Bühler Services.
Modular yet customized and flexible. From one-time service to service package. Bühler Basic Services Seite Installation and Start-up 2 Spare Parts 3 Technical Support 4 Bühler Advanced Services Updates and Reconditioning 8 Preventive Maintenance 10 Process Optimization 14 Engineering 18 Training 20 Bühler Individual Services Foundry Optimization 24 Maintenance Contract 26 High profitability requires high productivity, quality, and uptime of production systems. To be successful, you require a stable manufacturing process with carefully matched operations. Bühler services offer you as a die caster maximum value and a competitive edge. Bühler will always have the optimal solution ready for you, regardless of whether you need spare parts or inspections or a productivity-enhancing service package tailored to your individual requirements. Bühler will always have the right solution for you. Why Bühler services? For over 80 years, Bühler has been proving its capabilities day in, day out and in all parts of the world. Our core competence is individualized consulting and the creation of the service package optimally tailored to your specific needs. Our motivated service pros are available to you worldwide 24 hours a day. They allow you to focus entirely on your own core competence the die casting of high-grade components.
Comprehensive and focused on benefit. Support throughout the cycle life of your production system. The broad range of Bühler services caters to a large number of individual customer requirements. They support you in designing new production processes, ensure the availability of your die casting systems, and help you fine-tune your production processes. Bühler services will make your life easier at all times. With its vast experience and extensive expertise, Bühler is your ideal partner. Life cycle consideration Evaluation Installation and Production / utilization phase Disposal Start-up OEE Updates and Reconditioning Time Individual Services Foundry Optimization Maintenance Contract Advanced Services Updates and Reconditioning Preventive Maintenance Process Optimization Engineering Training Basic Services Technical Support Spare Parts Installation and Start-up
Basic Services. Giving you time for the essentials. Benefit from our global service platform, customer support centers, spare parts centers, and service and installation engineers whenever you need them and in your vicinity. We attach great importance to offering you local support and consulting. Our aim is to be thoroughly familiar with your production conditions and foundry environment in order to fulfill your needs in the best possible way. For this reason, we have established global service platforms and staffed our customer support centers with highly qualified specialists to offer you competent Bühler contacts in your specific time zone. Our spare parts management in local distribution centers is second to none. Out of these centers, the spare parts you need will be supplied to your site quickly and reliably by a local logistics organization. We review our spare parts inventories annually on the basis of so-called spare parts priority figures, adjusting them to ensure that exactly those parts are on stock that you actually require. Our global network of locally stationed service technicians offers you fast access to local resources in the event of plant or machine downtimes. You will be professionally supported on site. This eliminates the need for long trips to your site and costly waiting times. We further develop our service technicians expert skills in regular training and continuing education courses. They know the new products from Bühler and can pass on this knowledge to our customers. Our service technicians motivation is a major success factor. Our installation engineers are close to your site. We specialize in installing and starting up the systems we supply in a professional manner and on schedule. BÜHLER SERVICES 1
Installation and start-up. Fast and competent. The capital you spend on new production systems will not be paid back before you have started up regular production. Therefore, the time required up to start-up is crucial. Bühler installation and start-up is fast and reliable. Regardless of whether stand-alone machines or complex die casting systems are involved, our installation and start-up specialists have been carefully prepared for their missions. Our engineers vast experience in construction site management, careful project preparation, and solid system knowledge slash the time to production start-up. This enables you to achieve a faster return on your investment. Your benefit Fast start of production according to schedule 2 BÜHLER SERVICES
Spare parts. Short delivery times thanks to local distribution centers. Spare parts are crucial to ensuring smooth production processes. But they also lock up capital. Bühler will supply you with the parts you need within a very short time and to any site in the world. We will supply you with genuine spare parts. Our supply chain ensures a very high availability of parts from stock. Daily contact with couriers and renowned shipping companies ensures swift supplies. Only genuine Bühler spare parts will work on Bühler systems under a warranty, for they not only meet top standards, but have also been designed exactly for the particular application. Your benefit Easy procurement Fast delivery time High-quality genuine parts BÜHLER SERVICES 3
