle
via coil-fed integrated punching and laser cutting systems

Dallan group established in northern Italy 1978
• Roll forming machines (1978)
• Coil fed punching machines (1989)
• Packaging systems (1995)
• Coil fed laser cutting systems (2014)
• 150 Employees
• 30M$ Sales
104 international patents
Dallan group

What we’ll cover
• 3 simple LEAN concepts
• Vision systems applied to manufacturing processes
• Punch/laser combo systems
• ELLECI case
• Laser cutting systems from sheets and coils
• UGUR case

Lean production concepts
• Value-driven analysis (analyzed from customer’s perspective)
• Analyzing the manufacturing steps that add value to the product
• Putting these steps as close together
1. Minimizing Work in Progress
2. Minimizing Waste
3. Analyzing hidden «waste»: setup times
• Optimized productivity by optimizing the setup of the presses

Classic manufacturing cycle
Raw material arri
-val and storage
Blanking line Storage of Blanks
Punching
machines
Storage of
punched
material
Laser cutting
machines
Storage of cut
parts
Bending, Panel benders,
Forming
Storage of bent
parts
Paint line Storage of parts
for assembly
Assembly and packaging
line
Storage of fi
nished prod
ucts
M1
M2
M3M4
M5

In-line manufacturing cycle
1. Minimizing WIP
Raw material arri
-val and storage
Storage of cut
parts
Bending, Panel benders,
Forming
Storage of bent
parts
Paint line Storage of parts
for assembly
Assembly and packaging
line
Storage of fi
nished prod
ucts
M3M4
M5
In line punching and laser cutting from coils M1 and M2
are eliminated

2. Material optimization
Optimization of rectangular products on standard size sheet
Optimization on standard size coil On slit to size coil

3. Productivity and Flexibility
Minimizing setup times
Productivity
High
Low
Low
Stamping with
press
Coil fed
punching and
laser
Turrett
punching
Flexibility
High

All the advantages of the in-line layout
• Storage of materials in coils
• Reduced number of formats to keep in stock
• Reduced WIP
• High Value operations are easily connected by the in-line layout
• The final storage of punched and cut parts occupies a small space as
the products are flat
• Higher material utilization than standard technologies
• Minimum setup time thanks to the in line laser

Vision systems and software is the key
• Easy optimization in line processes
• High definition camera takes the picture of the part
• Confronts the «is» situation to the «should be»
• Produces an output
• Measured deviation
• Presence or absence of a specific hole

Vision system: pattern recognition

Application of Vision Systems
• Recognition of position of the side of the strip
• Possibility to re-position long sheets on the same working area
=> In line laser systems
40 in
D C B A
Feeding dir. Exit of cut parts
Area in
process

Application of Vision Systems for in line lasers
• Recognition of pre-punched holes to reference the laser cutting
• Recognition of the sheet edges
• Recognition of the integrity of punches
• Quality control of the part

Punch/laser combo
• Punching and laser are separated to maximise output
• Laser module with vision system can be applied after any punching
machine, to create a combo system

Punch/laser combo application: Elleci Spa
• Italian producer of high quality fully assembled metal components
• 100 employees, 200,000 sqf covered production
• Standard punching, laser, punch+laser
• Coil fed punching, Coil fed laser
• Bending, panel bender
• Welding stations
• Powder coating lines
• http://www.ellecispa.net/

Punch/laser combo application: Elleci Spa

Elleci system under construction

System installed at Elleci premises

Example of applications
Multiple holes are obtained in servo
electric punching machine
Embossing and threading obtained
in punching machine
A

Lean concepts included in this system
• Just in time production
• Tool change is reduced to minimum
• Material optimized 100%
• No skeleton = reduced labor cost
• In line quality controls
(on punches, for example)

In line laser cutting
• Continuous and automatic production

Autonomous production: Example
• 1 coil in 22ga = 0,7mm
• 10000lb = 4500kg
• 30inch = 750mm wide
• Length = 1100 meters
@ 4 meters per minute (simple parts) = 4,5 hrs production
@ 2 meters per minute (low complexity) = 9hrs production
@ 1 meter per minute (medium complexity) = 18 hours production
@ 0,5 meters per minute (high complexity parts) = 37 hours production

Sequential process
160 in
40 in
D C B A
Feeding dir. Exit of cut parts
Area in
process
• Sequential process
• 40 or 80 inches in length
• 40 or 60 inches in width

Total flexibility to process coils and sheets

In line laser application: Ugur
• Turkish producer of refrigerators http://www.ugur.com/
• 1,850 employees - 2,150,000 sqf covered production
• Supplier of major beverage producers
• Advanced application of Lean Production concepts
(1 fridge every 12 seconds)
• Need for high productivity and flexibility on 0,3mm thick aluminium
and steel

Ugur systems under construction

Systems installed at Ugur premises
No.2
1kW laser systems 1000x2000mm

Examples of produced parts
On these parts Ugur has reduced process
time from 90 seconds to 44 seconds

Lean concepts included in the in line laser
• Reduction of the waste
• Continuos production – all value-added operations
• Tooling time reduced to zero
• Working with no skeleton = reduced labor
• Automatic production

Conclusions: advantages of Combo lines
• Extremely high REAL productivity thanks to the simultaneous action of
punching and laser
• Execution of deformation,
embossing, threading
• Optimization of material to 100%
• Eliminating the skeleton
Reduced labor

Conclusions: advantages of Laser lines
• Versatility to work from sheet and from coils
• Extremely high flexibility
• Optimization of material to 100%
• Eliminating the skeleton
reduced labor

THANK YOU!
• Contact information:
www.dallan.com; info@dallan.com
www.dalcos.com; info@dalcos.com

Vision systems and coil fed in line laser applications by andrea dallan

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