Forge Monchieri’s press software optimisation

Customer: Forge Monchieri, Cividate Camuno (BS)

Sector: Open Die Forgings

Objective:

Forge Monchieri, a well-known company in the industrial forging sector, has in its machine park a press considered strategic for its daily production, which showed a complex situation: the press’s outdated PLC presented risks of part availability and was not efficient for processing.

The main objective was to upgrade the press system, ensuring stable operation and optimising performance to reduce cycle times, improve accuracy and minimise energy consumption. The next phases of the project (which are still ongoing) also include the recertification of the system after the necessary upgrade activities.

Implementation Process

1. Preliminary analysis and planning:

A detailed analysis of the hydraulic circuit and the operational needs of the plant was carried out, involving the Forge Monchieri maintenance team to identify their expectations and specific requirements, which was immediately shown to be very skilled.

2. Software development:

After clarifying the customer’s needs, the Project Group team developed new proprietary software and a new operator interface, specifically designed for the press in use. This phase included simulations and the necessary theoretical tests.

3. Installation and commissioning:

After developing the software, installation and integration into the press was carried out. Commissioning was particularly challenging: the team worked for nr. 3 consecutive weeks, without interruption, in order to respect the timing and minimise any inconvenience for the customer.

• 4. Operational tests:

The press underwent rigorous testing to verify the operation of the new software, with a focus on accuracy, speed and reliability. This ensured optimal fine-tuning before the press was fully operational.

Operational benefits and results:

Accuracy and speed: The speed of the work cycle has improved, with an estimated 15% to 20% increase compared to the previous software.

Energy savings: One of the main benefits of the new system has been energy efficiency. Thanks to the recalibration of the system and the optimisation of the number of pumps required, the improvement in the electrical efficiency of the P12000 press in terms of KWh/tonne is 20%, saving around 1,300 KWh per working day.

Operational continuity: For Forge Monchieri, this press is considered a strategic element and its operativity is crucial to the entire production process. With the upgrading, the risk of machine stops has been significantly reduced, ensuring more operational continuity and minimising downtime.

Team feedback and reaction

The success of the project was welcomed with great enthusiasm by the Forge Monchieri team. The company has particularly appreciated the technical expertise and commitment of Project Group, which has shown empathy and constant attention to the customer. This collaborative approach made it possible to successfully meet a complex challenge, developing customised solutions even without initial support from the original manufacturer.

The quality of service and the availability demonstrated has created a strong trusting relationship, which has been able not only to solve pre-existing issues, but also to take the company to a new level of efficiency.

Conclusion

Forge Monchieri’s press optimisation project is an example of how dedicated technical management and support can turn a critical issue into a strength for the customer. Thanks to the new software configuration, Forge Monchieri can now count on a reliable, precise and more energy-efficient system, providing a significant improvement in both operational and economic terms.