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UL and the UL logo are trademarks of UL LLC © 2012
Industry 4.0 for plastics Testing
„ From Vision to Reality“
Dr. Bahman Sarabi
24. testXpo Internationale Fachmesse für Prüftechnik
Ulm 12 – 15 Oktober
Contents
UL “a Global Company”
Evolution of Plastics Testing
UL TTC “ One Stop Service Provider “
Form Industry 4.0 to Business Model 4.0 @ UL TTC
Global Integration of Customer in UL TTC Process Chain
Resource Efficient by Manpower- IT- Automation System
Real-Life Example
Track Record of UL TTC by Industry 4.0
Summary, Outlook and Future Development
UL “ a Global Company”
North America United States
- Northbrook
- Camas
- Melville
- Research TP
- Santa Clara
CanadaLatin America Argentina
Brazil
Mexico
Europe Germany
France
Denmark
Italy
Netherlands
Poland
Spain
Sweden
Switzerland
United Kingdom
Asia Hong Kong
China
India
Japan
Malaysia
New Zealand
Singapore
South Korea
Taiwan
UAE
Vietnam
Key Data Leading safety brand Worldwide presence
~ 12,000 employees 23 billion UL Marks on products 67,000 customers in 103 countries
$1.4 Billion USD 88,000 products tested annually 73 labs and certification facilities across the world
UL family of companies today
Commercial&
Industrial
UL Environment
UL Verification Services
UL Life & Health
Sciences
UL Knowledge
Services
1920-1940 1950-1970 2003-20141500
Load
measurement by
weighing of sand
Manually Load
measurement by
spring scale without
compounding,
Injection molding
and Extension
measurement
Analogue Technology
without compounding
and injection molding
Digital Technology
and interaction of
Human-Machine-
IT world wide incl.
Compounding
Injection Molding
and Tests
1st
Industry Evolution2nd
Industry Evolution3rd
Industry Evolution4th
Industry Evolution
Test Lab Testing CenterLeon. Davinci Test Lab
Krefeld-Uerdingen
UL TTCRheinuferstraße 7-9
Gebäude R33
47829 Krefeld-Uerdingen
Tel.: +49 2151 – 5370 370
www.ulttc.com
From Industry 4.0 To
Bussines Modl 4.0 @ UL TTC
One Stop Service for Operation and Commercial
Key
Account
Certifi-
cation
B2BFollow
-
up KIS
Existing major
customer
world wide
New major
customer
Recipe, order,
costs calculation
Result-report
Global Interaction of Customersin UL TTC Process Chain by Industry 4.0
Compounding
Testing
Finishing
Test sample production
order
KIS
Simplified discription of Content
Master Data Managment
Account Data Managment
Order / Contracts
Process Parameter
Intermediats,Operating and Machine Data
Test Time for Accounting Utilisation
ID of Customer Term of Payment
Visibility Tool “ actual state of Order Worldwide“.
Number of Test Bar , Amount of Compound, Test Method
APS
IT Level User Level
KIS
Firewall for Secure Comminication and Data-Protaction
UL TTC Performance incl.
Injection molding
• 100 different specimen molds• Thin wall technology• Shrinkage• Preparation of test specimens
Testing Technology
Long Term Creep Test for
Thermoplastics Composite
up to 300°c
40 automated Systems for:
• Mechanical• Thermal• Rheology• Weathering• Flammability• E/E• Thermal Analysis
Weathering
Ozone Weathering
Fogging Test and Analysis of evaporates
• 46 different standards• 24 different automotive standards• Development for accelerated weathering• Weathering for different UV-A and UV-B• Automated optical measurement
Crash Properties
• Temperature -40 to 200°C• Speed 20 m/s
Thermal Aging
• 240 ovens• Climatic cambers ≥ -70°C• Media resistance• Temperature Index for 5000 h and
higher• Certification for plastics (flammability,
thermal aging)
Flammability
MCC” Microscala CombustionCalorimetry
Analysis of nonhalogen flame retardance
• LOI (lowest oxgene index)
• TL 1010, USMVSS 302
• UL94
• Glow wire
• Needle flameMCC
Implementation of Test Labs
Global setup of Injection molding and Testing Center
Advance Compounding
of Thermoplastics
NEW
NEW
NEW
NEW
NEW Applications
Contents
UL “a Global Company”
Evolution of Plastics Testing
UL TTC “ One Stop Service Provider “
Form Industry 4.0 to Business Model 4.0 @ UL TTC
Global Integration of Customer in UL TTC Process Chain
Resource Efficient by Manpower- IT- Automation System
Real-Life Example
Track Record of UL TTC by Industry 4.0
Summary, Outlook and Future Development
Turn Around Time of manually Flam Test
without IT computer added flam program
19
5-10 10-15 15-20 20-25 25-30
Turn Around Time in Working day
Nu
mb
er
of
Test
in %
20 %
23 %
11 %
16 %
20 %
IT-Technology and Automation for
Flamability test „ UL 94“
0,0 7,5
Test according UL
regulation
Certification test for key
account
Test series with LIMS
hWorking time
Test time Administration time 20 min. 4 min.
