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carla 3

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Prezibase Designs

on 7 October 2016

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Transcript of carla 3

Plan B: Reverse Engineering
and Equipment Retrofits

Abstract
Introduction
Introduction
When purchasing new equipment is
not an option
Reverse Engineering
(Ingeniería Inversa)
Equipment Retrofit
Quality and Regulatory challenges
Customer complaints
Safety
Ergonomics
Environmental
Consumer product protection laws
Serialization (Drug Supply Chain Security Act)
Unique Device Identification (UDI)
Retrofit benefits
What to retrofit?
Ismael Segarra
Managing Partner
Plastics Technical Solutions Corp.

An overview of the evaluation and justification of Reverse Engineering or Equipment Retrofits to meet
In tough economic times, tight capital budgets often force companies to delay purchases of new equipment
Manufacturing Companies are always on the ongoing need to increase productivity
Many of the Manufacturing Equipment installed during the past 10-15 years are inevitably starting to show signs of age
In more favorable economic times companies would have invested in completely new equipment, but in the current environment the funds may not be available
Upgrading the existing machine can bring many of the benefits of new equipment at a fraction of the cost
Equipment Retrofits
Reverse Engineering
Disassembling an object or a system to analyze and to see how it works in order to duplicate or enhance it

Parts
Tooling
Controls Systems
Equipment
Reverse Engineering
Reverse Engineering is commonly performed when…
OEM is not available
Reverse Engineering Tools
3D CAD has become a practical tool to create a three-dimensional virtual model of an existing physical part or mechanical system
Reverse Engineering Hardware and Software Tools
The physical object can be measured using
Scales, calipers, micrometers, etc
3D scanning technologies like coordinate measuring machines (CMM) or laser scanners
Retrofitting refers to the process of updating older equipment with new technology
Saving money

When to retrofit
Productivity falls
A machine’s age and the company’s budget usually determine what to replace
What to Retrofit?
Mechanical Systems
Drive systems
AC Motors, AC Drives, etc
Pneumatics or hydraulics
Actuators
Valves
Replacements by Energy Efficient Systems
Controls
Sensors
Software
HMI
PLC
PC
Retrofitting a control system versus buying new
Always consider a controls upgrade to existing machinery before proposing a new machine
Commonly used tips
Retrofitting can increase the life of equipment
Equipment Lifecycle Management
Productivity

ROI
Much of the savings depends on the application
If the retrofit represents 10 to 20% of the machine value, and can give new-machine performance, the machine owner saves 80%
If the retrofit push productivity beyond previous levels, the upgrade lets users avoid purchasing a more-capable machine
ROI Example
Industrial Internet of Things (IIoT)
IIoT systems provide features and data that add value to the production line
Work with current production lines and can mount on existing equipment
Examples: smart sensors, cameras
Cost, Productivity, Quality and Regulatory challenges.
When should I use Reverse Engineering or Retrofits?
What do I need to know in order to make the right decision?
Improve documentation shortcomings
Repair: by creating new parts from old, fractured, or worn originals
Tool making: by reducing the time required to develop tooling and improve tool accuracy
Obsolescence
The use of 3D CAD, computer-aided manufacturing, or other computer-aided engineering applications has made RE easier
Software reconstructs it as a 3D model
reverse engineering allows users to quickly digitize a part or object and create a fully surfaced CAD model which can then be used to reproduce an item
Regularly used to add functionality to many types of systems, including control systems, mechanical systems, robots, pneumatics, etc
Smoothly integrate mechanical and control systems, empowering workers and equipment to be more productive
Extending equipment lifecycle and value
Improving plant optimization efforts

Plant has higher productivity and lower maintenance costs
Staff continue using equipment they are comfortable with
Maintaining staff efficiency and effectiveness
Retrofitting costs are far less than buying new equipment
Incorporate “state-of-the-art” technology
Robots & Motion Control
Vision Systems
Laser Printers
Machine controls
Ethernet vs hard wiring
Restore the equipment functionality
Support costs begin to rise
Increased downtime: The machine frequently needs calibration or complex and time consuming repairs
The original machine is no longer being made and repair parts are scarce
Supporting the PLC controls are HMIs, servo motors and drives, pneumatic valves and actuators, AC motors and drives, etc
Typically the PLC lie at the heart of a retrofit
Along with a new machine, upgrading controls on other equipment may yield the best overall results
If the goal is to increase productivity beyond what a retrofit can accomplish, a new machine may be necessary
If a retrofit won’t help productivity, it may be a waste of time and money
Know the application requirements
But for a machine scheduled to be replaced in six months or more, less-costly short-term fixes may keep it productive until then
Cost of ownership
Scrap
OEE
* FAT and travel expenses are not included
Retrofit
New machine
Retrofit cost = $123K ÷ $782K = 15%
Full transcript