Dormer Pramet with IBM Evaluates Key Production Stages using Industry 4.0

Dormer Pramet, incorporates Industry 4.0 within its production processes and is working with one of the world’s leading data analysis companies, IBM, on several key projects. This requires using large amounts of data to map the value chain throughout every department of its production unit in Sumperk, Czech Republic, and incorporating computer software.

Network Model

In the first project, the company used advanced algorithms and statistical methods to track every indexable product order from the last two years and how the item moved through the production unit, creating a network model of the entire plant. This model explained how the machines communicate and how process disruptions such as unscheduled downtime can spread through the whole system. It recognized crucial points in the process where small issues can cause major inefficiencies later. These points were ranked by severity to help focus where improvements were needed to maximize efficiency and achieve the greatest impact.

First Phase

It uses an IBM inspection station, which is used to scan inserts with a variety of cameras, lights, and mechanical elements inside a pressing unit. An automatic machine image recognition powered by artificial neural networks, is performed to locate / identify the type and severity of the defect at the very beginning of manufacture. Also, by adding as many examples and information as possible will constantly help to teach the machine what is good on a product. This not only improves the accuracy of recognition, but helps to detect less obvious defects, reduce false alarms, and identify problems.

Second Phase

In this phase of the project, the company looked at the definition of the metrics that quantified as an issue, such as quality, maintenance downtime or compliance with the production plan. These metrics were again analyzed to identify further areas of operational change and suggest changes.

The digital elements and initiatives aim to enhance Dormer Pramet’s existing high standards of manufacturing capabilities and form part of t its ‘Make the Shift 2030’ activities which have been established to help create a more sustainable business.

Image Source: Dormer Pramet