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Documentation and traceability in metallurgy

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IoT Use Case - ALD - Melt Review Sheets
3 minutes Reading time
3 minutes Reading time

Melt review sheets enable the precise recording and tracing of all process data in metallurgy. Real-time monitoring, automated documentation and integration into ERP and MES systems guarantee maximum quality and efficiency in production.

The challenge: A complex melting process

Melting and remelting in vacuum metallurgy is a complex process that only leads to high-quality results through precise fine control of the melting process. This includes controlling the atmosphere to prevent oxidation, precisely monitoring the pressure and temperature and homogenizing the melt by (electromagnetic) stirring.

To ensure the quality of the results, it is necessary to record and track the entire melting process in detail. Companies must ensure that all process parameters are within the specified target values. This is the only way to achieve consistent product quality. In addition, it is now common practice to integrate the data into IT systems after the melting process. The IoT platform (ALD EXPERT GRID) from ALD Vacuum Technologies GmbH has all the necessary functions.

The solution: Melt review sheets for seamless process documentation

All ALD melting and remelting systems can be connected and operated with ALD EXPERT. This is a web-based IoT platform that connects machines and devices in different production environments, collects and analyzes their data. One of the core functions of the ALD EXPERT system is the visualization of process data.

By monitoring all production data in real time, machine conditions such as temperature, pressure and gas flow as well as historical data can be displayed simultaneously on a user-friendly platform. Visualization is usually achieved via dashboards. They allow data to be monitored in real time and enable a rapid response to potential problems or inefficiencies.

Melt review sheets are an important function of this software system. They record the entire melting process and make it traceable. Crucial in this regard is the integration with modern IT systems. In most cases, the users of our systems have either an Enterprise Resource Planning (ERP) or a Manufacturing Execution System (MES).

The two software systems often work hand in hand. In any case, the aim is to be able to control production and evaluate data, for example to keep an eye on raw material consumption or ensure the quality of the results. The connection of ALD EXPERT to ERP/MES ensures bidirectional data transfer between our melting systems and the higher-level software systems.

Another main function of the software is the automatic generation of review sheets for quality control. It monitors all process parameters and automatically fills in the sheets at the end, resulting in precise documentation of the melting process. The companies can determine whether there are deviations from the specified target values and whether the process parameters are within the specified ranges. This enables a company to precisely determine at any point in the production process which parameters have been applied.

The result: Traceability through comprehensive process monitoring

The use of melt review sheets allows for detailed recording and tracking of the entire melting process in metallurgy. By automatically monitoring and documenting all process parameters, deviations from target values are immediately detected, significantly enhancing quality assurance. Integration into existing ERP and MES systems ensures seamless information flow and efficient production management.

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