By using a software module tailored to the specific application area, the monitoring of production processes in the metal industry can be significantly improved. The solution enables precise analysis of key process parameters, increases transparency and supports quality assurance. It is provided on-premises to meet the highest requirements regarding data security and integration into the existing system landscape.
The developer of this solution is ALD Vacuum Technologies GmbH, a manufacturer of vacuum technology systems for metallurgy and heat treatment. The company consolidates its expertise under the branding ALD EXPERT, a product portfolio of software and hardware solutions that provide overarching functionalities for machinery and equipment in the fields of metallurgy and heat treatment.
The challenge: control and verification in process monitoring
In industrial manufacturing, transparency and traceability of processes are crucial for the quality of the manufactured products. This applies to all industries, especially the process industry and, in particular, the metal industry. Seamless process monitoring is absolutely essential.
Monitoring key process parameters is essential for higher product quality, compliance with cost requirements, and the economic efficiency of the company. Many companies face this challenge because traditional ERP and MES systems are not suitable for this purpose.
ERP systems clearly focus on order-related data, whereas MES systems do not offer the ability to accurately record and monitor process parameters such as temperature, pressure, melt rate, or tension. This gap reduces the transparency of processes and makes it difficult to provide documentation to end customers and authorities.
What is needed, therefore, is a solution that offers process monitoring and evaluates all relevant data and parameters that previous software solutions have been unable to capture. Based on its digital IoT platform, the ALD EXPERT GRID, ALD Vacuum Technologies GmbH has developed a specific solution for process monitoring in the metal industry.
The challenges at a glance
- Traditional systems (ERP, MES, etc.) do not capture central process data.
- Process monitoring is missing in many production processes.
- Compliance requirements for third party verification are difficult to meet.
- Software solutions must be individually adaptable.
The solution: A platform for process monitoring
The “Process Monitoring” software module from ALD EXPERT was developed for use in metallurgy and heat treatment. It is primarily used in melting and remelting processes, as well as in the coating of technical components. The underlying technology allows configuration for different use cases without requiring fundamental adjustments to the existing software framework. This makes it possible to use process monitoring even in companies that want to map processes outside their original target industries.
On-premises solution with plant expertise
The technical implementation of process monitoring is carried out exclusively on-premises. This type of deployment meets the high requirements for data security, integration capability and IT compatibility in industrial environments. Customers receive a turnkey solution, usually provided as a virtual machine for integration into their IT infrastructure. It can also be supplied on an industrial PC upon request.
A key advantage is the deep integration into each system, which is always developed as a one of a kind solution for its intended use. As a manufacturer in special machine engineering, ALD is highly familiar with the control technologies used and the respective production processes. This expertise feeds into the development and commissioning of the ALD EXPERT solutions and forms the basis for process monitoring.
This ensures that the functions can be tailored precisely to the needs of the specific application, which makes the process monitoring solution so distinctive.
Rapid parameter monitoring for greater process reliability
The direct connection to the system’s control level enables fast acquisition of all relevant process data and its visual representation. This is the only way to ensure continuous process monitoring during operation. Deviations from defined target values are detected and displayed immediately. The application offers two methods for setting the tolerance range.
- The customer defines target limits for individual parameters in the form of upper and lower thresholds.
- The customer uses a reference curve based on an exceptionally successful batch known as the golden batch.
The current process curve is then compared with the reference curve. This method allows standard deviations to be calculated precisely and process changes to be captured accurately. The process monitoring system creates the basis for proactive intervention and reduces dependence on the individual experience of specific employees.
The primary target group for the solution consists of process engineers, maintenance teams and people responsible for production or product quality, since these groups have a strong interest in evaluating data during operation or retrospectively. Thanks to the storage of all information in the database, historical analysis is possible at any time. The system is also suitable for machine operators, as they receive visual feedback in the application, for example in the form of alerts when defined tolerance limits are exceeded.
The result: Greater quality and traceability
A key reason for using the Process Monitoring module is the increase in transparency enabled by continuous process monitoring. Companies can reliably verify whether their processes remain within predefined limits, for example for melting rates, melting temperatures or pressures. The monitoring enhances both process quality and the quality of the final product. The system also ensures complete traceability because all process data is stored by batch and recipe.
This provides customers with a tool for quality assurance and a foundation for future oriented manufacturing strategies. The high degree of adaptability, the integration into existing structures and the ability to perform data-driven analysis create the conditions for continuous improvement of process reliability and productivity. Companies that wish to invest in digitalization and process security receive a future-proof tool with strong practical value and a solid basis for sustainable production systems.
Companies that want to make their processes safer and more efficient can request detailed information about the IoT-based solution for the metal industry, including application examples and direct contact with the experts.
Summary of results
- Data-driven process monitoring with defined limits.
- Tangible improvement in product quality.
- Complete traceability of every batch.
- Integration into existing structures ensured.
