Key Metrics to Monitor in Aluminium Extrusion Production

Key Metrics to Monitor in Aluminium Extrusion Production

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Key Metrics to Monitor in Aluminium Extrusion Production Lines

Published by: ALUTimes | Date: July 15, 2025

Table of Contents

Introduction

Tracking the right metrics in aluminium extrusion production lines is essential for improving productivity, ensuring quality, and minimizing costs. With growing demand for precision and sustainability, manufacturers must go beyond basic measurements and adopt smart data-driven approaches. This guide explains the key metrics extrusion plants should monitor for better output and higher efficiency.

Categories of Extrusion Metrics

  • Operational Efficiency: Output per hour, downtime, OEE
  • Quality Assurance: Defect rates, tolerance levels
  • Energy & Cost: kWh/tonne, scrap rates, maintenance cost
  • Safety: Incident frequency, maintenance logs

Performance Metrics to Track

  • Extrusion Speed (m/min): Influenced by billet type, die design, and alloy used
  • Cycle Time: Includes billet heating, pressing, and cooling
  • Die Life: Average number of cycles per die before rework or replacement
  • Utilization Rate: % of time press is actively running vs idle

Quality Control Metrics

  • Surface Finish Grading: Visual + profilometry ratings
  • Profile Tolerance: Deviation from dimensional standards
  • Twist & Bow Measurements: Post-extrusion shape deviations
  • Defect Classification: Split, tear, surface streak, hot crack incidence

Energy and Cost Metrics

  • Energy Consumption per Tonne: kWh/tonne or MJ/kg
  • Scrap Percentage: Material lost vs total output
  • Maintenance Downtime: Minutes/hours per week
  • Tooling Cost per Run: Average spend on dies, lubricants, etc.

Real-Time Monitoring Tools

Today’s leading aluminium extrusion companies use smart factory systems that track:

  • Temperature sensors at billet, die, and profile points
  • Press load and speed sensors
  • Vision systems for profile inspection
  • IoT dashboards for shift-by-shift tracking

Case Example: Improving Efficiency by 18%

One extrusion company in South India integrated smart dashboards across 3 presses. By tracking real-time press utilization, die wear, and cooling time, they:

  • Reduced unplanned downtime by 22%
  • Improved OEE from 67% to 79%
  • Cut scrap by 3.5% monthly

The result was over ₹45 lakh annual energy and material savings.

Conclusion

Monitoring metrics isn’t optional—it’s mission-critical. With the right KPIs in place, aluminium extrusion plants can continuously improve quality, reduce costs, and remain globally competitive. Start by setting benchmark values, then track and optimize using smart tools and team training.

Disclaimer

Information in this article is provided by ALUTimes for knowledge-sharing purposes. Actual plant performance may vary based on location, equipment, and operator skill.

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