Technical support. Worldwide support. The most advanced engineering and professional maintenance cannot entirely rule out operating trouble. Reliability, rapidity, and specialist competence are required. Bühler service technicians will be on site quickly, thanks to our global presence. You will receive the support you expect through our technicians interdisciplinary knowledge and detailed expertise. Regular training and vast experience ensure the most up-to-date know-how. This maximizes your system uptime while minimizing your maintenance costs. Bühler Customer Service Center Modern die casting systems are very reliable. However, malfunctions can never be ruled out, which may generate high costs. This calls for rapidity and competence. The Bühler Expert Center will assist you in troubleshooting and propose immediate action. Equipped with cuttingedge data communications tools and their expertise, our specialists will take charge in case of trouble. They will always offer you the necessary support whenever possible in your local language. In addition, advanced information technology tools offer new possibilities to maintain your production systems and fine-tune your casting processes. Bühler remote diagnostics will help you eliminate downtimes. The causes will so to speak be analyzed in real time. State-of-the-art Bühler die casting systems are network-enabled. With an Internet link, you can benefit from our remote diagnostics services. Our experts will assist you with their specialist knowledge of production system operation and process technology. 4 BÜHLER SERVICES
How does Bühler remote diagnostics work? We will only access your production systems with your permission. If your system is linked with us through the Internet, all you have to do is send an e-mail to our Diagnostics Center. Our specialists will log in and analyze the situation. After a predefined time, the Internet link will be automatically disconnected. The access rights will be defined together with you when the system is installed. Thus, you will only release the information you wish. Your benefit Short downtimes of production systems Know-how transfer to your maintenance crews High rapidity and competence Low maintenance overhead Short trips to your site thanks to local stationing Fast and easy support Very easy handling High economy Short downtimes Faster analysis of causes Interdisciplinary, multilingual teams BÜHLER SERVICES 5
Advanced services. Combinable as required. Bühler offers you a wide range of extended services covering the entire lifecycle of a die casting machine and supporting you in all matters related to the die casting process. Reconditioning and updating Custom-built machine reconditioning workshops and our own reconditioning companies enable us to overhaul old machines and to give them a new lease of life. Bühler updating services allow your die casting machine to be equipped with the newest-generation control system and thus to increase its operating reliability. Preventive maintenance Take advantage of the competencies of our service engineers stationed around the world to perform your regular inspections and machine checks. Only perfectly maintained systems can ensure high uptimes. Process optimization It is only with great difficulty that errors committed during specification of a die can be corrected in the production phase. It is therefore important to invest time and money in die design. This is an area where Bühler can offer you strong support, as well as in production fine-tuning. Engineering Bühler will support you in the engineering phase and in retrofits by offering you well-thought-out system designs. Project managers make sure that your systems go on stream as scheduled. Training Profit from the wide range of product and process training courses that we offer you in our training centers in Switzerland, the United States, in China and in India. We would also be pleased to hold these courses at your own local site. By monitoring the conditions of the most important components of your die casting system, our customer service has an additional tool to inform you at an early stage about any departures from its desired condition. This in turn enables you to prevent prolonged downtimes. BÜHLER SERVICES 7
Updating and reconditioning. Fresh air for existing production systems. Today s breathtaking technological change demands adjustments to new situations. Investments may rapidly fail to keep up with modern production requirements. Bühler reconditioning and updating services offer you commercially thought-out solutions to enable you to meet the challenges of the future with your equipment. For example, you may wish to increase the level of automation of your die casting cell or even overhaul your machine. With Bühler, you can find the optimal solution in the form of a general overhaul, control system update, or extension of functions. Your needs determine the standard that our specialists apply. The focus in this is always on the benefits and efficiency that you gain. Reconditioning Years of production service leave their traces on your die casting systems. Having your systems reconditioned by experienced specialists is always the most profitable longterm solution, allowing you to extend the lifecycle of your machine. For this purpose, Bühler has set up its own workshops and also collaborates with specialized reconditioning companies. Decades of experience, paired with the design know-how of Bühler, are the optimal symbiosis ensuring that your profitability, reliability, and quality requirements will be satisfied. 8 BÜHLER SERVICES
