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Description
Metrol offers services for the production and processing of metal parts. The project responds to the customers'' needs regarding the quality of the manufactured parts, and aims to reduce material and energy losses generated in the production process. The manual welding techniques used in our plant are burdened with a lack of repeatability and imprecision of human work, which result in unacceptable dimensional deviations and defects in welds qualifying the products for improvement or scrapping.
Therefore, we intend to implement a low-waste automated technology for welding metal parts, based on the use of an original design of a robotic welding station, a unique welding algorithm developed in the course of development work and a system for heating welded elements. The project will result in the reduction of waste by 19 tonnes per year (77.6%), reduction of electricity consumption by 24.8% (0.03 GWh) and reduction of CO2 emissions by approximately 58.6 tonnes. Precision of welding will be improved - dimensional deviation of metal parts will be reduced to a level not exceeding 0.3 mm.
The project involves the construction of a production hall in which the automated welding station will be installed along with a system for heating workpieces. A PV installation will be purchased to power the new technological process. A scientific unit will be commissioned to perform metallographic tests and develop recommendations for welding parameters.
Summary of project results
The project will focus on the commercialization of R&D work in the field of low-waste and automated metal parts manufacturing technology, which will be environmentally friendly. Thanks to the investment, we will introduce a solution to the market that will simultaneously lead to a reduction in raw material losses, offer better working conditions, and positively impact the quality of the components. In the following descriptions, we present the actions we will take to achieve this goal and the beneficial effects.
PROBLEMS IN THE WELDING PROCESS
The starting point for this new initiative was the issues arising during the welding process. During the application of the weld, there are deformations in the parts and defects in the welds, such as leaks, lack of penetration, or gas bubbles. The R&D work conducted shows that the frequency of defects is closely related to the lack of repeatability in the process, which is dictated by the fact that it is performed manually. We employ welders with many years of experience and extensive knowledge in the field of welding. Despite this, statistical analysis of the results shows a relatively large proportion of parts in total production that require rework or are scrapped. Therefore, we decided to carry out R&D work, which was fully completed in 2019. In addition to identifying current problems and determining their scale, we developed a new process
The aim of the project is to increase the competitiveness of our company by implementing actions aimed at introducing a low-waste and automated technology for the manufacturing of metal parts. The new technology was developed based on both in-house and outsourced R&D work, which helped to identify existing process defects and develop a new manufacturing method. This will result in, among other things, a reduction in the percentage of defective products (waste reduction), higher product quality, and reduced energy consumption.
The project has achieved the following aspects:
- Its implementation has allowed for the introduction of a new process for manufacturing metal parts, which will directly contribute to achieving the program''s indicators. The use of our proprietary automated welding station, part heating system, and a new welding algorithm will lead to reductions in material waste and electricity consumption:
- We will reduce material waste by approximately 19.0 tons per year,
- We will decrease the electricity consumption required for the production process by approximately 32 MWh per year.
These benefits will result from, among other things, a reduction in the percentage of defective parts, which will be produced in a more consistent manner. The introduction of the new process will have a positive impact on the sustainable development of our company, which is based on increasing competitiveness through the introduction of new technologies and a strong focus on environmental care.
- We will change the energy balance of the process by replacing fossil fuel-derived energy with energy from a photovoltaic installation. The use of environmentally friendly technology will allow us to generate approximately 43.5 MWh of green energy annually on average. We emphasize that currently, 80% of electricity produced in Poland comes from the combustion of fossil fuels, which are one of the main factors negatively affecting the environment.
- The introduction of the new production process, as well as the change in the energy balance through the use of a photovoltaic installation, will allow us to reduce CO2 emissions into the atmosphere.
- By implementing the project, we will introduce an innovative process for the production of metal parts into the company. Its novelty on a national level results from the following changes:
- A proprietary welding algorithm that increases precision,
- A custom-designed robotic welding station that includes, among other things, two welding robots and a 3-axis positioner,
- Heating system that helps reduce weld defects.
The innovative process will result in greater consistency in the production of parts, which is crucial for our customers.
- Satisfying customer needs by offering them higher quality products will allow us to expand our sales markets and establish new business contacts. According to our financial analysis of the project, this will increase the company’s revenue and profits by 7.4% and 11.4%, respectively.
The need to carry out R&D work and implement new technology arose during a business-environmental analysis of our company''s current development level. The first aspect relates to cooperation with our clients. The foreign companies we cooperate with enforce highly rigorous standards regarding the quality control of the parts we supply. This means that, to meet their expectations, we are obligated to implement new technologies that address their needs. The second factor concerns the development potential of our company while simultaneously implementing environmentally sustainable technologies.
1. IMPORTANCE OF THE PROCESS FOR OUR COMPANY
The new welding technology will have a significant impact on processes within our company.
A. Technological – The innovation will increase our company''s technological potential, which will, in turn, enhance production quality and manufacturing capacity. Moreover, implementing the automated process will improve efficiency and relieve some workload from our employees.
B. Business – The higher quality of manufactured parts will strengthen our relationships with existing partners and help attract new clients. The market demand indicates high commercialization potential, driven by the significant advantages of the new technology.
C. Managerial – By reducing material waste, we will be able to manage the resources required for production more efficiently.
D. Economic – We assess the economic significance of the innovation from several perspectives:
- Reduction of costs related to material waste, which will decrease by approximately 300,000 PLN annually,
- Increase in order volumes, leading to higher overall revenues and profits for the company (as reflected in the project’s indicators).
2. IMPORTANCE OF THE PROCESS FOR OUR CLIENTS
The implementation of the innovation will impact our clients in several ways:
- We will offer them parts of higher quality, measured by a reduced maximum dimensional deviation. This will allow our products to be used for new purposes, including in highly precise devices and mechanisms.
- The parts will have more durable welds with a significantly reduced rate of hidden defects, which will positively affect their lifespan.
- Increased production capacity will shorten order fulfillment times.
3. GLOBAL IMPACT – POSITIVE ENVIRONMENTAL ASPECT
Thanks to the implementation of the new technology, the welding process will be environmentally sustainable.
According to the economic analysis of the undertaking, in the first year after implementation, the new process will achieve the following indicators:
A. A reduction of annual waste by approximately 19 tons.
B. A reduction of annual electricity consumption by approximately 0.032 GWh.
C. A reduction of annual CO2 emissions by approximately 58.6 tons.