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© PSI BT GmbH 2007Slide 1
Стратегия
ЯдроБизнес Процессов
Самый большой в своей нише
МеждународноеПрисутствие
© PSI BT GmbH 2007Slide 2
От руды до готовой продукции, от заказа до отгрузки
Интеграция, Оптимизация Управление Производством
PSIin
tegr
atio
n
© PSI BT GmbH 2007Slide 3
PSImetals
Упростите свои IT проблемы
ERP (SAP)
SAP NetWeaver
© PSI BT GmbH 2007Slide 4Home - Index - We dedicate our self to the best customer solution and his success
Integrated Production Management with PSImetals
SAP
L2’sSMP
L2’sHRM
L2’sCRMSY CY
Planning
Warehouse& TransportMgmt.
ProductionExecution
PSIm
etal
s
%Factory Model
PSIintegration
PSIintegration
© PSI BT GmbH 2007Slide 12
PSImetals: IT-Решения для Металлургии
Примеры внедрения
© PSI BT GmbH 2007Slide 13
ThyssenKrupp Steel today
Five locations operate twelve different MES.
History: Different companies has been mergedIndividual development of MES Software for
the specific requirements of each plantMost systems operate on Tandem Hardware,
one operates on IBM Mainframe
Result:High maintenance costs No transparency across the production sites No possibility to compare the plantsHigh system administration costs
123
54
8
67
910
Duisburg
Bochum
Dortmund
Siegerland
1112
Finnentrop
© PSI BT GmbH 2007Slide 14
PSImetalssystems
PSImetals Systems at the Salzgitter GroupВыплавка
чугуна Сталеплавильный цех Производство продукции из стали
Выплавка Разливка Горячая прокатка
Холодная прокатка
Окончательная обработкаДоменные печи
Управление процессом на 3 доменных печах Планирование и диспетчеризация
Система организации производства
Автоматизация МНЛЗ
Интегрированная система управления складами и
транспортными потоками
Перспективное и оперативное управление
Система организации производства
Система организации производства / Оптимизация раскроя (пореза)
Перспективное и оперативное управление
Перспективное и оперативное управление
Система организации производства
© PSI BT GmbH 2007Slide 15
SzFG:Production Equipment and Facilities
01 2 Coke oven batteries, 108 coke ovens, 46,0 m3 each02 Sintering plant – 180 m2
03 3 Blast furnaces, hearth Ø 11,2/10,8 m04 3 x 220 t LD converters05 Continuous casting machines: 2 strands 250 mm thick, 1.100 - 2.000 mm wide 1 strand 250 mm thick, 2.000 - 2.600 mm wide 1 strand 250 mm thick, 850 -2.100 mm wide06 Hot strip mill07 Continuous pickling line and push-pull pickling line08 Hot strip cutting line09 Cold rolling mill10 Hot-dip galvanizing No. 1 and 2 11 Electro-zinc coating line12 Organic coating No. 1 and 213 Sheet in coils14 Surface-coated sheet in coils15 Sheets16 Narrow strip, rim material17 Hot-rolled strip
Home - Index - SzFG: Production Equipment and Facilities
© PSI BT GmbH 2007Slide 16
ThyssenKrupp Nirosta GmbH PSImetals PES for 3 stainless steel CRM
The situation:Old mainframe system, high maintenance costSystem structure do not support Business processesDifferent solution per plant
The Aims:Overall Production Execution System for the entire enterprise of ThyssenKrupp NirostaState of the art system solution System support for the special requirements of a stainless steel production Overall standardized Quality Control and Reporting
PSImetals APS/ALS + PES
Plant KrefeldPlant Krefeld
Plant BenrathPlant Benrath
Plant DillenburgPlant Dillenburg
© PSI BT GmbH 2007Slide 17
ThyssenKrupp Electrical Steel PSImetals PES/APS/ALS для 2 заводов
Plant BochumPlant Bochum
Plant GelsenkirchenPlant Gelsenkirchen
Ситуация:Много различных, самостоятельно разработанных системВысокая стоимость обслуживания и поддержки
Цели:Высокая степень интеграции с SAP Технический и финансовый контроль Планирование заказов, планирование на цеховом уровне
© PSI BT GmbH 2007Slide 18
Annealing, Insulating linesPickling line, Rolling stands
Cold rolled Coil
(Semi)
Package
(Finished)
Stichplan-
rechner KWR 1
Bandin-spektion Beize
Loch-suchger.UWA
1/3
Band-profil-
rechner KWR 3
Loch-such-gerät EBR
Loch-sucher DO 5, 6
Loch-sucher DO 4
Band-profil DO 5
Ober-flächen-inspek. DO 5, 6
Schichtdickenmessg.
