Holistic Logistics Solutions as a Major Driver to Optimize ... · 9/19/2019 · Restricted ©...

Restricted © Primetals Technologies 2019. All rights reserved. primetals.com

Holistic Logistics Solutions as a Major Driver to Optimize

Productivity in a Steelworks Markus Ringhofer, Sales Manager – Industry 4.0

primetals.com

Restricted © Primetals Technologies 2019. All rights reserved. M. Ringhofer | EA I4.0

Production Flow

Online Heat Scheduling Caster

Scheduling HSM Scheduling

Slab Yard

Management

Coil Yard

Management

Coil Demand Slab

Demand

Heat

Demand Iron Demand

Through Process

Optimization

Holistic

Ironmaking

Sep 2019

Online Heat Scheduling Caster

Scheduling

Restricted © Primetals Technologies 2019. All rights reserved. Sep 2019 M. Ringhofer | EA I4.0

Key Performance Indicators of

Production and Logistics

Market situation

& conditions

Planning priorities

& trade-offs

Short through-put time

Flexible product mix

Short delivery time

High equipment utilization

High production capacity

Less capital tied up


Is the right input material being charged?

Conveyer Belt

• Analysation of emitted sounds at take over points

• Determining of material type, material quality (amount of

fines), …


Ironmaking Expert

Efficient Coordination of Ironmaking Plants

Ore

preparation Sinter plants

Stockyard

BFs BOFs Coke plant Hot

blast stoves

Pelletizing

O2

assignment

O2

assignment

Stoves

coordination

Coke

production

& quality

Sinter production

Target sinter basicity

Burden chemistry

Hot metal production

O2 enrichment

Blast Flow

Blast Temp

Required HM Amount,

Si content, HM Temp

• Optimized production fulfilling requirements of respective downstream plants

• Cross plant coordination for optimal gas network utilization

• Transparent and traceable production decisions

• Reduction of costs and increase of production

Restricted © Primetals Technologies 2019. All rights reserved. Sep 2019 M. Ringhofer | EA I4.0 Page 7

Understanding the scheduling

and planning constraints of the customer

Example: Complex scheduling

at single bay layout with mutually competing cranes:

• reduce ladle lead times: less energy demand & refractory wear

• high sustained production capacity without sequence breaks

• avoid blocking and delays of the cranes

• cranes to consider ladle maintenance transports in same bay


Cranes: Different Cranes on One Crane Way

A

B

Unreachable for cranes

2 & 3

Unreachable for cranes 1 & 2

crane 1

crane 2

crane 3

1. Split crane way in three parts

2. Overlap split crane ways (creating transfer positions)

3. One crane way with three cranes (calculate best crane and if necessary displace other cranes)

1 2 3


Crane and Yard Management

Degree of automation

Manual

No terminal in crane

cabin

Crane driver directed

by person on the

ground

Manual update of

piece location in L3 by

user

No automation

integration with coil

shuttle cars

Semi-Auto

Terminal in crane

cabin

Crane driver receives

transport orders from

L3 based on

routing/schedule

Automatic update of

piece location

x,y,z coordinates

WiFi Network

Automation integration

with coil shuttle cars

Fully-Auto

No crane cabin

Crane automation

receives transport

order from L3, No

crane driver

Fully automatic

transport order

execution

x,y,z coordinates

WiFi Network

Seamless integration

with coil shuttle cars

Transport Order

List


Understanding the scheduling

and planning constraints of the customer

Example: Complex scheduling

at single bay layout with mutually competing cranes:

• reduce ladle lead times: less energy demand & refractory wear

• high sustained production capacity without sequence breaks

• avoid blocking and delays of the cranes

• cranes to consider ladle maintenance transports in same bay

Success factor:

• Implementation team with process know-how

• Involve actual shop floor people to capture their experience & knowledge


Advanced Tracking System

Benefits of Ladle Detection and Tracking

• Fully automated tracking system for

metallurgical plants

• Heat counter

(How many heats on a ladle in total)

• How many heats on a ladle

since last relining

• Contact time of heat with ladle

• active/inactive ladle

(inactive means when ladle is at one of four

maintenance locations; active means

whenever tracked after dry- or preheating

station)

• mounted/installed equipment on

ladles, like slider gate, plate,…

(entered manually at maintenance shop)


• 20% reduced costs

due to better logistics

• Reduced rental cost for

rail wagons

Cost

Reduction

Yard Management

Typical Benefits

• By integration of planning

and logistics

• By improved shipment

Reduced

Inventory

• Better use of available yard area

• Bottleneck of shipment yard eliminated by an increased throughput of 25%

Reduced

Storage Space

• 100% material location and

identification with Yard

Managment

Improved

Material

Tracking

Restricted © Primetals Technologies 2019. All rights reserved.

