How GF Casting Solutions uses AI to reduce costs and environmental impact through innovation

GF Casting Solutions Showcar

Lesen Sie diese Mitteilung auf Deutsch.

GF Casting Solutions, a division of the Swiss industrial corporation GF, is one of the leading solution providers of lightweight components in the mobility and energy industry. The company is using AI to be able to faster optimize the production process during the ramp-up phase of a component to maximize quality while minimizing energy consumption and waste.

GF Casting Solutions with its headquarters in Schaffhausen, has been driving its digital transformation for many years, using modern technologies not only to improve efficiency but also to innovate for the benefit of its customers. In the area of lightweight components for the mobility and energy industry, GF Casting Solutions, one of the three divisions of GF, is known as a driving force for innovation and is thus leading the industry in shaping the development of sustainable mobility leadership.

Focus on environmental impact and manufacturing costs

To take advantage of emerging new technologies such as Artificial Intelligence (AI), the GF Casting Solutions R&D team based in Switzerland has partnered with AI pioneer Microsoft. The objective of the joint efforts was to establish a solid, data driven understanding of GF Casting Solutions’ complex casting processes which contain many steps. “Environmental impact as well as manufacturing costs increase with every process step”, explains Ilias Papadimitriou, Technical Expert at GF Casting Solutions. “Hence, it is desirable to determine as early in the process as possible whether a produced part will make it all the way to the customer or whether it will need to be scraped in a later process step.” Reasons for scraping can be manifold, says Ilias Papadimitriou, ranging from distortion that exceeds the customer’s tolerance specifications to porosity in the produced part.

Highly automated high-pressure die-casting process
Highly automated high-pressure die-casting process in GF Casting Solutions production site in Altenmarkt

Using Machine Learning to identify most influential parameters

With the help of Microsoft’s Azure Machine Learning cloud service, the data generated during the high-pressure die-casting process was combined with distortion measurements and other process data obtained along the process chain. “This data was then analyzed for patterns using Microsoft Research’s latest advancements in automated machine learning”, says Marc Schöni, Cloud Solution Architect and Specialist for Data and AI at Microsoft Switzerland. “Using Azure Machine Learning’s built-in model interpretability capabilities, we were able to identify the most influential process parameters.” These insights were later discussed with and validated by the GF’s production experts.

Master control station: Dozens of process parameters are analyzed and optimized

More joint projects in the pipeline

The team was able to make suggestions on how to improve the production ramp-up process to maximize quality while minimizing energy consumption and waste. The implemented actions, which will be then integrated into the production process and first indications show that it could lead to a significant reduction of scrap rates during the ramp-up phase of production. Ilias Papadimitriou says: “By using modern technologies like AI, we will be able to continuously optimize our processes and products not only for the benefit of our customers, but also for the preservation of the environment. Therefore, we will continue to use our partnership with Microsoft to innovate and reduce our environmental footprint through the power of AI.”

Related Posts

Microsoft’s AI Access Principles: Our commitments to promote innovation and competition in the new AI economy

As we enter a new era based on artificial intelligence, we believe this is the best time to articulate principles that will govern how we will operate our AI datacenter infrastructure and other important AI assets around the world. We are announcing and publishing these principles – our “AI Access Principles” – today at the Mobile World Congress in Barcelona in part to address Microsoft’s growing role and responsibility as an AI innovator and a market leader.

LUKS führt automatisierte Dienstplanung in Zusammenarbeit mit Polypoint und Microsoft Schweiz ein

In a pioneering move, Luzerner Kantonsspital (LUKS), one of the first hospitals in Switzerland, is implementing an AI-driven automated shift scheduling system. This initiative aims to significantly reduce planning efforts, allocate more time to core tasks, and enhance employee satisfaction, in collaboration with Polypoint and Microsoft Switzerland. The automated scheduling system is set to launch at LUKS in the first half of 2024 after successful pilot tests.

Microsoft Receives Award for Most Popular Employer 2024

Handelszeitung and PME, in collaboration with market research company Statista, have announced the “Best Employers 2024”. For the third year running, Microsoft Switzerland has secured the top spot as the best employer in the category “Internet, Telecommunications and IT”.

Microsoft erhält Auszeichnung zum beliebtesten Arbeitgeber 2024

Die Handelszeitung und PME haben in Zusammenarbeit mit dem Marktforschungsunternehmen Statista die „Besten Arbeitgeber 2024“ gekürt. Microsoft Schweiz erreicht das dritte Jahr in Folge in der Kategorie „Internet, Telekommunikation und IT“ den Spitzenplatz.