“Industry 4.0 aims for faster, more flexible and efficient production, as well as self-organizing production facilities,” Stefan Pelech, MD, HERTWICH Engineering

HERTWICH is a leading provider of equipment and technology for the aluminium industry. Stefan Pelech, a graduate from Technical University, Vienna, Austria joined Hertwich Engineering some 15 years ago as physicist and process engineer. He was responsible for all R&D activities within Hertwich, and was from the outset intensively involved in the development of melting and casting equipment. He also handled some strategic recycling projects as project manager. Since 2018 Mr. Pelech Stefan has been serving as the Managing Director of Hertwich Engineering. Here, he shares his views on Industry 4.0 applications with AlCircle in a brief interview.

AlCircle: What does Industry 4.0 mean to the aluminium industry? How can the implementation of its framework benefit the industry in the current scenario?

Stefan Pelech: Stefan Pelech: Like all other industries, the so called “Smart Factory” concept is the future for the Aluminum industry and each of its sectors. Industry 4.0 aims for faster, more flexible and efficient production, as well as self-organizing production facilities.

AlCircle: How has the use of digital techniques changed the aluminium industry?

Stefan Pelech: It starts with product development. Numerical simulation helps a lot to optimize machines with reduced need of experimental testing. Now numerical techniques are also used in control software – keyword “Virtual Twin” – enhancing the accuracy and speed of automatic controls. There are many automated quality control systems on the market, enabling a 100% testing of product properties improving the reliability of production processes and quality of the end product. Also Production Planning – MES and Resource Planning – ERP are available. All these make the aluminum industry more efficient, safer and more environmentally friendly.

AlCircle: How has automation helped in improving efficiency, productivity and safety in aluminium casting sector?

Stefan Pelech: Let’s start with safety. The higher the degree of automation, the better is the separation of workers from the process, resulting in fewer accidents. This alone is making it worth improving automation. And the welcome side effect of this is the commercial advantage. Processes are more stable and optimized in terms of energy consumption and environmental soundness.

AlCircle: HERTWICH has a 40 years’ history as a leading provider of machinery and equipment for the aluminium industry. How has Hertwich evolved over the years to fit into the Industry 4.0 framework of today?

Stefan Pelech: Hertwich, founded in 1973, has always been a front runner in terms of using modern IT technology for its machinery. At that time automation technology lagged behind the programming by 10-20 years. That’s why we had to develop our own PLC in the 80s, gradually developed a soft – PLC and further compiler software that allows to feed most complex custom-made automation to standard SPS hardware. Today we already use virtual twins and simulation tools in our automation concept.

AlCircle: HERTWICH is the world leader in the field of Continuous Homogenizing Plants for extrusion billet with 90% market share. How do you maintain this position amid strict competition?

Stefan Pelech: We focus on our customer’s demand which is to produce the best quality product with a Hertwich homogenizer. The high degree of automation ensures maximum process reliability and digitalization tools help us to further improve the current process and future plants.

AlCircle: What is your view on robotics in aluminium industry? Give us a heads up on how Robotics is being used by HERTWICH in its products and services?

Stefan Pelech: Robotics help to keep humans away from the process. As mentioned before, this is improving safety tremendously. We use robotics especially in processes like cutting, stacking marking and packing where lowest possible cycle times are needed. But we are not willing to use robots just because it looks modern. We evaluate very carefully whether it really needs an expensive robot for an often simple process step.

AlCircle: Brief us on some of your recent projects that have helped companies upgrade to the Industry 4.0 environment?

Stefan Pelech: In principle, we always implement the latest state of development of our automation technology in all our projects. This means, for example the use of state-of-the-art sensor technology and the collection of as much process data as possible. Especially in the field of automatic quality measurement (surface inspection and 100% ultrasonic testing), we have installed systems that automatically generate feedback to the casting machines and reliably minimize rejects. Self-learning process parameters, material tracking, failure diagnostic systems, alarm Manager and maintenance support are our standard. And even a Manufacturing Execution System (MES) made by Hertwich has already been implemented in two foundries with one of our customers, where it supports the production planning process and optimizes the scrap input in the melting process.