Smart Furniture Production
June 2019 A Furniture & Joinery Production Supplement
SMART&HUMAN FACTORY SMART&HUMAN FACTORY SMART&HUMAN FACTORY
DISCOVER DISCOVER DISCOVER SMART&HUMAN SMART&HUMAN FACTORYFACTORY AT LIGNA 2019 13 SMART&HUMAN FACTORY AT LIGNA 2019 - HALL 13 - HALL scmwood.com scmwood.com AT LIGNA 2019 - HALL 13 scmwood.com
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Comment I’m sure it won’t have escaped readers’ attention that since the creation of the internet in the 1950s – and Tim BernersLee’s World Wide Web invention back in 1989 – we have become increasingly familiar with life in a new, connected age. Then factor in mobile technology, which drives so much change, first socially, then, increasingly, commercially. We often hear the term ‘disruptor’ used to describe businesses who seemingly appear overnight, taking advantage of digital technology and consumer behaviour to great effect. Disruption is all around us – take the fashion and automotive industries, in which the breadth of choice and the ability to supply bespoke products incredibly efficiently has utterly changed the purchasing dynamic. Fast fashion has been a reality for a number of years – ask anyone born after 1990 how they buy their clothes, and many will say “online”. And when buying a car, customers are typically invited to specify their vehicles online – this may take place through a local dealer, but essentially we’re designing our own cars. Consumer expectations are evolving rapidly, and new businesses which are able to pre-empt or mirror this change can gain significant commercial traction compared to those cannot see the value in this model. Consultants fully expect this Millennial/Generation Z behaviour to become part and parcel for the furniture and joinery market – and it is this behavioural change in particular, driven by the internet and mobile technology, that is changing our manufacturing landscape. In this supplement, we shine a light on new manufacturing technology from some of the businesses leading the global furniture and joinery manufacturing industry towards an Industry 4.0 model. At Furniture & Joinery Production, we’re only beginning to explore this subject – but it’s a topic that I have a feeling we’ll be returning to with increasingly regularity in the future. John Legg
I hope you enjoy the supplement.
PUBLISHER Nigel Gearing EDITOR John Legg Tel: 01424 776104 john@gearingmediagroup.com Twitter: @FurnitureProdEd ADVERTISING MANAGER Lisa Williams Tel: 01424 776102 lisa@gearingmediagroup.com Twitter: @FurnitureProdAd PRODUCTION James Ash (manager) Tel: 01424 775304 james@gearingmediagroup.com Mike Beales Tel: 01424 775304 mike@gearingmediagroup.com
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DIGITAL CONTENT Nyall McCurrach Tel: 01424 776107 nyall@gearingmediagroup.com COPY ADMINISTRATOR Steve Merrick Tel: 01424 776108 production@gearingmediagroup.com PROOF READER Keith Fitz–Hugh ACCOUNTS Wendy Williams Tel: 01424 774982 wendy@gearingmediagroup.com SUBSCRIPTIONS subscriptions@gearingmediagroup.com REPRO, PRINT AND DISTRIBUTION Stephens & George
DISCLAIMER: All material submitted for inclusion in Furniture Production is done so entirely at the contributor’s own risk. No responsibility is accepted for the safe-keeping of contributors’ materials. Whilst all attempts are made to ensure accurate reproduction, Furniture Production accepts no responsibility for variations. Artwork undertaken by our studio remains the copyright of Gearing Media Group Ltd and may not be reproduced or stored without prior permission. Some articles in Furniture Production have been submitted by companies and organisations. Monies may have been accepted in some instances to offset production costs. All rights reserved. In respect of artwork originated free of charge as part of a booking, clients should know that excessive work (more than one set of corrections, known as ‘authors corrections’) is chargeable at £55 per hour. DATA PROTECTION “OPT OUT” STATEMENT: Readership data held by Gearing Media Group Ltd may be shared with any member of the Gearing Media Group Ltd and associated companies for the purposes of customer information, direct marketing or publication. Data may also be made available to external parties on a list rental/ lease basis for the purposes of direct marketing. If you do not wish data to be made available to external parties for list rental or lease please write to: Data Protection Co-ordinator, Gearing Media Group Ltd, 4 Red Barn Mews, High Street, Battle, East Sussex TN33 0AG. SUBSCRIPTIONS: Refunds on cancelled subscriptions will only be provided at the publisher’s discretion, unless specifically guaranteed within the terms of the subscription offer.
