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Restricted © Primetals Technologies 2016 All rights reserved. primetals.com
The Digital Unity –How Customers benefit from a ProductionManagement SystemWarsaw, June 2017
Restricted © Primetals Technologies 2015 All rights reserved. primetals.com
Restricted © Primetals Technologies 2017 All rights reserved.
Digitalization is driven by steel producers‘ requirementsand enabled by new technologies
June, 2017 K.Herzog / EA I4.0Page 2
NEW TECHNOLOGIESSTEEL PRODUCERS‘REQUIREMENTS
Communication technologies
Computational power
Internet technologies
Cloud technologies
Big data analytics
Self-learning systems
Mobile devices
Augmented reality
End-customer integration
Lot-size 1
New business models
Know-how management
Supplier integration
New steel grades
Availability of information
Ergonomy/operator support
ACHIEVED BY HOLISTIC AUTOMATION
QUALITY
FLEXIBILITY PRODUCTIVITY
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Three major requirements in steel productionshall be supported by digitalization
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• Outstanding quality• Reproducible results• Seamlessly documented
• Flexibility to customer requests- Flexible product specification- Shorter delivery times
• Flexible in used raw materials• Flexible in optimization criteria
- Production- Energy consumption- Equipment lifetime
• Throughput• Yield• Plant availability• Operational costs• Maintenance costs
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A digitalized plant is like an orchestra –The Metals Orchestra
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Metals OrchestraTeach your players to play better
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Metals OrchestraThe Primetals Technologies portfolio
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Know more – improve your processes More focus on the essentials Your plant and its digital twin
Smart sensors provide additional informationabout the process or the entire plant.
Smart sensors either directly measure physicalvalues or use existing measures to indirectlycalculate additional information.
Smart sensors are the enablers for theimplementation of advanced automatic functions,process models, as well as condition monitoring.
Repetitive, labour-intensive and dangerouswork is supported by fully-automatedmechatronics solutions.
This gives more room to focus onthe essential tasks.
Process models, digital “twins” of the plant,enable process optimization in real-time aswill as offline simulation.
This means perfect process guidance andfull support for further process development.
Example:Camera-based slag detection and free-boardmeasurement for converter tapping
Example:Automated converter tapping incl.the positioning of the ladle transfer carand alloy charging
Example:Blow-end calculation
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Metals OrchestraThe Primetals Technologies portfolio
June, 2017 K.Herzog / EA I4.0Page 7
Knowing how your plant “feels” Get connected – anytime – anywhere All the necessary information –when and where you need it
Comprehensive information about the conditionof the equipment an the respective processesenables predictive maintenance, which will helpto avoid unplanned outages.
This means improved plant availability andtherefore increased plant productivity.
Advanced communication technologiesallow for information to be transportedbeyond conventional limitations.
From the collection of sensor data in harshenvironments or from mobile equipment todisplaying the information on mobile devices.
From the shop floor to the „manager‘s pocket“
To ensure best possible operation andmaintenance of a plant, a vast variety ofinformation sources is required.The core concept of “smart work” is that allpersonnel will automatically receiveexactly the information they need at thetime to get their job done. This means thatall information is automatically tailored tothe actual needs of the staff.
Example:Converter tilting-drive monitoring,LTC drive-train and railway condition monitoring
Example:Wireless data transmission from theladle transfer car,KPI dashboards for mobile devices
Example:Online-documentation retrieved viaQR-coded equipment,augmented reality applications to guidemaintenance work
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The Digital Unity –The conductor of the Metals Orchestra
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The Digital Unity –The conductor of the Metals Orchestra
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Production Management SystemA comprehensive approach
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PRODUCTION EXECUTIONRealtime information about the
production processTransparency across the whole
process chainLogistics
PRODUCT DEFINITION,ORDER DRESSERTransformation of sales orders to
process and quality instructionsCentralized processknowledge base
ORDER & LINE SCHEDULINGCross-plant scheduling of the
order bookThroughput optimization
PLANNINGHolistic planningfrom melt shop to shipping,from demand planning to
material planning
Benefits• Increased utilization of production facilities• Higher productivity with increased flexibility and better quality• Reduced inventory
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Production Management SystemOrder dresser
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State-of-the-art technology
• Comprehensive translation of sales orders toproduction orders including routings and processinstructions considering production capabilities,technological rules, standards and quality directives.
• Creating test and sample instructions along theproduction route.
