Category Archives: Cool Applications

Creating Logistic Efficiencies

PROJECT

Grand Rapids Metrology was contacted by a logistics company who worked with automotive parts. They sought a process that could be done in-house and would increase the accuracy of their logistic procedures and movement along the supply chain. Before GRM’s intervention, the company contracted this process to a third-party which increased cost of their daily operations.

INITIAL NEEDS & CHALLENGES

This firm focused on pre-staging automotive parts for vehicle assembly. They received parts from their suppliers then performed a physical transfer of pieces from the supplier’s packaging into their own packaging. The issue was the company often received an incorrect number of pieces from their supplier. This resulted in inaccuracy and lost time and money to fix the recurring error. Ultimately, the company saw a need for a piece weight and total package weight solution.

SOLUTION

GRM’s solution employed five systems; two floor scales and three bench scales. The process now weighed each piece of material once it was in a box. An indicator would display the number of objects in a box, if the number in the box was correct, a stacking light would signal green. If the number of objects was incorrect, the stacking light would signal red. Regardless of the colored signal, a label would be printed and applied to the package with a barcode indicating part number, part count, etc. If the weight and part count was over or under the requirement, the logistics firm could inform their suppliers that their shipment was incorrect. This system ultimately aimed to ensure accuracy to the number of parts based on weight measurements.

RESULTS

This was another successful solution! After Grand Rapids Metrology’s implementation, the system reported to increase accuracy and efficiency, save time, and lower costs.

Numerous aspects of this applications can be adopted in other industries. For a manufacturing or handling company, the label printing and barcode scanning application can be incorporated. For a company that utilizes a filling process, a stack light could be implement to maintain and verify a procedure.

To find out how GRM can improve your day-to-day operations, please contact of Solutions Team member, Terry Benjamin, by email at terry.benjamin@grmetrology.com or by phone at 616.249.1210.

A Load Cell & PLC Solution

An agricultural company Grand Rapids Metrology has a long-standing relationship with contacted us with a need for a customized solution. Based near Grand Rapids, MI, they previously had four silos in place that incorporated a fast load out system which was originally crafted by Grand Rapids Metrology. Throughout the years as technology advanced, the system needed updating. The customer trusted Grand Rapids Metrology to continuously work with them and update the fast load out system numerous times.

In recent years, the company invested in eight more silos each with a capacity of roughly 225,000 pounds. GRM partnered with a third-party contractor to install the eight new silos and solely installed four new load cells under each silo with indicators, one dedicated for each group of four silos. The previously updated fast load out system was replicated and implemented twice during this project totaling to three systems with twelve silos. Our extensive relationship and knowledge of this company has allowed us to scale to their growth and continue to implement such projects.

One of the company’s biggest requirements for the new system was the desire for printed tickets to include the product name and product code. GRM has vast experience with Ethernet IP and PLC (Programmable Logic Controller) communication as well as incorporating PLC’s and indicators. We were able to create communication between the PLC and the scale indictor utilizing Ethernet IP which allowed the printed weight tickets to include the product code and product name, just as the company had hoped.

A challenge encountered during the process was working to certify the company’s outgoing products on their trucks for Legal for Trade. GRM worked closely with the customer and the State of Michigan to fulfill the requirements of having products Legal for Trade, one of those being an accurate weight measurement. The new communication system and load cells produced extremely accurate results. Our Solutions Team also integrated an auto- adjusting and auto-learning pre-act system that allows the measurements of product to become more and more accurate as time goes on.

The use of load cells has applications in numerous industries as does a communication system similar to the Ethernet IP and PLC one utilized here. For inquiries about our custom engineered solutions, please contact of Director of Operations, Terry Benjamin by email at terry.benjamin@grmetrology.com or by phone at 616.249.1210.

Balanced Automotive Spot Checking

Grand Rapids Metrology has an on-going, long term relationship with an automotive manufacturing company. This company desired to know the weight distribution of its vehicles quickly after their assembly. Essentially, they required a quality spot checking of vehicle’s weight off of the production floor. These measurements are mandatory by EPA Standards in this industry.

Before GRM’s implementation of a custom engineered solution, this auto manufacturer utilized third-party providers. Due to production issues, they decided that spot checking would be the best option for their operation. Instead of using multiple third-party organizations, this company was able to hone in on just one, Grand Rapids Metrology.

The new process GRM created incorporated four platforms, one to weigh each wheel all connected to a central indicator. All four wheels were weighed at once as was the total weight of the vehicle. The weight distribution data was then collected and analyzed by the company. An operator watches the computer monitor for a green light to flash that displays a successful transmission has occurred. The data is accrued centrally for all assembly plants located through the world. The company can then use the data to verify that the vehicle has meet its specifications.