An overhaul includes, for example: Comprehensive reconditioning of all core components Consistent checking of the condition and repair of all components Replacement of wear parts and components that cannot be repaired Assurance of the compatibility of genuine spare parts Compliance with safety regulations Repair or replacement of the electrical installation Warranty Updating to the newest-generation control system Range of services Partial and general reconditioning of die casting machines Extension of functions Fine-tuning of die casting systems Your benefits Decades-old track record and professionalism Genuine spare parts Safety updates Profitability Compatibility that ensures servicing ability Global Bühler service network BÜHLER SERVICES 9
Preventive maintenance. Reduction of unscheduled downtimes. To satisfy productivity requirements, production systems must be properly maintained. But production service also means wear. Early detection and elimination of trouble is crucial for ensuring high system uptime. Bühler preventive maintenance offers you customized inspection and maintenance routines. They are available either as one-time services or as part of an entire service package. You decide what makes sense and is useful for your production plant. We will be pleased to advise you. The Bühler preventive maintenance program comprises inspections and maintenance. It maintains the desired condition and value of your production systems. The top priority in this is to maintain the performance of your systems during production. Regular maintenance is of elementary significance. Inspection of production systems: (semi-annually and/or annually) Regular assessment of systems Checking of electrical and mechanical functions Assessment and appraisal of wear parts Determination of maintenance requirement Documentation of defects and risks Advice on action to be taken Assessment of performance capabilities Safety-related checking 10 BÜHLER SERVICES
During annual inspections, the following work will be done: Tie bar and tie nut maintenance Leveling of the machine Checking of sliding pads and sliding tracks Checking for leaks inside and outside Checking of condition and performance of: central lubrication system Lock mat shot valves cooling system hydraulic system filter system sensors and actuators control system components Diagnostics: pump systems and proportional control hydraulics System and safety checks Your benefit Reduced operating costs Increased system uptime Longer system life cycle Reduced unscheduled downtimes BÜHLER SERVICES 11
The top priority in maintenance is to maximize system uptime and minimize maintenance and production costs. Preventive maintenance provides the basis for assuring production availability at a high level. Bühler condition monitoring provides you with an overview over the current condition of your production system. Our die casting systems take full advantage of the possibilities of advanced control engineering and sensor systems. With its expert knowledge and experience in the design and construction of die casting systems, Bühler can offer you new, trend-setting possibilities to fine-tune your maintenance processes. Bühler condition monitoring services show you when to perform specific maintenance routines. They increase the maintenance intervals, streamline your decision-making processes, and assist you in planning necessary maintenance. You save time and money! How does Bühler condition monitoring work? Modern Bühler die casting systems continuously identify the condition of vital components. Warnings and downtimes are registered. Components are continuously selftested. Fully and partially automated performance checks provide information on the condition of important components. The data from the process control system is transmitted via the Internet to the Bühler expert systems and evaluated. Trends are revealed, correlations determined, and concrete information gained on the condition of the components. Bühler condition monitoring services comprise Continuous registration of service-relevant data Evaluation and assessment Regular condition reports Determination of maintenance requirements Documentation of defects and risks Advice on action to be taken Condition monitoring comprises regular monitoring of machines and systems by measuring meaningful quantities. The goal is to reveal and visualize the current condition of the system and to improve maintenance scheduling. This reduces your maintenance costs, and preventive maintenance is replaced by condition-oriented maintenance. This enables the service life of strategic components to be utilized to their specification limits. Your benefit You will reduce your operating and maintenance costs increase your maintenance intervals improve the coordination of production and maintenance reduce downtimes visualize the current condition of your system reduce the workload of your maintenance crew perform condition-oriented maintenance 12 BÜHLER SERVICES
