Automation, digitalization, and the Internet of Things (IoT) have become buzzwords in nearly every industry, including glass tempering. But what do these terms mean for glass processors, and how can they drive business improvements?
The goal of automating a glass tempering line isn't about adopting technology for its own sake. It’s about streamlining operations by eliminating tasks that don't add value. In this blog, we’ll explore the steps toward achieving full automation in glass tempering and the technological challenges we need to overcome to get there.
A Familiar Analogy: Cars and Tempering Lines
To understand automation in glass tempering, let’s draw a parallel with the automotive industry. Consider Tesla's advancements in self-driving cars. While fully autonomous vehicles are still in development, features like automatic parking and adaptive cruise control have already transformed driving.
In glass tempering, the motivations for automation differ. Rather than convenience, they revolve around increasing production capacity, improving customer satisfaction, enhancing cost efficiency, and optimizing factory operations.
Five Levels of Automation in Glass Tempering
The journey toward full automation in glass tempering mirrors the five levels of car automation:
Level 1: Basic AssistanceEarly innovations provided operators with measurement tools to monitor the tempering process.
Level 2: Enhanced Operator AssistanceOver the last few years, advancements have begun to offer actionable recommendations to operators, helping them refine the process.
Level 3: Integration with ERP SystemsBy linking the tempering line with enterprise resource planning (ERP) systems, operators can automate processes based on predefined recipes. While this is effective for stable glass mixes, complex cases still require further technological development.
Level 4: Self-Learning MechanismsToday, many tempering lines serve as data hubs. By connecting machines to share information, they collectively drive innovations, much like Tesla vehicles contributing to the company’s R&D efforts.
Level 5: Full AutomationThe ultimate goal is a completely autonomous tempering line. Achieving this will require flawless measurement devices, cost-effective solutions, and reliable performance across diverse glass types and conditions.
Data as the Driving Force
Every tempering furnace acts as an R&D tool, collecting and sharing data to improve processes. Real-time production reports already allow manufacturers to monitor efficiency and adjust processes. As we progress, this data will fuel automation and create self-learning systems.
For example, automation enables operators to focus less on manual tasks and more on analyzing data to optimize production values, improving glass quality and overall profitability.
Overcoming Challenges
Several hurdles must be cleared before full automation becomes a reality:
Measurement Accuracy: Devices need to deliver precise and repeatable data under all conditions.
Cost Efficiency: Developing affordable solutions is essential for widespread adoption.
Reliability: Systems must operate flawlessly, ensuring consistent glass quality.
Glaston, for instance, uses data from its extensive installed base to refine its automation strategies. This ecosystem helps push the entire industry toward smarter, more efficient tempering processes.
Preparing for the Future
Automation and digitalization are reshaping industries, including construction. Within five years, purchasing systems for glass and other materials are expected to fully digitalize. This shift will impact everything from pricing and planning systems to the overall business models of glass processors.
Key questions to consider:
Are your systems ready for open-source technologies and digital purchasing?
Can your business adapt to selling high-value products like low-anisotropy glass?
How will automation affect your profitability metrics, such as profit per hour?
Final Thoughts
Automation isn’t just about efficiency—it’s about transformation. By embracing digital tools, glass processors can not only improve their processes but also create new value for customers and redefine their business models.
Are you ready to navigate this shift? Now is the time to prepare, innovate, and lead the way into the future of glass tempering.
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