Interview on the road to K 2025 with Timo Horn (photo), Head of Operational Services in Extrusion Technology at Hans Weber Maschinenfabrik GmbH

Mr. Horn, to what extent is Hans Weber already relying on artificial intelligence?

Some time ago, we launched a digital customer portal that allows our customers to view operating instructions and create enquiries, among other things. Our next step is to integrate artificial intelligence into this portal, which will make it available to our customers in the near future. This will enable users to address their questions directly to the AI instead of having to search for answers themselves; for example, they can request information on machine maintenance. The aim of this project is to significantly improve user-friendliness. Our customers will be able to access the knowledge provided there and find solutions of their own accord.

Where is AI being implemented?

We opted for a browser-based cloud system that can be accessed from any workstation, as not all customers are willing to integrate machines into their internal network. In addition, operators are often not allowed to access other systems via the HMI while the machine is in operation. Our AI-supported customer portal therefore operates on a browser-based system that can be accessed from any workstation. Maintenance managers, operators and shift supervisors can access the web portal from any location and retrieve information about the machines. The AI we have implemented has been specially trained and optimised for the requirements and characteristics of our machines.

Are you already thinking about incorporating AI within your machines?

No extruder currently exists that has the ability to control itself and make adjustments independently in the event of deviations. Nevertheless, I am convinced that we will be able to effectively integrate technologies in the field of machine learning in the near future. However, this requires us to gain access to a wide range of comprehensive information and diverse data sources. I am confident that there will soon be a time when machines will be able to take appropriate measures and respond accordingly when an error occurs.

The development of AI has gained significant momentum in recent years. What does the future hold?

It is difficult to make a clear prediction - however, significant progress within a very short period of time is certainly conceivable, especially given the latest developments. At the beginning, we were only able to ask our artificial intelligence basic questions. Now, just six months later, it is able to search through extensive documents and analyse transcribed texts effectively. It is reasonable to assume that completely different capabilities will be achievable in another six months.

To what extent can AI alleviate the shortage of skilled workers?

The current shortage of skilled labour is a significant challenge for many of our customers. Small-scale companies that have implemented fewer automated processes are often affected to a greater extent compared to larger companies. In this context, artificial intelligence (AI) can be of great benefit: it enables specific questions to be asked, for example regarding maintenance requirements, the optimal time for filter changes, and many other aspects. Of course, this information is also contained in the operating instructions. However, it is more time-saving to consult AI to obtain the desired information. In view of the demographic change, we are all confronted with the fundamental problem of the loss of expertise, which can only be mitigated to a limited extent at corporate level. I am convinced that many companies will strive to further digitise, automate and optimise their processes in order to proactively counteract the shortage of skilled workers. Skilled workers will continue to be needed, but with the help of AI, it will also be possible to entrust people with the operation of complex machines, without extensive machine knowledge.

What is Hans Weber doing in terms of sustainability?

One outstanding feature of our company is our very high vertical range of manufacture. This enables us to supply our machines with high-quality spare parts for decades. In addition, we develop our control systems in-house, enabling us to update them comprehensively. If a customer owns a 20-year-old machine and wants to collect data as part of digitalisation measures, we can offer them a tailor-made retrofit package for our modern WEBER OS5 control system. This package can be installed by the customer themselves or by our qualified technicians, allowing us to offer our customers the opportunity to reach a new level of technology. In addition to modernising control systems, we also support the retrofitting of innovative and efficient drive systems in three-phase technology. This provides our customers with the opportunity to even enhance older machines to be state of the art, thereby increasing their competitive edge in the long run.

Where does mechanical engineering currently stand in terms of digitalisation?

Digitalisation plays a central role in mechanical engineering. In future, it will be essential to have a digital presence. The implementation of digital solutions will increase efficiency in production and throughout the entire process, enabling production processes to be precisely controlled. The data collected can be used to track how long machines are in operation, and whether they are running smoothly. This data can be used to make well-founded decisions. For example, if a shift supervisor is responsible for several machines and notices that processes are not running optimally, they have to rely on information from the operators. However, if they have additional data, they can immediately see whether there are pressure fluctuations, profile breaks, or other irregularities. This enables them to make more reliable decisions to optimise processes. In addition, this digital transformation phase opens up new perspectives for us as a machine manufacturer for the development of innovative business models. Based on the data obtained, we are able to offer new services to our customers. For machine builders, digitalisation is therefore not an optional trend, but a key driver for the future viability, innovation and competitiveness of our industry.

Photo: Timo Horn, image source: Hans Weber Maschinenfabrik GmbH