TPT November 2020

T E CHNOLOG Y

100 per cent analytical approach in the GRP market through the Effective Filament Winding ® method

TOPFIBRA, a company that specialises in the design, manufacture and installation of high capacity GRP Production Plants, has introduced the first 100 per cent analytical approach in the filament winding composite market, known as EFW ® (Effective Filament Winding ® Method). This highly successful method for reducing costs and waste, improving and increasing production flow and final technical specifications, began as a method to improve the GRP competitiveness and is becoming a revolutionary production mentality globally. Mauricio Facchinetti, CEO and co- founder of Topfibra, said: “In the filament winding industry, where the raw material costs are high, you first need to be effective and only then can you work on the efficiency.” Indeed, in the GRP technology, a unique recipe, a unique raw material or mix of raw materials, or an optimal process that would ensure the optimal cost, does not exist. Also, thinking about a ‘typical plant layout’ or a ‘perfect configuration’ of the continuous filament winding line, which would work in any worldwide GRP production plant, is the easiest way to lose profit during the production. The difference between investing in GRP pipe production and investing in the production of pipes composed of other materials, implies a significantly higher effort from an analysis point of view. To do it carefully and systematically, a complete analytical method from the beginning is needed, to avoid wrong decision making. Additionally, in order to ensure that GRP pipes perform in the best possible way, they must be designed and produced with the final project design and the installation conditions being taken into consideration. Inshort, theEffectiveFilamentWinding ® method is a 100 per cent analytical, continuous improvement, promoting system-wide effectiveness and efficiency. The Effective Filament Winding Method is more than just a better way to design a complete manufacturing plant, and

Mauricio Facchinetti (right): “Be effective first, then strive for efficiency.”

design, produce and install GRP pipes. Essentially, it is a ‘school of thought’. And while there are many notions that make up this school of thought, much of the power for this system is contained in just five primary concepts: be effective and only then you can be efficient; fight against the statement: “We’ve always done it this way”; develop a detailed understanding of the production process; clearly define the results you need to achieve; correct all the activities that do not allow you to achieve these results; and re-start the process optimisation loop once more. While many assume that the Effective Filament Winding method only benefits the production plant, the fact is that the investors also benefit from it, avoiding the loss of time and money. EFW ® principles can impact on the average GRP pipe producer in a powerful way that extends beyond just financial gains. Here are some of the many powerful benefits of adopting the EFW method: - Identifies and implement the missing information for a correct GRP industry

feasibility study, helping the investor with analyses of the critical elements and to define the most reasonable technology and production range for the production plant. - Identifies the success of the company as the value of the product and the ability of execution as defined by the market demand, thus leading to more satisfied customers. - Identifies and optimise each design and production phase, reducing operational costs and maximising profits. - Reduces and removes wastes and scrap during production, seeing that in the GRP industry there are numerous areas of waste that go overlooked. - Identifies and removes the hidden wastes in the GRP production (ie the overdesign of a pipe due the higher raw materials specifications). A reduction of waste and non-value-added activity increases total system efficiency; - Increases the GRP pipe performance, reducing the cost per meter. - Shortens cycle times and increases production, due to the analytical approach applied to production and logistics.

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NOVEMBER 2020