Working with powdered metal involves a process involving more than just pressing the powder into a part. From receipt through inspection and certification, a powder metallurgy part can go through several processes. Each of these processes can add value to the genealogy of the finished component.
While tracking a lot of information about the material properties of a finished part is valuable, even more so is how that information can be integrated with other processes, equipment, work-in-process and the final certification of the finished component.
In this article, we'll explore what a digital thread in PM manufacturing looks like, how it connects data and information relating to powder and production and then the tools that help support it.
Let's start at the beginning - the powder lot.
The Beginning of a Digital Thread: the Powder Lot
The digital thread doesn't have to begin with the production of a part.
In fact, it could begin when a powder lot enters the facility. Information relating to a particular powder lot can help identify the starting point of production genealogy for the component.
The digital thread could follow as that powder lot is blended, produced into a green part, sintered, and so on.
This could look something like:
Powder Lot
↓
Mixing / Blending
↓
Compaction
↓
Green Part
↓
Sintering
↓
Inspection / Testing
↓
Certification
Each of these steps can add attributes and information to the digital thread.
WIP Integration is Critical
When dealing with WIP, a manufacturer needs to know not only general production information, but specific work in process data.
From one plant floor to the next, these green parts and processes may get shuffled around. If information about the WIP is stored in one location and the material and production in another, establishing the complete provenance of a given WIP is difficult.
Linking this WIP information with the production elements provides a richer source of information.
By using a digital thread, a particular data record could be linked with the powder lot, equipment, production stage, and WIP.
The value of doing this isn't simply about being able to find the WIP - it's about understanding where that WIP has been, and how that information might impact the process going forward.
Quality Isn't Just Post-Production - Testing and Inspection Data
Quality information and data can play two roles in a digital thread.
First, there's information about the material itself. Then, there's information about the outcomes of production.
When inspection or testing data can be associated with a particular production history, it adds more context and value to that production record.
This is especially useful when there's a quality problem down the line.
Rather than having to sift through disconnected data sources about the production run, material and testing or inspection, a properly-integrated digital thread makes the relationship between the element clear, improving overall quality.
From Genealogy to Certification and Beyond
One of the easiest ways to think about a digital thread in PM manufacturing is genealogy tracking.
This looks at the relationships between materials purchased, received and put into production, and then the production processes, equipment, work-in-process, until it becomes a finished part.
For a PM component, this could look like:
Powder lot information
Mixing or blending history
Production equipment
Tooling
WIP details
Processing information
Inspection data
Test results
Certification information
This creates a history going from the purchased raw material or powder lot, through production, testing and finally the certification.
This gives a rich genealogy of a component.
Now, let's take a look at what kinds of tools would be useful in enabling a digital thread across production.
Enabling the Digital Thread: AIoT Technology
A digital thread involves creating connections between many points in a manufacturing operation.
It goes well beyond simple relational databases. Information needs to be pulled from many sources, including machines and sensors on equipment, RFID systems, production software, Bluetooth Low Energy (BLE) devices or even manually-entered paper work or spreadsheets.
This is where Industrial IoT technologies can create substantial value, and specifically AIoT technology.
AIoT combines industrial technology such as RFID or Industrial IoT sensors, with edge computing processing, data integration technologies and data analytics to help create a digital thread around manufacturing processes.
PowderForge AI offers connected manufacturing intelligent specifically focused on PM manufacturing, including powder inventory, tooling, WIP, people, equipment, and connected traceability.
The main point with a digital thread is about these elements being interconnected and intelligible.
Creating a Digital Thread: Not an Overnight Process
There isn't one magic bullet or piece of equipment, that creates a digital thread overnight.
PM manufacturers should evaluate at least one use case for a digital thread. This could be connecting powder lots to a given production run. Then, WIP, equipment, tooling, and so on can be included as necessary.
The focus is on getting the right relationships between physical objects and data records established in the first place.
Now that we've taken a look at some of the concepts behind a digital thread, let's step back and look at the bigger picture in this final section.
The Bigger Picture: Powder Metallurgy Component History
When finished, a PM component is a lot more than its inspection data.
Behind every part is a set of relationships between the equipment and processes which made it, the materials which went into it and the workers who handled it.
A digital thread can store this connected history, from powder lot to finished component. It can provide a genealogy of WIP, materials and certification.
This is a lot more valuable than disconnected islands of production data.
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