ISSN 2396-9024 www.furnitureproduction.net © Gearing Media Group 2019
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BY THE BY THE NUMBERS NUMBERS
45,000 + + 45,000 ACTIVE USERS WORLDWIDE ACTIVE USERS WORLDWIDE According to the latest CMA According to the latest CMA Benchmark Study, more Benchmark Study, more woodworkers choose our products woodworkers choose our products than any other software system. In than any other software system. In fact, it’s not even close. fact, it’s not even close.
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ALPHACAM ALPHACAM && CABINET VISION CABINET VISION THE WORLD’S #1 SOFTWARE SOLUTIONS THE WORLD’S #1 SOFTWARE SOLUTIONS FORFOR THETHE WOODWORKING INDUSTRY WOODWORKING INDUSTRY ALPHACAM & CABINET VISION offer the complete engineering solution for the ALPHACAM & CABINET VISION offer the complete engineering solution for the woodworking industry. Our strength is in providing innovative solutions that can woodworking industry. Our strength is in providing innovative solutions that can grow with your company. grow with your company. ALPHACAM provides unparalleled ease of use, process automation, and ALPHACAM provides unparalleled ease of use, process automation, and sophisticated toolpath generation, seamlessly integrating both 2D and multi-axis sophisticated toolpath generation, seamlessly integrating both 2D and multi-axis cutting strategies which can be applied to any type of component. cutting strategies which can be applied to any type of component. CABINET VISION is capable of custom cabinet and room design, photo realistic CABINET VISION is capable of custom cabinet and room design, photo realistic rendering, material optimisation, bidding and costing, cutlists and bill of materials. rendering, material optimisation, bidding and costing, cutlists and bill of materials. Combined with the powerful Screen to Machine Center, it can automatically create Combined with the powerful Screen to Machine Center, it can automatically create machine ready G-Code for your CNC machinery. machine ready G-Code for your CNC machinery.
Alphacam.com | CabinetVision.com Alphacam.com | CabinetVision.com
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SCM’s Smart&Human Factory responds to the Industry 4.0 requirements SCM took its smart manufacturing concept – a technological range of products increasingly in line with Industry 4.0 requirements – a step further at the recent Ligna event.
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After launching its Lean Cell 4.0 for highly automated industrial production two years ago, from the same Hannover event, SCM has gone further still with its breakthrough concept of smart manufacturing. From its impressive 4000m2 stand, the Italian woodworking giant presented its Smart&Human Factory: a cutting-edge production model based on digital and automation systems allowing for advanced man-machine interaction and 3600 control over the entire production flow. SCM’s model is based on highly innovative, flexible, modular and easily reconfigurable systems, designed to respond in an increasingly effective and fast way to the challenges of mass customisation. A new smart and human factory – also making progress in terms of workflow thanks to the integration of robotics, low-added value and repetitive human tasks are now minimised. Top-level technological innovation “Ligna 2019 proved to be one of the key international events for SCM – traditionally a historic and reliable partner for the entire woodworking industry”, says the SCM division director, Luigi De Vito. “We showcased top-level technological innovation, designed to support more and more companies in their business and help them meet new Industry 4.0 requirements. “The current, new production trends, were the focus of this Ligna, and are expected to widen the gap between more- and less-intensively automated companies. By offering a new model of interaction between machines and industrial and collaborative robotics, ground-level logistic handling and software, SCM has as its mission to help partner companies work toward achievable, successful and smart goals.”
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“SCM’s model is based on highly innovative, flexible, modular and easily reconfigurable systems, designed to respond in an increasingly effective and fast way to the challenges of mass customisation. A new smart and human factory – also making progress in terms of workflow: thanks to the integration of robotics, low-added value and repetitive human tasks are now minimised.”