The success of this project has been overwhelming. The automotive manufacturer has implemented this process into all its plants across North America. Knowing the weight of each wheel and the vehicle as a total has enabled the organization to (1) comply with government regulation, (2) become more knowledgeable and efficient in the research and development of new vehicle design, and (3) inform engineers of any inaccuracies that have occurred along the production line.

A similar system could be utilized for any manufacturer of large objects and vehicles, for instance, farm equipment or RVs. For inquiries regarding our custom engineered solution, contact our Director of Operations, Terry Benjamin, by email at terry.benjamin@grmetrology.com or by phone at 616.249.1210.

Temperature Mapping of Ovens

Recently, Grand Rapids Metrology was contacted by a manufacturing company. They were curious about the possibility of temperature gradients inside of their inert gas ovens. Before approaching GRM, the company was utilizing single point measurement. Although single point measurement provides accurate temperature data for an oven, it does not provide enough data to determine the temperature gradient of the entire oven.

The customer was inquisitive about temperature fluctuations in various locations within the oven, as the entire oven is used in their manufacturing process. Upon GRM’s intervention, a nine-point temperature mapping of the oven was agreed upon. The nine points consisted of one point in each corner of the cube and one in the center, all of which had three temperature set point of 600°F, 800°F, and 1,000°F. This solution was able to provide the manufacturing company with a complete temperature gradient of the oven which was their biggest desire from the beginning. Likewise, it enabled them to use the data provided by the nine-point structure for their quality system.

Although having less experience with temperature than other facets of our business seeing as it in newer to our arsenal of capabilities, Grand Rapids Metrology has performed various adaptations of temperature mapping for several companies and industries. For inquiries regarding temperature mapping or GRM’s other temperature capabilities, please contact our Metrology Manager, Kyle Mack, by email at kyle.mack@grmetrology.com or by phone at 616.249.1220.

Automated Batching System

PROJECT | AUTOMATED BATCHING SYSTEM

Grand Rapids Metrology was approached by a customer in need of a solution for a current manual process. This company manufactures printer ink for large, industrial printers and hoped to convert their manual batching system for mixing ink into an automated operation.

 

INITIAL NEEDS & CHALLENGES

Prior to the project, the customer employed a manual process of batching and mixing ingredients to formulate different colors of inks. The company used an operator who manually opened the valve on one of seven supply tanks, switched on a pump to started the flow of ingredients into one of the mix tanks, then stopped the pump and closed the valve once the product was mixed. They have recipes for each color, but the final product was measured manually by the operator which left room for human error. The company sought to reduce the room for human error and create a process that was more efficient and timely.

 

SOLUTION

Our IDEA team engineers designed an automated batching system that would mix ink colors in a more efficient and effective manner. The system now utilizes floor scales with Weigh-Tronix indicators and a Programmable Logic Controller.
The automated process is run by one system that is connected via Ethernet to the indicators and scale-base which is attached to each tank. The system stores the recipes required to produce all their colors and is able, via touchscreen, to automate the batching process from one central location. The operator will select the color he/she wishes to produce on the touchscreen, which will send a signal to the correct valve to open on the supply tank, then signal to activate the pump to push product into the correct mixing tank. The system uses a “smart fill” function that essentially learns the habits of each pump and auto-adjusts each fill for extreme accuracy.
An additional improvement is that the system allows the operator to run all six mix tanks at once – a feat not allowed by the former manual process. If the company wishes to mix a new color, they must simply enter the new recipe into the automated batching system. The system is equipped for a manual mode through the touchscreen, used mostly for diagnostic purposes.

 

RESULTS

The anticipated results where that the automated system would (1) make the process of batching and mixing ink colors much more accurate by reducing the probability of human error to almost zero and (2) make the process more efficient. The same operator who had to manually facilitate each step of the batching process beforehand will now be able to hit a few buttons on the touchscreen and their job will be complete. This will in turn allow the operator to manage several mixings at once or perform other necessary duties in the facility.

The actual results exceeded GRM’s and the customer’s expectations for this custom engineered system. The newly automated process cut batching time in half as well as allowed the company to mix up to six batches at once, whereas they previously could only mix one batch at a time through the manual process.

This batching system was customized based on the specific needs from the organization, for their existing preventive maintenance agreement will cover the calibration of the scales and indicators used in the system, and while no routine maintenance is required on the batching system, our engineers are available if it needs servicing. Grand Rapids Metrology is committed to providing creative, quality and accurate solutions to our customers. Our IDEA team engineers are available to assess your current manual processes and advise on measurement-based automated solutions.