Smart ProdACTIVE, an Enginsoft solution, is an example of an innovative foundry platform that can diagnose the quality, energy and cost of the production process in real time, covering 100% of the products and proposing the appropriate feedback to optimize the set-up of process parameters using predictive cognitive models (based on artificial intelligence).

Data from smart prod ACTIVE for processing with the Cost Model:


Real cycle time measured from different phases
Instantaneous energy consumption of the different systems: oven, press, robot, cutting machine, thermoregulator....
Current number of rejects on number of bars
Machine downtime of any size
Operator in action
The development of these tools has been supported by numerous research projects (from the Metro project to MUSIC) all oriented to Zero Defects Production (Zero Defect Manufacturing) through the study and innovation of 3 fundamental elements:


PROCESSES and MATERIALS: evolution in alloys, their characterization and new legislation
PEOPLE: skills of yesterday/ today, training courses and new profiles of the future
TOOLS: integrated systems from simulation, to defect mapping, to pro-active production control

The future holds us a new challenge in bringing all the knowledge acquired in recent years into a digital system able to integrate Processes, People and Tools to effectively manage foundry processes in the production of high quality and lower cost castings.

In particular in the context of digitalization in the foundry, standardization and regulation in quality mapping is a prerequisite to correlate the class of defects with the data mining of the production process.

A monitoring system must be supported by Alarm and Warning logics that guide the operator towards finding the defect and the causes that generated it to proceed with an effective and timely feedback.

How do I digitize quality mapping?
What are the causes of defects and lower mechanical performance?
How do you suggest feedback?
The optimal solution of the production cycle expresses the best compromise between maximum quality, lower energy consumption and cost reduction. The cost model can be used to guide the design choices and to control the effect of waste, maintenance operations and in general production management on the cost of the single jet produced.