Process optimization. Applications engineering and die-making. Productivity, system uptime, and component quality dete rmine success or failure. Be sure to make the right decisions during the die design stage in order to maximize the number of accept components during production on the basis of fine-tuned shot parameters. Gating system design When designing the gating system, our die specialists will define the runner, the gate, and the gate position for casting your component. In order to check the modeled gating system, the design will be verified on the basis of a numerical cavity filling simulation and if necessary revised. The gating design includes Runner specification 3D modeling of the runner Casting calculations Your benefit Short production starts Stable die cavity filling characteristics Reduced costs by minimizing of modifications during production starts 14 BÜHLER SERVICES
Cavity filling and solidification simulations Casting simulations allow you to identify critical areas in the cast component and in the die as early as in the development stage. Utilize our process experience for the quick and reliable development of a quality- and processrelated solution. Die layout This provides you with a proposal for specifying the die you need for making the component you wish. It enables a die-maker to detail the design on his own. You will receive a precise runner design and a general representation of the die design. Die layout comprises Inclusion of the component in the insert Runner design Overflows with vents Proposal for insert sizing Notes on temperature control General representation of die design General representation of core slides Complete report Your benefit Short production starts Excellent cast component quality Reduced cost due to few modifications during production Controlled and stable filling and solidification characteristics Short development times BÜHLER SERVICES 15
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Applications engineering support: Whether in your foundry, on the phone, or by remote diagnostics our globally stationed process engineers will offer you competent advice and support. On-site support at your site: Preparatory work and investigations Technological support Creation of a report showing additional potential for optimization Assistance from Uzwil comprises: Analysis of the current situation on the basis of your materials Remote diagnostics by Internet Determination of cause Identification of potential for optimization Short- and long-term measures Your benefit Improved cast component quality Process stability Cycle time reduction BÜHLER SERVICES 17
Engineering. Careful system design, on-schedule start-up. Cost pressures that foundries face call for production systems using highly efficient automation solutions. Productivity and system uptime are crucial. Bühler will support you by offering you optimized system designs during the design stage as well as in retrofits. Cell engineering Based on your component data and your casting cell requirements, our engineering experts will create casting cell layouts. Our specialists will determine the required machine size, create an optimal automation and finishing concept, and conduct a cycle time analysis. This will provide the production figures and manufacturing costs. Your benefit Decades of experience in system engineering Fast and straightforward implementation Economic solutions 18 BÜHLER SERVICES
Project management Short delivery times and on-schedule start-up are important for ensuring high system productivity and uptime. Bühler will offer you professional support. Our experienced project managers will coordinate the implemen tation of your system. In close contact with you and vendors, Bühler will take charge of overall coordination and ensure on-schedule start-up. Special-purpose machines and systems In special applications for which our standard system or control designs are not suitable, Bühler will develop a special-purpose solution for you. Our engineering experts seek the best solution for your specific application no matter whether it requires a software modification, a special machine retrofit, or a special-purpose production system. Your benefit One-stop shopping for your entire order Coordination of vendors Assurance of compliance with schedule Professional project management up to hand-over of the ready-for-production system Monthly progress report Decades of experience in special-purpose system design Rugged and economic solutions BÜHLER SERVICES 19
