FactoryOps for
steel & metals
From casting to rolling, forging, and more, Amperon Technologies helps operations teams reduce downtime, optimize throughput, and keep production on target.
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Amperon's Autonomous Production for Metal Works Industry
Discover your first steps in Autonomous Manufacturing using Amperon' innovative FactoryOps® which drive quick & deep improvements in your metal manufacturing processes, from your oldest manual lathe to your newest CNC laser cutter.
Key Processes in the Metal Works Industry
Metal removing
remove material from metal workpieces.
Metal Shaping
deform metal without removing material.
Joining
connect two or more metal parts together.
Surface Treatment
modify the surface of metal parts for function or aesthetics.
Processes such as machining, metal shaping, joining and Surface treatment which are typically linked to High-mix, low-volume orders with frequent changeovers facefour main challenges: operational inefficiency, Rework & Scraps, Complex jobs tracking & Scheduling and high energy costs.
Challenges Faced by Steel and Metal Manufacturers
Operational inefficiencies
Each project is unique ( new materials, and new fabrication steps). This induce High setups and changeover times. Coupled to unexpected machine breakdown all of this results in low machine utilization and poor work standardization.
Compex tracking / Scheduling
Many custom orders, each with different lead times and dependencies and reliance on paper based job tracking induce chaos in the shopfloor with inevitable delivery delays and idle times.
Rework & Scrap
Inconsistent execution and operator dependency (especially in welding operations) lead to defects, rework, and unpredictable outcomes
High energy costs
Ensuring that energy waste is avoided during idling is a critical challenge. Managers still pay for unnecessary energy related to auxiliary systems especially in Laser and plasma cutting machines. Energy costs for new projects are hard to predict.
AI FactoryOps® smart solution
delivers you in just One Week
Real-Time Visibility
- •Second by second machine status (Run, Idle, Stop)
- •Monitoring of idle times and inefficient operations
- •Updated Job status for best scheduling
Automatic Anomalies detection
- •Early detection of abnormal configurations or abnormal durations
- •Predictive Maintenance
Tracking KPIs & Operations
- •Tracks machine utilization, OEE and energy intensity
- •Operational traceability for QA and improvement
- •Energy cost per project type for more effective pricing and negotiations
Optimization Insights
- •Recommend maintenance before breakdowns occur
- •Smart suggest for job grouping
- •Identify jobs with low margins
- •Machine power-off to save energy
3 Steps to Reach Sustainable Peak Performance
Get real-time visibility and insights in minutes — no complex installations required.
1.Clamp
Connect to any machine through low-cost, non-intrusive electrical sensors
2.See
Empower your operators with real-time machine status and AI-powered predictive alerts
3.Analyze
Track and improve manufacturing and energy efficiency KPIs through traceability and root cause analysis
Real Time Machine status
Low-cost data capture, with high reliability and immediacy, which, processed with digital intelligence, allows knowing the real machine status and the elaboration of patterns for each machine/operator.
Evaluation by the end of shift of the realduration of metal processing and the lost production time..
Start unlocking the "hidden factory" by identifying current machine utilization.
Make informed CapEx investment through knowing current utilization
Reduce downtime due to changeover / cleaning / no operator…
Through providing context to automatically detected downtime durations (no human intervention), Changeover, Cleaning and other operations can be improved by identifying abnormal durations related to a specific machine, a specific operator , a specific job and a specific material.
Real Time automatic Parts /Cycle time tracking
Automate your cycle count data collection. no PLC integration needed. No human input required. Every created part can be seen through the power profile or through electrical actuators status.
Detection and alerts of deviations in manufacturing cycle times
Real-Time anomalies detection
Power profiles reflects anomalies during the metal processing. Operators can detect in time issues related to a defect in the cutting tool, a malfunction of the actuator or an incorrect operator behaviour
Having immediate knowledge of overconsumption, scrap, defective parts, abnormal feeding etc., allows avoiding big losses
Reduce Scrap and uncontrolled process
Critical process variables such as welding currents, are essential to achieve the required quality in each part, so their control in real time is fundamental. Traceability is ensured for every variables 1 Sample/s.
Managers can be alerted in RT if there’s any deviation (accidentally or intentionally) from preset parameters.
Anomalies can be linked to process variables, So it can be used to train AI based Quality detection models.
Identify inefficiencies
Tracking KPIs between projects, machines and material types allow the identification of the cause of inefficiencies.
Avoid Hydraulic units / Electric drives breakdown
Identify early signs of fault within Hydraulic units / Electric drives.
Scale what’s working best to every site
Expand to more plants, track OEE across every stage from melt to machining, and layer on insights to strengthen quality and efficiency over time.
What to expect from FactoryOps®
Expected impact with ROI in "2 months"
-40% to -70% Stops reduction through early detection of breakdown / bottlenecks and killing downtime causes.
-30% reduction on scraps costs
+15% production speed by uncovering hidden performance losses.
-20% reduction of labor costs related to quality inspection and machines supervision
-30% energy consumption by avoiding unproductive consumption.
90% pricing accuracy during negotiations
Potential Savings:
ROI in just 2 months
Fast return on investment guaranteed
Key Takeaways
Real-Time Operational Improvements
Real-Time Machine Data Visibility at the lowest costs creates many opportunities for quick wins
Quality Defect Identification and cycles count are easily obtained in Real Time
Machine/ tool breakdowns are avoided with Digitized Maintenance
Real Time Job tracking enables on-time delivery
Automatic standards per material enables better scheduling
Workforce Cost Reduction by maximized utilization rate
Operational Impact:
Rapid Value Realization
Quick wins and continuous improvements
Ready to take your operations to the next level?
Let's talk about how Amperon Technlogies can help your team reduce downtime, boost output, and drive performance across every line, shift, and site.