‘You will never work alone’ The claim ‘you will never work alone’ effectively summarises the goal of the new SCM product range: to supply a user-friendly wood panel processing automation system, with the option to reconfigure the production process whenever this is necessary, to quickly process increasingly smaller order-to-production batches. At Ligna, SCM will demonstrated an automated system for all the phases of furniture production, from furniture designing to the generation of machine programs and from panel processing to cabinet assembling. The process aims to optimise – as much as possible – panel cutting, edgebanding and drilling operations, so as to reduce waste, rejects and retooling requirements during product changeovers, to then reassemble orders back together at the end of the process and delaying customisation until this stage. SCM clearly demonstrated that with this system, low-added value and repetitive human tasks are minimised, thanks to the use of Kuka industrial anthropomorphic robots, assisted by collaborative Universal Robots in the final process stages – assembly, hardware insertion, glue dispensing and surface finishing – and ensuring totally safe conditions without the use of enclosures. Finally, process logistics are made flexible thanks to the use of MiR intelligent autonomous self-driving shuttles. The entire process at Ligna was managed and supervised by the Maestro Watch supervi-
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sion software, monitoring the state of each of the products being machined throughout the process, and by the IoT Maestro Connect system, which collects and analyses SCM technology data, ensuring on the one hand full control over the production flow and, on the other, the implementation of smart predictive maintenance models. Maestro continues to evolve To meet the needs of 4.0 industrial production SCM also presented new upgrades for the Maestro Connect IoT platform – it was extended to new technologies applied to the wide range of SCM machining options , such as cutting, edgebanding, drilling and routing, nesting and edgebanding, for both panels and solid wood. The data collected and the information available increase thanks to the introduction of specific sensor kits for technology capable of monitoring the vital components of the machine, detecting any critical or non-optimal conditions of use. This evolved data collection and analysis system originating from SCM machinery aims to offer the client excellent product flow control, achieve rapid, intelligent maintenance and effective planning of a spare parts strategy. A new paradigm of maintenance is real, based on the anticipation that a machine can be repaired as soon as it breaks down, so no time is wasted. www.scmgroup.com
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tapio – connecting the woodworking industry for a digital future The woodworking industry is rapidly changing and in a world where technology is the main driving force of the future, digitalisation is essential. Positioned at the forefront of Homag’s developments lies tapio – a digital platform specifically designed for manufacturers to gain more efficiencies from production. We spoke to Homag UK managing director, Simon Brooks, to understand more...
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How can digital technology shape the future of the woodworking industry? Unveiled for the first time in 2017, Homag presented its latest technological partner, tapio – a cloud-based service built in partnership with Microsoft. Working across the entire manufacturing chain, the platform opens up the countless possibilities of networked production to all workshops. Whether it’s a small workshop, mediumsized operation or a global co-operation, tapio ensures the accessibility of true transparency and optimally-controlled production. To produce Homag’s digital vision, tapio is creating an ecosystem for the woodworking industry. With the capabilities to currently connect to 32 partners – machine, tool and material manufacturers – tapio emphasises that collaboration within the industry is key for a digital future. Pooling knowledge of mechanical engineering, servicing, software and ultimately the status of machinery, tapio provides operators with live updates of their complete manufacturing facility. The platform also reports when future maintenance requirements are needed as well as sending warnings when a critical value exceeds or falls below a certain level, ensuring peak production times are not compomised. The data which tapio produces allows companies to monitor their entire production process, ensuring the performance of each machine is maximised at all times. What are the benefits of using products such as Homag’s MachineBoard with tapio? Delays in production can have a crippling effect to manufacturing and are unwelcome within any environment. The opportunity to tend to machines in good time and continuously react flexibly is an unquestionable advantage. Whether the remaining time of a >
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FP - June
Step into the world of digitalisation. Industry 4.0
The dawn of a new production philosophy From software and machinery to servicing and maintenance, HOMAG offers a smart solution for each stage of manufacturing to ensure maximum efficiency. The future factory vision begins with networked production and at HOMAG, there’s a solution for all levels of industry.