20 min. 10 min.
20 min. 35 min.
18
15
8
Number of tests
>50
22 h
2 min.
Workflow integrated into the
soft ware via KIS-Interface
Interaction of KIS and
Automation
Manual performing and
evaluation of Flam Test
Workflow:
Start and end of test period is marked with acustic signals
Eleminate individuel influences of burning times
Automatic evaluation of test results for Flam class
Automatic transfer of result sheet to the customer
Impact of Industry 4.0 for Flam Test @ UL TTCFlammability@ UL TTC• UL94
• MCC
• TL 1010, USMVSS 302
• LOI (lowest oxgene index)
• Glow wire
• Needle flame
25-30
days
10-15
days
Automation 35%
IT 40%
Staff Education 25%
Turn Around Time for fully automatic
Tensile Test in a MonthN
um
ber
of
Test
in %
Turn Around Time in Working day
7575 %
21 %
3% 0,8% 0,2% 0,01 %
1-5 5-10 10-15 15-20 20-25 25-30
UL TTC in Figures
40 automated systems to raise capacity
60 years of testing experience
100 different test specimen molds
180% productivity increase in 6 years
200 different plastics tests
24/7 non-stop testing and results access
5000 square meter facility
17025 accreditation (DIN EN ISO IEC 17025)
25
Choise of first Test: Flam Test UL94V in 3 Thicknesses
0,75 /1,0 / 2,0 mm
3
Materials
Test Bar
Thickness20 Number of Test Bar
26
Chois of second Test: Notch Impact Strenghth IZOD for
4 Temperaturen
3
Materials
4 Temperature
for Impact Test
Number of Test Bar10
27
Chois of Third Test : Coperative Temperatur Index
„CTI“
30
3
Materials
Number of Test Bar30
Rectangular plaque 60x40x10
28
Calculation of Injection Molding Condition and the Amount of Compounding
3
Materials
Amount of Granulates
4734 g
Injection Molding
Condition
29
virtuell Example for cost calculation for custromer
31
Turn Around Time
QualityCapacity
Track Record of UL TTC by Industry 4.0
Computer Networking: 100%
Automation Systems : 40
UL TTC after Implementation of
Industry 4.0UL TTC as Industry 3.0
Innovation ( Patents) : 17
Summary for Industry 4.0 @ Ul-TTC
34
Computer Net Working between all machines within TTC-Lab and result
with the customer (Elimination of the manual input into the test equipment)
Providing of necessary tests incl. standards for customer order
Calculation of type and number of test bars incl. Injection molding
condition
Calculation of necessary amount for compounding incl. cost
Visibility tool : One line actual State of job while operation for customer
Express button: rapid and immediate operation to meet the urgent
customer needs
Automatic transfer of result sheet to the customer
No installation costs for the Customer due to using the Citrix server
35
1. Consistent Automation
2. Optimizing of Turn Around Time
3. Development of Multipoint Search Toll of Data with Customer
Optimizing of Turn Around Time
36
TAT
2
6
1
3
45
Man PowerKnowledge / Ability of staff
„ Allrounder!“
Equipment Capacity
Volume of Orders
Peparation Time
Test Time (Physik)
UL International TTC GmbHwww.ulttc.com
Material testing
you can trust.
Underwriters
Laboratories