Yard Management

Reference: ATI Allegheny-Ludlum – USA

• No Personnel

• Automatic Coil Car unload

• Automatic Coil storage

• Automatic rail car loading

• Automatic saddle loading/unloading

• Automatic coil ferry loading

• Storage Strategies, Rules

• Full Integration

• Coil Shuttle Car System

• Yard Management

• HSM Automation

• Crane Automation

• Safety System

• 100% accurate inventory

Fully Automatic Yard Management


Yard Management

Reference: ATI Allegheny-Ludlum – USA

• Fully automatic coil transport from

HSM coilers to storage yards

• Integrated system

• Warehouse Management

• Mill Automation

• Coil Shuttle Cars

• Safety

• Target location finding by WMS

• Automatic pick up by crane

Sep 2019 M. Ringhofer | EA I4.0 Page 15


RFID Labels Marking Machines

QR Code

Product identification at any product stage of production

provides more secure traceability of products

Additional RFID Labels can

support the tracking of products in

the yard.

Marking via alphanumeric

characters Painted, stamped or on

labels.

Additional marking of products with

a QR Code for identifying.

Reading of marking via crane or installed reading station: The marking of the product will be identified during pick up of the slab with a camera system or RFID reading

unit which is installed on the crane. The Data will be interlinked with the overall Yard management system.


Production Management Solution

A comprehensive approach


QUALITY

• Comprehensive quality from definition through quality

control

• Seamless integration and application of Through-

Process Optimization

• Handling of quality deviations by integration of

deviation management with production control

PRODUCTION MANAGEMENT

• Order-based production

management

• Manufacturing execution

• Raw-material and stock management

• Production tracking

• Management of production equipment

LOGISTICS

• Stock management

• Order-based transport coordination

• Transport optimization and execution

• Shipping and delivery

PLANNING AND SCHEDULING

• Anticipation of future demand

• Material-flow optimization

• Capacity utilization

• Material allocation

• Order and line scheduling

• Evaluation of planning, KPIs

BENEFITS

• Optimal plant and equipment utilization

• Reduced order-turnaround time

• Reduced inventory

• Reduced logistics costs

• Improved delivery performance

• Higher product quality

• Lower production costs

• Lower energy costs


The information (including, e.g., figures and numbers)

provided in this document contains merely general

descriptions or characteristics of performance based on

estimates and assumptions which have not been verified.

It is no representation, does not constitute and/or evidence a

contract or an offer to enter into a contract to any extent and

is not binding upon the parties. Any obligation to provide

and/or demonstrate respective characteristics shall only

exist if expressly agreed in the terms of the contract.

These estimates and assumptions have to be analyzed on a

case-to-case basis and might change as a result of further

product development.

Primetals Technologies excludes any liability whatsoever

under or in connection with any provided information,

estimates and assumptions. The provided information,

estimates and assumptions shall be without prejudice to any

possible future offer and/or contract.

Any use of information provided by Primetals Technologies to

the recipient shall be subject to applicable confidentiality

obligations and for the own convenience of and of the sole

risk of the recipient.

Contact


Dr. Markus Ringhofer

Sales Manager – Industry 4.0

Primetals Technologies Austria GmbH

Turmstrasse 44

4031 Linz

Austria

T +43 (732) 6592-9358

M +43 (664) 6150708

[email protected]

primetals.com

Holistic Logistics Solutions as a Major Driver to Optimize ... · 9/19/2019 · Restricted ©...

Documents

Transcript of Holistic Logistics Solutions as a Major Driver to Optimize ... · 9/19/2019 · Restricted ©...