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CNC program needs to be checked, impending set-up processes need to be viewed or the glue unit on an edgebander needs to be remotely activated, the MachineBoard’s capabilities are indisputably valuable time savers. Homag’s MachineBoard collects live status information for all the machines across the tapio system. This allows MachineBoard to produce automatic push notifications which can be displayed on smartphones or smartwatches enabling operators to act as soon as manual intervention is required. Philipp Ullrich, project engineer at Dethleffs is a current MachineBoard customer. He adds: “During a three-shift operation we see the advantages of using tapio, as possible downtimes are reduced. The employee is informed preventively if, for example, any operator intervention is necessary. This includes everything such as a tool change or a label roll change.” Does tapio have any servicing solutions? Yes, with ServiceBoard customers receive faster support and can even reduce service costs. Roughly a quarter of service tickets can now be solved using digital methods. As customer you can quickly and easily create service cases, including pictures, and send them to the right service partner without the need for a phone call. Additionally, you can also use the video function via a smartphone or tablet to solve issues through a live video call. This quick service method significantly reduces downtime and ensures your machines are running again as quickly as possible. Can tapio save backups of production data? When a machine breaks downs or malfunctions, it can be detrimental to a business. Setting up the machine again and working out the previous tools and configurations can mean costly downtime for several days. The DataSave feature ensures that data losses and related problems are a thing of the past. It automatically and securely saves production data, tools set-up and machine configuration data in the tapio cloud so that the repaired machine can quickly be restored to its original settings.
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How can you access tapio-based products? Accessing tapio-based products is simply a matter of registering your company at www.tapio.one – you can then add the machines within your facility to your profile, add colleagues and assign purchased services (both from tapio and our partners) to your machines. If you have a tapio-ready machine with the QuickConnect function, it only takes five minutes for the machine’s status to display in the tapio MachineBoard. If you visit tapio’s YouTube, you can find a video tutorial to quickly get you started. Are there any security risks when machines are connected to the Internet? Many studies show that Internet-based solutions are significantly more secure than previous local systems. Security is an essential component for the large providers of computing power. They therefore invest a great deal of time, money and experience into this area. What can we expect from tapio at Ligna 2019? Visitors to hall 15, stand G05 can look forward to previewing the latest developments and apps. Our experts will be on hand to demonstrate how tapio can help manufacturers master everyday production more efficiently. Simon Brooks, managing director at Homag UK comments: “On the surface, the world of tapio and digital products may seem complex. However, once manufacturers see demonstrations of the apps and begin to understand how they operate, the benefits truly do speak for themselves. “I highly recommend you take the time to explore tapio to see how it can increase efficiencies for your business. If you would like to learn more, please contact my colleague, Adele Hunt.” 01332 856424 www.homag.com
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Grasping the opportunities afforded by Industry 4.0 Industry 4.0 promises to transform the way we manufacture and distribute goods and services. No longer simply a concept, it is very much of the ‘here and now’, and the opportunities for growth and productivity it affords to manufacturing enterprises of all shapes and sizes are ripe for the taking, as Lenze’s Neil Beaumont explains.
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Industry 4.0, the industrial internet of things (IIoT), big data, the cloud – these are terms that would have appeared alien to industrial automation specialists a decade or so ago.But the digital transformation of manufacturing industry is now in full swing, and the innovations that these terms represent are already bringing rewards for those forward-thinking enterprises that have embraced them. Manufacturing industry faces some fundamental changes in the way it produces goods, how it engages with its supply chains and serves its customer bases – and while Industry 4.0 may be at the heart of this transformation, questions about how it may be implemented, who best to consult on implementation, what the costs are in terms of investment and cultural change – all these must all be addressed at some stage. The how and who questions For the purposes of this article, let’s consider those first two questions regarding implementation: the ‘how’ and ‘who’. Who best to approach for guidance on how to implement the Industry 4.0 paradigm throughout an enterprise? The more obvious choices are those suppliers of basic and advanced production hardware and their associated systems engineering that manufacturers rely upon so heavily – the machine builders and systems integrators. Automation and networking have been fundamental aspects of manufacturing for many decades, and it is the machine builders and systems integrators that have pushed the technologies forward and who are now fully embracing the concept of Industry 4.0 and all its attendant technologies.
