The conversion of the Spanish metallurgical sector to industry 4.0 would increase its efficiency ratio by 16%

The Spanish metal sector is made up of a total of 62,471 companies that carry out their activity in various subsectors, ranging from foundry and transformation activities to the manufacture of all types of metal products, through the construction of machinery and mechanical equipment and the manufacture of electronic equipment.

The conversion of the Spanish metallurgical sector into industry 4.0 would allow the efficiency ratio of this sector to be increased by at least 16%, according to an analysis developed by aggity, the Spanish multinational software for the social digitalization of companies.

According to the analysis, this increase in efficiency derives from the various impacts that the integration of this type of social management of manufacturing plants (connection between business processes, machinery and people) would have in this sector. Thus, and according to aggity, product delivery times would be reduced by 27%, by 18% the percentage of “non-conforming” products and by 24% the Work in Progress (WIP) index, which defines partially finished products awaiting completion.

Parallel to the improvement in these processes directly associated with production, the analysis indicates that the reduction in time spent on data collection would also be reduced by 74% and process management, both production and production, would be eliminated by 90%. Internal management, paper based.

Aggity has announced these improvement indicators associated with the implementation of Social Factory solutions during its participation in the second edition of the “Productivity Day”, which was recently held in Barcelona with the boost of the Center for Industrial Productivity (CPI ) of the association CEAM (Center for Metallurgical Studies and Advice), a meeting that has influenced the need for innovation in the metal sector..

The Social Factory by aggity solution is the result of adding to the logic of traditional Social MES systems, an extra layer based on a new generation of Social Business applications for collaborative management based on instant messaging, social networks and machines connected to networks corporate, which interact with each other, with apps, web applications and all kinds of mobile devices, in a secure environment and with guarantees of confidentiality.

Lean manufacturing and TPM methodologies

Social Factory by aggity responds to the requirement of maximum efficiency in key aspects for companies operating in the metallurgical sector, such as production control, process and product quality, planning and traceability. Likewise, these solutions are revealed as a first-order ally when implementing TPM (Total Productive Maintenance) methodologies, aimed at optimizing the use of productive means and resources.

The TPM methodologies are framed in the lean manufacturing philosophy and seek to make the most effective use of machines and productive resources, eliminating any type of inefficiency with the double objective of reducing breakdowns and incidents to zero, and registering a production completely free of defects.

According to Oscar Pierre, president and CEO of aggity, “the fourth industrial revolution is underway and, as is happening in other industrial sectors, in the metal sector will be the smart factories or smart factories the only ones that will continue to set the pace” . “The power of Social MES”, – adds Pierre- “goes beyond the automated collection of information by enabling the transformation in knowledge of this permanent flow of data and information, and providing a complete and real-time view of the operation of the factory and allowing people, as well as machines, systems and processes, to participate actively in the manufacturing dialogue ”.

Productivity and Quality Office