A 52 per cent reduction in scrap rates with Monitizer | PRESCRIBE AI

Reducing scrap and driving growth

ItalPresseGauss has established itself as a reliable partner in the die-casting industry, particularly when working with customers who require high production capacity and quality. The customer, who has been working with ItalPresseGauss since its foundation in 2016, produces over 300,000 die-cast parts and assemblies per year for the global automotive industry. To continue this positive trend, the two companies jointly sought digital solutions to reduce the scrap rate and optimise the performance of the die-casting lines.

The solution: AI-driven process optimisation. In collaboration with IIoT experts from Monitizer, a sister company of ItalPresseGauss, Monitizer®│PRESCRIBE was installed in one of the customer’s 11 die-casting cells.

With a proven track record of success in both high-pressure and low-pressure die-casting environments, PRESCRIBE is an ‘AI-as-a-Service’ solution operated by AI partners at DataProphet. PRESCRIBE works by analysing historical and live die-casting data to learn which process settings deliver the best quality results.

Based on this knowledge and taking real-time production conditions into account, it proactively prescribes control adjustments that keep production stable and ensure consistent quality.

Steven Li, Aluminium Project Director at ItalPresseGauss, said: “The customer already had its own Manufacturing Execution System (MES) for recording basic machine data. As Monitizer is compatible with existing equipment and software solutions, implementation was straightforward. We were able to expand capacity without having to replace or upgrade anything.”

Ready to implement quality improvement measures

In just one production run, PRESCRIBE enabled the customer to reduce its average scrap rate by 52 per cent, and is now helping it to maintain this impressive performance.

If the results of this project – which involved specific moulds in one cell – were replicated across all moulds and products, the customer could save almost 130,000 euros per year through the reduction in scrap alone. And that’s without taking into account additional energy savings and productivity gains.

Steven Li added: “This customer tells us that they value our high-pressure die-casting machines for their ease of use, and that the machines deliver reliable performance with minimal maintenance requirements. I believe they now feel the same way about their digital solution! PRESCRIBE has delivered excellent results quickly and will enable the customer to continue doing so. We are already discussing expanding the project to include more moulds and aiming for a broader implementation.”