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Modern production machinery must offer a high degree of compatibility with other elements of the production system if it is to serve the purposes of Industry 4.0; it must also be scalable and modular in its configuration in order to adapt rapidly to changing production needs – and these changes may be very rapid indeed in a fully digitised manufacturing environment. Those companies supplying the machine building industry must have a product portfolio that is uniformly compatible and scalable, ensuring the greatest flexibility in implementing modular machine concepts and facilitating automation solutions tailored to meet the requirements of the task in hand. A good example of this is Lenze’s new i950 servo inverter, which allows the machine manufacturer to use the standardised technology modules in the company’s FAST Application Software Toolbox and adapt these modules individually for specific customers. This approach allows machine modules to be developed in a standardised way and, with very little outlay, gives the machine builder a comprehensive library of re-usable software – whether for modules with a decentralised intelligence in each axis or for modules with a powerful central control for complex multi-axis movements. From the software-engineering point of view, it will be irrelevant whether a servo inverter is integrated into the machine topology as a simple activating drive, as a parameterisable axis, or as a freely programmable axis. Digital transformation But modern Industry 4.0 automation solutions are not merely restricted to the networking of modular machines on the shop floor. Digital transformation of the enterprise is inextricably linked to the interconnectivity and interoperability of IIoT-enabled devices and the almost infinite capabilities of cloud computing whereby data from machines and production systems are collected in the cloud, analysed there, and then linked to other enterprise information systems on demand. The huge amount of manufacturing-pertinent data and computing power available to production machinery from the cloud will ultimately transform machines from standard controlled entities to intelligent, independent systems, capable of making decisions and acting upon them without human intervention. Connectivity to the cloud, via the IIoT, will become a standard feature of field-level devices over the coming years, rather like the proliferation of fieldbus communication between devices on the shopfloor developed in decades past. Standardised protocols such as the data-intensive, platform independent OPC UA, or lighter MQTT messaging protocol, will thus become important additions to any automation portfolio – Lenze says this will guarantee a certain level of future-proofing, even in the age of cloud computing.
Security Of critical importance to all this, of course, is security. The interconnectivity and integrated processes that define Industry 4.0 are worlds away from the isolated control systems of the past. When control systems are directly connected to the business IT environment, with free flow of data via the cloud throughout the enterprise and beyond into the outside world, there is the potential for every point on those networks to be vulnerable to cyber attack. A determined cyber attack could see the theft of intellectual property, data corruption, production losses, damage to capital equipment, reputation impact, injury to shop floor personnel or even loss of life. In terms of protection, a security policy should adopt a combination of technologies and approaches which might include strategies for isolating very sensitive areas from the network altogether; making use of industry standard encryption technologies; making multiple firewall implementations, using artificial intelligencebased systems that continuously monitor network traffic to look for suspicious activity, and frequent testing of attack scenarios to help train and bolster awareness among staff. Security is a complex and continually changing challenge, but by adopting modern devices, platforms and tools, and by taking a systematic approach, machine builders and equipment owners can balance the costs and risks and, by doing so, help promote the true benefits of enterprise digitalisation and the brave new world of Industry 4.0. 01234 753200 www.lenze.com
“Manufacturing industry faces some fundamental changes in the way it produces goods, how it engages with its supply chains and serves its customer bases – and while Industry 4.0 may be at the heart of this transformation, questions about how it may be implemented, who best to consult on implementation, what the costs are in terms of investment and cultural change – all these must be addressed at some stage.”
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Comau – delivering innovative engineering solutions with enabling technologies
In addition to a vast range of modular, flexible and highly-configurable products, Comau offers interconnected digital service solutions which are able to transmit, elaborate and analyse important machine and process data, thereby increasing efficiency for smart manufacturing. The full portfolio includes: joining, assembly and machining solutions for traditional and electric vehicles, robotised manufacturing systems, a complete family of robots with extensive range and payload configurations, autonomous logistics, and asset optimisation services with real-time monitoring and control capabilities. The offering also extends to project management and consultancy, IoT services, and maintenance and training for a wide range of industrial segments.
Comau, a member of the FCA Group, is a worldwide leader in delivering advanced industrial automation products and systems. Combining innovative engineering solutions with enabling technologies, Comau helps companies leverage the full potential of digital manufacturing.
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Comau’s sensitive new robot A robot that wants to be collaborative must be able to interact with man, and to do so, it needs to respect these factors. Comau’s recently launched AURA (Advanced Use Robotic Arm) is the company’s new collaborative robot featuring a significant 170kg payload and high sensitivity. Thanks to the simultaneous use of six safety layers, Aura can identify the presence of a person and interact with him in a totally secure way. AURA is a unique technical solution in the field of collaborative robots and, above all, solves a number of issues of today’s existing solutions.