• Calculating material demand for each productionstep
• Considering cost and time models
• Easy system integration with ERP including certifiedSAP I/F
• Modern GUI for easy data administrationThrough Process Know How
Benefits• One central knowledge base with all production related data to determine how to
produce products from casting to finishing lines. - Fewer systems to maintain• Integrated with planning, scheduling, production and quality. - No complicated and
expensive interfaces
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Production Management SystemPlanning and Scheduling
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State-of-the-art technology
• State-of-the-art technology• Holistic planning – from melt shop to shipping and from
demand planning to detailed scheduling• Streamlined and consistent decision making across
sales,planning and production processes
• Maximizing throughput, quality and service level• Minimizing costs, energy consumption, stock levels and
lead times• User-friendly, fast and adaptable schedules and plans• Planning evaluation based on KPIs and scenarios
comparison• Central repository of planning rules and priorities
Benefits• Highly specialized optimization models for metals specific production technologies like casting,
rolling, hot charging, etc.• KPI-driven Planning: Plan and schedule calculation can be adapted to specific and dynamic
business goals• Supports multiple demand fulfilment models: make-to-order, make-to-stock, …• Highly adaptable user interfaces optimized for planner's daily tasks
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Production Management SystemProduction Execution
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Material and Stock Management
• Administration of all material types• Goods receipt, movement tracking and goods issue on material
and batch level• Management of scrap yards, bunkers, small part areas, semi
finished products and equipment
Schedule Execution
• Fast reaction to production issues bymodifying released line schedules
• Management of line schedule states
Production Order Lifecycle
• Managing production orders during theirlifetime
• Status Management
Production Tracking
• Tracking of material flow• Registration of all production data in the different facilities• Basis for reporting and quality control
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ProductionCoke quality
ProductionTarget basicity
Burden chemistryProductionO2 enrichment
Blast FlowBlast Temp
Required HM Amount,
Si content, HM Temp
Holistic ironmakingEfficient coordination of ironmaking plants
Orepreparation Sinter plant
Stockyard
O2 assign-ment
O2 assign-ment
BFs BOFs
• Optimized production meeting requirements of respective downstream plants
Coke plant
• Cross plant coordination for optimal gas network utilization• Transparent and traceable production decisions• Reduction of costs and increase of production
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Stovescoordination
Hot stoves
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Through-Process Optimization (TPO)Quality along the entire production chain
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Benefits• Quality management support• Reduced manual inspection, rework and downgrades• Support for quality certification (ISO/TS16949)• Reduced influence of human factor
THROUGH-PROCESS KNOW-HOWProcess and quality optimization
Metallurgical and process rulesProduct development
QUALITY MONITORINGContinuous recording & supervision of
quality parametersAutomatic identification of deviationsRoot cause identificationKPI evaluationStatistical process controlProduct genealy across the entire
process chainData storage for big data analytics
QUALITY CONTROLCorrective actions feed forward
and feedbackRule based expert system
Quality grading
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Through process optimizationProduct genealogy
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TPQC keeps track of each productthroughout the production chain andthereby directly supports the TS16949requirements of identification of theproduct throughout the productrealization.
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Through process optimizationExample of a Root-Cause Analysis – CCM
Corrective and Compensational Actions
• Corrective Action: Set of actions for resolving the cause of the problem.
• Compensational Action: Set of actions compensating the nonconformities.
Root-CauseIdentification
nonconformities
Compensational-Action
CorrectiveAction
schedule slab for scarfingto remove surface defectsschedule slab for scarfingto remove surface defects
Possible root-causes:ý Casting speed change > 0.4m/miný Mold level fluctuationsþ Wrong casting powderýWrong SEN typeý Critical analysis
Possible root-causes:ý Casting speed change > 0.4m/miný Mold level fluctuationsþ Wrong casting powderýWrong SEN typeý Critical analysis
change casting powder tomeet grade specificrequirements
change casting powder tomeet grade specificrequirements
Example: slab inspection reveals longitudinal surface cracks on slab
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Through process optimizationKPI Examples
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• Overview of productionand quality relatedperformance at a glance
• Indicates effectiveness ofQM-measures related toquality and processimprovements (typicallyrequired by automotiveindustry and acc. qualitystandards e.g. ISO9001,TS16949)
• Reviewing theeffectiveness of correctiveactions with respect toquality and productionefficiency
• Overview of theachievement of businessplan objectives
June, 2017
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Computerized Maintenance Management SystemMaintenance Asset Technology (Mat)
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Benefits• Smart Maintenance schedule adjusted to order scheduling and vice versa• Trim your expenses according to the best maintenance strategy for your plant• Maintenance data available for analytics and deep learning
MAINTENANCE MANAGEMENTReal time transparency on work,material, assetsAutomatic work order suggestionsbased on your asset strategiesAdvanced planning, mobile workexecutionData History for every assetLink business data to ERP
MAINTENANCE KNOW HOWPACKAGES
Actionable items for your team fromcondition monitoring information
Analytics on your growingmaintenance know how base
Select maintenance strategyto maximize asset performance
Based on advanced analytics
Increase productivity through smartnetworking with plant data and PMS
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PREDICTIVE MAINTENANCEPre-set link to CMSAnalytics on CMS data and maint historyenables predicitive maintenance
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The Digital Unity –An outlook
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Know the impact of the plantcondition on product quality
Dynamically align productionand maintenance schedule
Feed TPO learning back to ODS
Re-assign products to customerorders in case of deviations
Schedule production based onquality prediction based on
condition prediction
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The Digital Unity enables steel producersto achieve their targets
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QUALITY
FLEXIBILITY PRODUCTIVITY
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Restricted © Primetals Technologies 2017 All rights reserved.
The information (including, e.g., figures andnumbers) provided in this document containsmerely general descriptions or characteristics ofperformance based on estimates and assumptionswhich have not been verified.
It is no representation, does not constitute and/orevidence a contract or an offer to enter into acontract to any extent and is not binding upon theparties. Any obligation to provide and/ordemonstrate respective characteristics shall onlyexist if expressly agreed in the terms of the contract.
These estimates and assumptions have to beanalyzed on a case-to-case basis and might changeas a result of further product development.
Primetals Technologies excludes any liabilitywhatsoever under or in connection with anyprovided information, estimates and assumptions.The provided information, estimates andassumptions shall be without prejudice to anypossible future offer and/or contract.
Any use of information provided by PrimetalsTechnologies to the recipient shall be subject toapplicable confidentiality obligations and for the ownconvenience of and of the sole risk of the recipient.
Contact
June, 2017 K.Herzog / EA I4.0Page 23
Kurt HerzogHead of Industrie 4.0
Primetals Technologies Austria GmbHTurmstrasse 444031 LinzAustria
T +43 (732) 6592-6781M +43 (664) 6151208kurt.herzog@primetals.com
primetals.com
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