Training. Opening up new perspectives by continuing education. New requirements demand a willingness to continue one s development and embrace repeated reorientation. In this, knowledge is crucial. In seminars, workshops, and hands-on training sessions, we will impart to you the know-how you need to secure your success now and in the future. Until recently, the focus of interest in training was set solely the die casting machine. Today, it is the entire die casting process. System uptime, productivity, and quality of the castings set the standard. Bühler seminars offer you numerous continuing education opportunities. Training courses held in Uzwil, the United States, or China; in-house seminars; individual training sessions we offer you a range of customized solutions. Our offerings combine the theoretical fundamentals with hands-on applications. Product training courses in servicing and maintenance Bühler product training courses impart the knowledge necessary for operating die casting systems properly and efficiently: System hydraulics System electronics Die casting cells/integrated devices Training in process engineering A technology is only as good as the user s ability to utilize it. Take advantage of our process engineering training courses: Set-up Process fine-tuning Die development Alloy and laboratory science 20 BÜHLER SERVICES
Individual training sessions tailored to your personal needs Individual training sessions are part of modern continuing education. Do you as a member of management wish to familiarize yourself with the subject of die casting? We offer you the basic and starter courses to this end. Bühler Training Center classroom and hands-on work combined We hold product and process training courses around the world in our training centers. They impart hands-on user knowledge: You hone your skills on state-of-the-art die casting systems and on components of a wide range of machine generations. The courses cover the entire bandwidth from basic training to specialty applications. The trainers are experienced service experts with a didactic background. Small groups work intensively on the machines and on application-specific subjects. They profit from the exchanges in the training groups with their international mix of participants. These training centers are located at Bühler in Switzerland, in the United States, in China and in India. The instructors Whatever seminar you choose, you can be sure to receive solid training by our trainers. Our specialized seminar leaders are highly qualified, practically experienced, and acknowledged specialists in their respective disciplines. Your benefit Extensive knowledge transfer Intensive, practice-oriented training in small groups Exchange of experience BÜHLER SERVICES 21
Individual Services. Tailored to your specific needs. To ensure that you receive exactly what you need to cover your requirements, we place rigorous demands on our services. High productivity, uptime, and component quality we will support you with our die casting knowhow and highly qualified and experienced specialists. This will enable you to obtain top value and achieve a competitive edge. Your benefit Productivity increases due to on-site applications engineering assistance. Foundry optimizations foundry analysis, definition and implementation of on-site foundry assistance measures. Maintenance contracts partial or complete maintenance of machines and production systems by specialist Bühler personnel. You can focus entirely on your core competence: the manufacture of die cast components. Why not contact one of our service pros, who will tailor a service package to your specific needs? This will allow you to generate added value and gain a competitive edge. BÜHLER SERVICES 23
Foundry Optimization. Systematic fine-tuning of all production processes. Every production system bears hidden potential for optimization. Even minor improvements should be made to achieve low-cost production. Continuous productivity enhancements will further strengthen your competitiveness. Bühler will analyze your foundry and show you where potential for improvement still exists. Take advantage of the vast experience we have accumulated in foundry projects. Our foundry analysts have been visiting customers plants for years. Let them inspire you with their knowhow and show you how to increase your productivity. Our goal is to have successful customers that is our ultimate effort. Scope of services 1: Analysis of your foundry Infrastructure: Electric power supply, compressed air network, gas network, cooling water treatment and network, hoisting equipment, in-plant handling and logistics. Material flow (Al/Mg): Invitations for material tenders; material quotations, treatment, melting, casting, return, and flow logistics. Casting process engineering: Mechanical condition of dies, die designs, gating system designs, shot sleeves and plungers, die venting systems, heat balance in dies (analysis by thermal imaging camera), die maintenance and availability, die and alloy changing procedures. Cast component quality: Analysis of a cast component or of a complete component family in ongoing production, proposal of solutions for improving component quality, creation of a Top 5 List of the parameters critical to quality matched to your specific production process. Condition of production systems: Personal safety, process and production reliability, energy channels, level of automation and potential for automation, efficiency analysis, spare parts management, maintenance concept, preventive maintenance, documentation of systems electric and hydraulic diagrams, spare parts catalogs, alignment and setting instructions, special programs, software filing. Personnel training: Level of training, safety awareness (safety first), work methodology troubleshooting procedure, procedure for changing process parameters utilization of existing documentation, compliance with setting and alignment instructions professionalism of employees. Risk analysis: It will reveal the critical areas of your foundry which will have a serious impact in the event of operating trouble or system failure. Bühler will propose solutions for eliminating the potential risks, for nothing could be worse than being unable to supply your end customers with components. Your benefit OEE enhancement Reduced operating costs Minimized risk Increased competitiveness 24 BÜHLER SERVICES