Headquartered in Turin, Italy, Comau has over 45 years of factoryproven experience and an international network of 36 locations, 15 manufacturing plants and five innovation centres that span 17 countries and employs more than 9000 people. A global network of distributors and partners allows the company to respond quickly to the needs of customers of all sizes, no matter where they are located throughout the world. Comau is also committed to improving human/machine collaboration by developing competencies through the formation of individuals and groups as part of its open automation approach. This includes hands-on training programs by Comau Academy that develop the technical and managerial competencies necessary to face the challenges and opportunities of Industry 4.0. Comau UK, formed in 1991, employs close to 110 people based in two sites; Rugby in the West Midlands and Gateshead near Sunderland. With a full range of competencies from concept engineering design to full-line integration, Comau UK has proven to provide flexible, tailored and value-added solutions to all clients from automotive to general industry.
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Combining competencies from working extensively with the automotive sector, Comau has sucessfully been able to grow into new industries with the help and support of its own virtual commissioning team and highly flexible workforce. The company’s new site in Gateshead strategically puts Comau in an excellent position to meet the needs of the northeast regions of UK and provide all of the products and services Comau already offers globally in a local setting. The company’s growth can be credited to the impressive alliances with local education/training providers in both its sites where the aim is to support the UK Government’s focus on bridging the skills gap in the manufacturing industry. Comau’s global, replicated values are strong in the UK which has given proven success in its communities and with its stakeholders, the company maintains that it continues to push boundaries and exceed expectations wherever possible throughout its activities. www.comau.com
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Comau
8 08:48
A family is never too big
Automation has improved working conditions, increasing efficiency, productivity and the quality of the final result. Progress, today, passes through full human-machine collaboration, research and training. The continuous growth of the Comau portfolio satisfies the unique requirements of each client, through all phases of the process, with new products designed to help business development.
Comau has been a precious ally for over 40 years: by your side, like a family member.
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Make it more profitably with a connected approach from Lectra Fabric and leather cuttting machinery manufacturer, Lectra, offers manufacturers a way to anticipate and control costs to make real material and financial savings throughout the production process.
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In today’s world, it is essential to control costs, effectively deploy hard-to-find skilled staff, optimise efficiency and minimise wastage at every stage of the product design, development and manufacturing process. Such imperatives impact on profitability because they add time and expense to the business of making furniture. As its name implies, Lectra’s Design to Cost approach is all about designing furniture while keeping the production cost in mind. This makes it easier to control margins throughout the process, from design to production. Questions such as: How does this style impact margins, and what is the right balance between the two? how to reduce development time and material use? How to shorten the design validation cycle so we get a firm fix on costs? How to reduce the number of physical prototypes?” provide a simple checklist to help anticipate and reduce likely costs – improving profitability. In addition, these questions will help manufacturers identify areas in which significant cost savings can be made, such as prototyping, a cost that can be three to five times more expensive per unit that the final product. That’s why forward-thinking companies are increasingly harnessing the possibilities of 3D virtual prototyping to allow designers to assess the interplay between materials, design, feasibility and cost. It is possible to test multiple alternatives in order to find the best solution to satisfy both aesthetic and cost specifications including changing dimensions, cut or style lines, and using standardised parts to reduce costs. All of these impact margins so anticipating their cost implications at the design stage delivers actionable insights, ensuring you send only the most profitable models into production.
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According to the company, developing a prototype using Lectra’s DesignConcept solution takes only half the time needed to do it manually. Virtual prototypes can be used later to develop other products in the same range very quickly, for example taking a twoseater sofa model to create a three-seater sofa. In addition to ensuring all products meet the required cost-tovalue ratio, concurrent prototyping and costing make it possible for several people to work on a model simultaneously: material use is forecast earlier and accurately, giving a real competitive edge when replying to tenders and purchasing raw materials. Control costs during pre-production Once a model has received final approval, Lectra’s DesignConcept solution automatically generates technical specifications, with sewing and internal structure plans containing comprehensive details of all elements, including wood and foam, which can be sent to the production department. Accurate documentation is an essential element in the quest for operational efficiency – it should always be completely up to date, taking into account all modifications which may be made later on. In addition, with DesignConcept, any changes to the 3D model are automatically reproduced when it is flattened back down to 2D for industrialisation. To help eliminate the risk of error, Lectra’s pattern-making and 3D software employs a system of dependencies which create links between pieces. Modifications made to one piece are automatically transferred to all linked pieces, eliminating the tedious and time-wasting task of making the same change multiple times. To optimise fabric consumption, DiaminoFurniture, Lectra’s automatic markermaking solution, positions the pattern pieces on the material, evaluating many different ‘what-if’ scenarios to find the most efficient combination. This will give users an accurate estimate of how much fabric will be necessary so that the cost can be calculated, just as if it was in a real production situation. Manufacturers can go even further by simulating different combinations to find the best mix of models and variants for maximum fabric and leather savings.
