Read the full presentation of the Research Paper presented at the International Conference on Extrusion and Benchmark, organized by the University of Bologna (October 3-5th 2011). Evidence based time and costs savings for die makers and extruders. Reduce die knock-off rate and die trials in press thanks to Thango®, the new SW-HW integrated system for die designs and correction feedbacks management, remote correction support.

1. The revolutionary dies digital archive
and remote correction system.
Time and costs savings for correction
departments.
D. Tedoldi, T. Pinter, N. Cividini
Alumat & Almax Mori Group
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2. Demonstrate cost savings due to Thango’s
introduction :
 Correction department management
improvement: increased efficiency due to time
savings for die correctors and plant managers
 Extrusion cost reduction due to die trials and
knock off reduction
 Die designs management improvement, due to
time savings for searching and retrieving paper
designs and correction notes, both for the
extruder and the die maker

3. Thango © Features
3 case histories to see how Thango can help
extruders to:
1. Eliminate paper and have digital die designs
archive
2. have instant access to corrections data and
statistics
3. immediately transfer feedbacks and correction
designs to die supplier for die design
improvement and trials reductions
4. Build an extensive correction knowledge base,
useful for problem solving and decision making
issues, as well as for junior correctors’ training

4.  Eurometal S.A.
 Aluminium du Maroc
 Profilati Spa

5. Eurometal: time and cost savings due to
Thango process for:
 correction notes digital sharing
 die trials and knock off rate reduction
Aluminium du Maroc:
 online correction support
 die trials and knock off rate reduction
Profilati Bologna:
 die feasibility studies and designs approval

6. 1. Die trial in press > profile out of tolerance
2. Profile start photo and correction notes
sharing after first trial, shared through
Thango
3. Remote correction support on behalf of die
maker, through chat interface and desktops
sharing
4. New die trial in press: profile in tolerance
5. First trial in press with repetitive die: perfect
profile

7. TIME SAVINGS:
Who Saved For what
what
15’ phone call / internal discussion after the
Die Shop first die trial in press
manager 30’ Compile die feedbacks on paper form
Die 2 hrs correct die 306943
correctors 1 hr correct die 306942 (correctors would
(press have tried to make equal thicknesses on
32MN ) the profile, to avoid a knock-off).

8. DIE TRIALS AND KNOCK OFF RATE REDUCTION:
Die Shop manager has calculated that, by constantly
using Thango© for feedbacks exchange, his
cooperators will lower the average number of die
trials and knock off rate as follows:
DIE TRIALS REDUCTION 0.2 points
KNOCK OFF RATE REDUCTION 7%

10. Average values, estimated for an extrusion line
with 7’’ billet container:
What Value
Average number of new or repetitive dies / year 250
Average number of dies subject to knock-off per year 500
per press
Average communication time saving per die that 15’
requires correction
Average correction time saving per die that requires 60’
correction
Average number of corrections per year that require 250
to be shared with die supplier

11. Average values, estimated for an extrusion line
with 7’’ billet container:
What How much €
Die trial 300
Die knock-off 300
Die corrector and 30
die shop manager
cost per hour

12. RESULTS:
 Extrusion cost savings, due to:
◦ time savings
◦ trials in press and knock off rate reduction
 Impact on behavior and habits: die correctors
and die technicians learn the importance of
die tests feedback sharing and become
motivated to do it

14. TIME SAVINGS:
Who Saved For what
what
40’ sharing of correction suggestions, die feedbacks
and profile photos (dead times elimination for
Die Shop
phone calls, photo and feedbacks sending and
manager
receiving via email or fax). )
and
correctors 75’ die correction on repetitive die
15’ manual search of archived designs and feedbacks
in their own die designs archive, to retrieve
Die 15’ correction comments in occasion of the new
maker’s
repetitive die order
Tech.
Office

15. DIE TRIALS AND KNOCK OFF RATE REDUCTION:
Die Shop manager has calculated that, by constantly
using Thango© for feedbacks exchange, his
cooperators will lower the average number of die
trials and knock off rate as follows:
DIE TRIALS REDUCTION 0.25 points
KNOCK OFF RATE REDUCTION 8%

16. RESULTS:
 Extrusion cost savings, due to:
◦ time savings
◦ trials in press and knock off rate reduction
 Real time remote online correction support
 Creation of an extensive correction
knowledge base and data collection for:
◦ statistical analysis
◦ correction process improvement
◦ junior correctors’ training

19. TIME SAVINGS:
Who Saved For what
what
Die 30’ in case the design is ok and needs no further
correction modifications;
manager & 60’ in case some modifications are requested on die
Die maker’s design or study provided by Alumat.
Tech Office
Profilati requires designs approval on 100% die orders (480
Dies/year), of which an average 15% requires changes prior
to final approval (72 dies).

20. PAPER AND PRINTING SAVINGS:
 average printing with traditional process
without Thango ©: 4 sheets for each approval
request (2 prints for the die maker and 2
prints for the customer)
 Total saving: 384€ paper print savings for
480 dies approvals (0,2€cent per b/w copy,
minimum cost estimation).

22. RESULTS:
Time and cost savings due to:
 Paper prints elimination of die designs with consequent
environmental positive impact on trees saving;
 Instant transmitting and receiving of die designs:
Thango© is installed within the correction department,
no time wastes or delays due to design transmission
through fax or pc in another office or plant area;
Die delivery times reduction due to:
 Time savings in feedbacks exchange for designs
approval
Notes traceability is under control and secure:
 by using 2 different colors and creating shared archives,
there’s no room for disagreement on what’s been
shared and discussed.

23. The revolutionary dies digital archive
and remote correction system.
Time and costs savings for correction
departments.
www.aluthango.com
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