ISA
Mech. Meßpl. DO 4-6 Dehng.
Magn. Meßpl.DO 4-6
Adjustage
Opt.-rechner
HGL
pickling cold rolling annealing coating slitting Adjusting andpackaging
Prematerial
(Raw)
PLSDOfen
BZ KWR, UWA EBR HGL DO ISAKWN LZ EBZ
batch annealing
LagerRechnerH10,H12
Messerbaukarte
SAP R/3 (PP)
Shopfloor• Process data/ error data• Quality checking• Production data acquisition+„electronic cold-strip-card“+ integration process computer
• Time and capacity scheduling • Line sequencing• Material tracking (Coils)• Production data messages to SAP• Cutting optimization
ThyssenKrupp Electrical Steel After: PSImetals PES at EBG
© PSI BT GmbH 2007Slide 19
PSImetals: IT-Решения для Металлургии
Benefits
© PSI BT GmbH 2007Slide 20
PSImetals APS/ALS– Benefits by the example of Arcelor EKO Stahl
90% according to schedule Steel making throughput is increased about 15%Throughput capability of cold-rolled coils is increased by about 43%Reduced coil yard inventoryThe whole central planning and supply chain management is handled by just 8 people
Home - Index - PSImetals – Benefits by the example of Arcelor EKO Stahl
© PSI BT GmbH 2007Slide 21
EKO Stahl: Plant wide Production Planning and Control
Targets achievedCreation of a complete production planning, guaranteeing total planning and fulfilment of all production ordersThe following process optimization was achieved:
• reduction of throughput times • optimization of all stocks• improvement in plant capacity allocation• high quality yield• improvement in meeting the delivery
scheduleExecution
All orders, partial orders, material stocks and production plants were fully integratedThe new production planning covers all various time schedules for planning and control simultaneouslyProduction planning integration into the underlying systems is true to time. Therefore, quick and accurate reactions to changes in day to day business are guaranteed
© PSI BT GmbH 2007Slide 22
V4V3V2V1
V8V7V6V5
V74V73V72V71…
CC1Seq 4711
Heat x
Heat 2
Heat 1
RF1 RF2 RF3
V 70
V 170
V 71
V 171
V 72
V 3
V 103
V 1
V 101
V 2
V 102 …P
4P 3P 2P 1
HRM Seq 3423
P1 P2P3
V101V1V102 ?……
V2 V103
Scenario Mixed Charging (1)
V104V103V102V101
V108V107V106V105
V174V173V172V171…
CC2Seq 4712
Heat x
Heat 2
Heat 1
In the first step a direct charging sequence provided by two caster is createdThe slabs will be distributed to two of the furnaces
P4
© PSI BT GmbH 2007Slide 23
PSImetals APS: Order combination
Home - Index - PSImetals APS – Material allocation
New combination orderin PSImetals
PO Routing
Rolling
Rolling
Skinpass
Skinpass
Cutting
Cutting
Finishing
Slitting
Packing
Rolling
Skinpass
Cutting
Packing
Basis production order PO1 from ERP/MES
Basis production order PO2 from ERP/MES
© PSI BT GmbH 2007Slide 24
PSImetals PES Achievement…
Increased Throughput• 1 extra 220t ladle/day, 1,5 – 2 %
Energy Saving• product reaches each stage with more precise timing• reduced need to reheat ladles (cost leadership)
Documented Quality• full documentation on quality of every piece, to ISO 9000 standards - a key
requirement in the automobile-industryFlexible & Adaptable
• new object-oriented system is very adaptable and easy to re-configure • Easy integration of new aggregates (4th vacuum degasser, 3rd casting
machine)
Home - Index - PSImetals PES Achievement…
© PSI BT GmbH 2007Slide 25
PSI‘s Project at Böhler Steelplant, Austria
The Benefits:Overall Production Execution System for the entire conventional and special melting technology as well as powder technologyIntegration of all production stages and all 23 facilities in one systemQuality assurance by standardizing treatment practices for different grade groupsHigh available, flexible and customizable system especially for configuration of new facilities and new characteristicsStandardized data collection and long-term archiving of all production relevant data for easier evaluationStandardized and consistent production reporting and feedback to SAP for all facilitiesReduction of system maintenance due to modern software technology
WITH PSImetals PES.