For leather, these functions are carried out by Lectra’s LeatherNest software taking into account quality zones and premarked defects. Clearly, with patterned fabrics it is essential that the different parts match perfectly for the aesthetic of the finished piece. Users are able to define pattern-matching rules to give the right finished quality with minimum material use. When relying on manual methods in the design and production of upholstered furniture, manufacturers inevitably build time and money into the process, reducing profitability. But Lectra’s approach is, why reinvent the wheel? Standardised structures can be saved and reused so that the product development cycle is radically shortened for future models. This reduces the cost of managing and developing new elements for each model and means furniture companies can industrialise new models very quickly. Secure costs during pre-production Material use may have been optimised during the pre-production phase, but to ensure profitability, cutting needs to be accurate too. Reworking rejected pieces costs time, material and money, so production has to be consistent and the quality repeatable. Complete visibility means that costs can be managed effectively and margins secured. Companies need to be checking and controlling accuracy of cost. Automation and standardisation help bring users closer to operational excellence and zero errors, which is why all Lectra solutions incorporate error-reduction tools. Reaching business goals with Lectra Long-life consumables, low electricity consumption and maximum availability through the embedded intelligence connected to Lectra’s call centers naturally all make production more profitable – not to mention the best material saving available on the market. Lectra’s automatic data flow ensures that all the information for each of a manufacturer’s models is always available, from prototype to production. Lectra also offers software to oversee leather costs. It compares supplier quality and surface area estimations with the quality and surface area actually delivered. This means its customers can base any supplier review or reclamation on hard data. www.lectra.com
“Lectra’s Design to Cost approach is all about designing furniture while keeping the production cost in mind. This makes it easier to control margins throughout the process, from design to production.”
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The future factory
– smart production with Homag UK Over the last few years, intelligent production processes have become increasingly prevalent within the woodworking industry. As technology has continued to advance, Homag UK has been at the forefront of launching smart innovations for workshops. From software and machinery to servicing and maintenance, Homag offers a smart solution for each stage of manufacturing to increase efficiencies.
Homag’s augmented reality tool – guided machine maintenance
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24 SMART FURNITURE PRODUCTION
The future factory vision begins with networked production and the communication between machinery and processes. Linking all compatible machines together within a facility allows them to communicate during production to ensure that the facility is running at maximum efficiency. Over the past couple of years, many companies within the woodworking industry have implemented a number of networked production concepts. This has enabled manufacturers to produce both batch size one and mass volume furniture designs whilst reducing delivery times. Homag UK can assist with the steps needed to introduce networked production which can increase productivity by up to 30%. Based around five key elements, Homag will implement a suitable infrastructure within the company to network all the machines and allow the system to collect workpiece data during the production process. Each workpiece is assigned a digital identity which ensures an end-to-end flow of information. Throughout the production flow, the system knows what the workpiece is, the processing steps it needs to take and how it should be stored. This ensures that machine capacity is increased and production capabilities are maximised as processes become smarter and more efficient.
TRANSBOT – AUTOMATED GUIDED VEHICLES FROM HOMAG As technology has continued to advance, Homag debuted its latest method of connecting manufacturing cells – automated guided vehicles (AGVs). Transbot is Homag’s automated guided vehicle which connects individual processing machines, automated cells and manual workstations together. The self-driving vehicles navigate freely through any space for the quick transportation of materials and workpieces. By continuously scanning and monitoring the environment, the AGVs maintain health and safety by avoiding any potential collisions with foot or vehicle traffic. Once a production stack is complete, Transbot moves underneath the tray, lifts it and transports the stack out of the machine. It then takes the stack directly to the next machine for processing or to an automated surface buffer between the processing steps. The AGVs can also be easily integrated into existing production facilities retrospectively. Additionally, should there be any changes to the production facility layout, such as new machinery, the AGV’s travel path can be easily adapted to the new set up. The ability to change its path demonstrates the flexibility of TRANSBOTS compared to traditional methods such as conveyors. This makes them the ideal solution for the future factory as they adapt with business changes.
