“While the project was underway, intermediate results already showed we were on the right track. Te improved synchronization of processes has a direct impact on energy efficiency and productivity.” —Reiner Eschen, technical managing director of FWH.
“项目的中间结果已经证实，我们行进在正确的方向”，FWH 的技术常务董事Reiner Eschen先生介绍道。“不断改良的同步流 程对能源效率和生产力都带来了直接的积极影响”。
rarely organized in a centralized manner. Rather, they are traditionally perceived as individual steps in isolation, mainly controlled through the skills and expertise of the foremen or individual departments at the firm. Another problem of such plants is the occurrence of bottlenecks for cranes and casting puts. The result is that processes are likely to be held up due to external and internal influences. The pro- duction chain is seldom transparent, with workers often waiting around and machines standing idle, thereby putting a massive strain on resources. Opti- mum energy efficiency is almost impossible here. PSI extended its standard modules and created
new interfaces to the energy consumption measur- ing systems. The concept proved to be the correct strategy. “While the project was underway, intermediate
results already showed we were on the right track,” said Reiner Eschen, technical managing director of FWH. “The improved synchronization of processes has a direct impact on energy efficiency and produc- tivity.” Efficient planning and control of the weekly
casting schedules on the basis of energy consump- tion is now possible with the help of the MES. All upstream processes (molding and coremaking) and downstream steps (emptying, fettling, processing, inspection, and dispatch) can be organized in the schedules and coordinated accordingly. The production planning and control depart- ment was set up to ensure more accurate planning. One important factor for the control process is the collection of shop-floor data, which is fed back to the new terminals in the production department. The program not only shows staff the daily work list but also the sequence of operations involved. The time actually taken for each task and disruptions are
骤，主要通过工头及各个独立部门凭借各自的经验和 技能进行控制。此类铸铁工厂面临的问题都是由于起 重机及铸造次序瓶颈问题而引发的。在工厂内外部因 素的影响下，这些工作流程极易被耽误。整个生产链 条相当不透明，工人经常白白等待在闲置的机器旁， 从而造成了巨大的资源浪费。彼时，优化能效几乎就 是不可能完成的任务。
为了解决此等问题，PSI Metal为能源消耗测量系 统开发了更多的标准模块，建立了新型界面。这一概 念被证明为行之有效的策略。
“项目的中间结果已经证实，我们行进在正确的方 向”，FWH 的技术常务董事Reiner Eschen先生介绍 道。“不断改良的同步流程对能源效率和生产力都带 来了直接的积极影响”。
在PSI Metal的帮助下，FWH现在可以基于能耗情 况，针对每周的铸造计划制定相应的能耗计划及控制 计划。所有的上游程序（制模及型芯制造）及下游步 骤（排空、铸件清理、处理、检查、派遣）都能有计 划有序地组织和协调起来。
FWH还建立了计划和控制部门，确保计划的准确 性。控制程序的一个重要环节是对车间数据的收集。 收集妥当的车间数据将会被反馈给生产部门的新终 端。该程序不但能告知员工每天各自的工作安排，还 能注明所涉环节的先后顺序。制造执行系统将会对每 个任务及故障所耗时间进行分析，从而制定出后续计 划，并及时发现瓶颈或故障，具有早期警告系统的功
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION May 2013
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