© PSI BT GmbH 2007Slide 26
PSI‘s Project at von Moos Steel, Switzerland
The Benefits:One overall Production Execution System for the entire von Moos Enterprise including all production stages from scrap yard to the rolled productExact time Scheduling for EAF, 3 LF, 2 VD and CCM as well as the crane leads to:
• increase of throughput• avoidance of caster sequence breaks• interrupts due to availability of the crane
Energy Consumption Forecast and Control leads to:• exact knowledge about energy demand • reduced energy costs
Standardized and consistent production reporting and feedback to SAP for all facilitiesReduction of system maintenance due to modern software technology and less interfaces
© PSI BT GmbH 2007Slide 27
PSImetals APS/ALS at Georgsmarienhütte: Improved Handling Capacity ...
Mill area• There is now flexibility to adjust campaigns, to take account of
changing order-book right up to time of rolling. Bottle-necks in the mill are minimised
Testing & finishing area• Throughput capacity is significantly increased -- thanks to improved
HMIs, and to automatic allocation of billets to the most appropriate of the 3 lines
Ability to view whole plant• The entire plant is now viewed as a whole. Transit times at
interfaces between areas are reduced, with benefits in lower inventory, higher throughput and precise delivery
© PSI BT GmbH 2007Slide 28
Georgsmarienhütte: Some Extra Benefits…"Just In Time" order planning
• Clients now order smaller batches at greater frequency, to reduce their own inventory.
• So the planning system must deal with more orders, and smaller quantities per order, just to meet the same throughput tonnage.
• In fact, the year 2000 was a record year, with clients ordering more than ever before. But the new system successfully handled the increased loading.
• What is more, the new system consistently achieves great improvements in timeliness of order completion
Excellent documentation• Orders are now processed with clear and
complete documentation, so that clients have the necessary quality documentationto meet their requirements
Fast project start-up• The project was completed in record time –
just 10 months from order to completion. In spite of this, start-up was on time, and the new system ran smoothly from the beginning
© PSI BT GmbH 2007Slide 29
PSImetals WTM for TKS, Beeckerwerth: Benefits
TKS plant in Duisburg is a large integrated works, including steelmaking, rolling and finish processing line (5 million t/annum)Reduced Costs
• Increased throughput and reduced delays• effective increase of 25% in storage space in the critical areas• total inventory is reduced by 80%• significantly fewer handling operations per coil• Transport trucks now spend 25-30% less time in loading, unloading and
waitingImproved quality
• Reduced coil damage• Fewer „lost“ coils• Better documentation• More timely delivery
Home - Index - PSImetals WTM for TKS, Beeckerwerth: Benefits
© PSI BT GmbH 2007Slide 30
PSImetals for Blast Furnaces
The task Balancing of the used materialsConfigurable collection and presentation of high speed process dataDetermination of the filling collection and representation of “burden” changesExecution of the burden calculation, model calculation
BenefitsThree different blast furnaces, one softwareHighly configurable Improvement of the operation by state-of-the-art HMISimplification of the system structureLong term data archives of the process data for a furnace travel (approx. 15 years)
Home - Index - PSImetals for Blast Furnaces