Scope of services 2: Evaluation of the analysis creation of an action plan We will determine and document the current condition of your foundry. Together, we will discuss the potential for improvement identified and define suitable measures. We will apply a purpose-developed software program to calculate and display the effects of these measures on the cost of component production and system operation and advise your foundry management. Take advantage of our global experience! Scope of services 3: Foundry assistance in the implementation phase Why not also take advantage of on-site foundry assistance! A Bühler expert will head the project. Together with you, we will implement the measures decided in a timely and sustainable manner. In this phase, we will selectively involve your specialist foundry personnel in the process. This transfer of know-how from the Bühler expert to the customer expert is highly valued. It provides a general understanding of foundry operations, specialist knowledge, and an awareness of the basic requirements of foundry production. Only excellently trained personnel can fully utilize all the technical advantages of a production system. Correctly selected shot parameters, faultless operation, and a competent maintenance crew will enhance the productivity of your foundry. And that is the foundation of your business success. BÜHLER SERVICES 25
Maintenance Contract. Assurance of system availability. Servicing / maintenance / system settings Modern production systems are exposed to a permanent performance pressure and are often in service on a 24/7 basis. Their capital cost requires round-the-clock utilization in order to generate a pay-back within a certain time. This places very high demands on both men and machines. Bühler as an equipment manufacturer knows its own production systems best. Bühler knows about the preventive activities related to on-site maintenance and spare parts management. We have experience in the fastest way to correct trouble, to eliminate sources of malfunctions, and to select production system settings so as to achieve quality and quantity targets in the most efficient way possible. Scope of services Bühler will provide all the necessary on-site servicing and maintenance at your foundry. We will ensure that your systems are operated with the best possible process parameters. This will allow you to focus on casting highgrade components, generating new business, caring for your customer relationships, and ensuring the commercial success of your business. Bühler makes sure that your systems are available at all times with their maximum performance capabilities. We have specialized in casting technology for over 85 years, have supported countless customer projects, and in the process have built our unique base of casting know-how to benefit you today. 26 BÜHLER SERVICES
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The modularity of our service portfolio allows us to offer you a customized package carefully tailored to your specific needs. Examples from the field prove that a maintenance contract will enable you to markedly enhance your OEE. Production systems that run smoothly and are correctly set are crucial to the commercial success of your business. The Bühler Full Service gives you a competitive advantage. Services designed for your benefit What services do you need? Our experienced staff will tell you what makes sound business sense for you, whether you need one-time services adding to your own capabilities or entire service packages to reduce your workload. What is important is that Bühler services offer you the freedom to focus on your core business. Whatever you choose Bühler services will boost the efficiency of your production process and allow you to keep tight control over your costs. What else might we do for you? Your benefit Bühler maintenance crew in round-the-clock shift operation (24/7) On-site troubleshooting Preventive maintenance and system inspections Condition monitoring, evaluation of results, initiation of measures Spare & wear parts and operating supplies management System settings that will increase uptime Process settings that will increase cast component quality and productivity Training and coaching of casters and operating personnel Registration and evaluation of operating data, OEE (Overall Equipment Efficiency), and other important characteristics together with you Continuous improvement process: fine-tuning of production systems on the basis of failure statistics and FMEA analyses 28 BÜHLER SERVICES
DC 60015 en 0415 50 gl Bühler AG CH-9240 Uzwil, Switzerland T +41 71 955 12 12 F +41 71 955 25 88 die-casting@buhlergroup.com www buhlergroup.com/die-casting