AUTONOMOUS MANUFACTURING CELLS One of the most efficient features of networked production is the creation of autonomous manufacturing cells. Autonomous cells allow production facilities to link production processes and automate the handling of materials in between cells. This opens up advanced manufacturing solutions for companies of all sizes and provides small- to medium-sized companies with the opportunity to grow.
TAPIO – SOFTWARE FOR THE FUTURE FACTORY Whilst technology has continued to advance to create the optimum future factory, it is the software behind the machines that really powers networked production. Homag has developed tapio – a digital platform specifically designed to enhance productivity. The app based software collects data from the manufacturing facility. It provides the user with live updates of machinery status, production processes, servicing requirements and software
“Over the last few years, Homag has developed and produced an innovative range of technology to improve production processes. As this technology has developed, it is now available for all aspects of production as there are now solutions to simplify maintenance and servicing.”
Homag offers the option of integrated workpiece handling in the form of its range of Loopteq return systems. Ideally suited for edge banding machines, these flexible return conveyors allow for the easy flow of materials. Once a workpiece has been completed, the system automatically takes it from the machine to its final destination without the need for manual intervention. Loopteq automatic return systems can be integrated with stacking systems which means finished workpieces can be ejected or automatically destacked. This not only reduces the system down to a one man operation but also reduces physical lifting of heavy panels. This in turn speeds up the production flow. Autonomous cells can further be automated using robotics. Robot handling is not only reliable for the transportation of workpieces and materials but also easy to operate and very cost effective. Only taking up a small amount of space, robot arms provide the gentle handling of materials for tasks such as aligning, rotating and transporting workpieces.
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The future factory– networked production with Homag
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updates. Additionally, tapio also monitors and produces data for capacity and throughput rates as well as any concerns such as machine errors or drops in productivity. Should any machines need operator attention, tapio will send notifications direct to smart devices such as watches, phones and tablets to minimise any potential costly downtime. This also includes the alerting of any machine services which need to be carried out in order to keep the machines running efficiently. By monitoring the complete facility, it ensures that any issues are not missed and productivity can be maximised. SMART SOLUTIONS FOR SERVICING AND MAINTENANCE As well as the production stages, Homag has developed a range of smart solutions for servicing and maintenance. These products enhance productivity by making tasks more efficient and quicker for manufacturers. The ServiceBoard app allows customers to live stream any service incidents to the service centre using wireless video diagnostics as and when they occur. This allows the Homag service team to identify any errors in a matter of minutes and in most cases, rectify them immediately. The ServiceBoard app is also capable of providing instant information and guides to users through videos, instruction manuals and diagrams which can be accessed at their own convenience. ServiceBoard users also have direct access to Homag’s eParts service where they can easily order machine replacement parts when needed.
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Transbot – automated guided vehicles from Homag
IMPROVE MAINTENANCE TASKS WITH THE AUGMENTED REALITY TOOL To further simplify machine maintenance, Homag has developed an augmented reality tool. With clear, user friendly, graphics it can be used as an aid to maintenance personnel to assist with resolving problems including changing tools and parts. Whilst some companies have experienced maintenance personnel based at their facility, there may still be some tasks which are rarely completed – especially if there are several different machines to maintain. The augmented reality tool can be used as a guide or refresher for those instances. The user simply points the camera on a tablet or smart phone at the machine. The system will then instantly highlight which areas on the machine need attention. It places a 3D drawing over the image taken on the camera or tablet and explains each required action, step by step, as an animation sequence. Simon Brooks, managing director, Homag UK explains: “Over the last few years, Homag has developed and produced an innovative range of technology to improve production processes. As this technology has developed, it is now available for all aspects of production as there are now solutions to simplify maintenance and servicing. “The tools available bring a large range of production benefits to all manufacturers irrelevant of size. Increasing production efficiencies, reducing downtime and maintaining machines is essential for all companies – whether they are mass production or batch size one manufacturers. “Homag is able to assist manufacturers with all aspects of enhancing their facility to future proof production processes. If you would like a demonstration or more information on any of our smart production products, please contact Adele Hunt on 01332 856424 or e-mail info-uk@Homag.com” www.homag.com
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