WHITE PAPER Shop Optimization White Paper
Transcript of WHITE PAPER Shop Optimization White Paper
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AISTECH 2010Presented by RAD-CON, Inc
Michael W. McDonaldVice President Operations
TAKINGBATCHANNEALINGOPTIMIZATIONTOTHENEXTLEVEL.
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AbstractMoreefficientBAFoperationnotonlyincreasesthroughputandprofitabilitybutalso
improvesscheduling
and
effectiveness
of
downstream
operations.
With
the
current
use
of
softwareforstacking,heatingandcoolingcycleoptimization,annealfacilitiesareachieving
significantefficiencies.
Yet,todaymorethanever,theneedtosqueezeoutmoreateveryturniscritical.
Sowhatcanbeconsideredthenextgenerationinannealoptimization? Andhowcanmore
outputbe
obtained
without
adding
manpower
or
equipment?
Thecurrentfocusofoptimizationtypicallyemphasizesimprovingsoftwareinvolvedwith
inventorymanagementandheating/coolingcyclemanagement. Butintakingabroaderviewof
theannealshop,anewoptimizationmodelmoredemonstrativelydirectsthediverseactivities
ontheshopfloortooptimizeoperations,craneandequipment,andflooroperatorandgeneral
managerefficiency.
Therearetwostepsforthisnew,nextgenerationoptimization.
FirstisShopOptimizationwhichutilizesheating,coolingandstackingmodeloutputsbutgoesfurtherbydeterminingthemostefficientuseofmanandmachinebyidentifyingand
minimizingthedelayoftheconstraintresource.
SecondisOperationsPlanningwhichdirectsresourceactivitiesaccordingtotheShopOptimizationoutput,suchasrealtimetaskassignmentstothecrane,floor,andfurnace
operators.Withtheadditionofacrane(locator),navigationalfunctionalityisavailablethat
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maximizesefficiencyofcranemovement. Together,thisnewmodelprovidesthehighest
utilizationofassetsintheBAF.
ThisnewmodelsqueezesmoreoutofHNorhydrogenBAF,eventhoseoperatingamixture
ofequipmentmanufacturers.
RADCONwillpresentthebenefitsoftheirShopOptimizationandOperationsPlanning
softwaretobeinstalledaspartoftheBAFportionoftheNewCRMprojectatSAILsBokaro
SteelPlant.
More
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IntroductionToremaincompetitiveinthecurrenteconomicclimate,steelcompaniesneedtofocustheir
attentionon
the
cost
of
production.
This
challenge
will
be
complex
as
the
economy
recovers
withreshapedmarketsandasnewandidledsteelcapacityisbroughtbackonline. Theability
tobeflexibleandoperateefficientlyduringthesedynamicmarketconditionswillbekeyfactors
toturningaprofit.
SAILsprojectinBokaroforanewColdRollingMill(CRM)complexincludescuttingedge
automationtocontroloperatingcostswhilemaintainingtheflexibilitytoadapttochangesin
themarket.Themill,whichisdesignedforautomotiveapplications,willutilizeRADCONsBatch
AnnealFurnace(BAF)modelingcapabilitiestoeasilyshiftproductmixwithoutequipment
changesorproductiondisruptions.
BokarowilloperatewiththenewCAPSShopOptimizationModelwhichbuildsonthe
processmodelspreviouslydevelopedbyRADCONtooptimizetheheatingandcoolingtimesof
thecoilsaswellasthestackingarrangementofcharges.ShopOptimizationtakesabroaderview
oftheannealshoptoincludetheequipment,cranes,andoperatingpersonnel.Themodelnot
onlycreatesaplantooptimizetheprocessbutalsoimplementstheplanthroughrealtime
communicationstothecranes,transfercars,andpersonnel.
Thisnewsoftwarefurtheroptimizestheprocesstomaximizethroughputcapacity,minimize
operatingcosts,andmaintainthehighestlevelofmechanicalpropertyconsistency.
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BAFOptimizationTherearethreelayersofoptimizationthatapplytotheannealshop,eachlayerbuildingon
theprevious.
The
first
layer
addresses
the
coil
and
control
of
the
heating
and
cooling
processing
manner. ThesecondlayerofBAFOptimizationaddressesthegroupingofindividualcoilsinto
batchesorcharges,consideringeachindividualcoilsneedsaswellasthechargeasawhole.
Finallythethirdlayertakesintoaccountthechargesalongwiththeequipmentandmanpower
intheshoptoarrangeandmanagethe
completeshop. Itisfromthisthird
layerthatnewefficienciesarebeing
achievedintheBAFthroughthe
additionofoptimizationmodeling.
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Figure1:BAFOptimizationLayers
Theactivitiesaddressedbyeachof
theselayersarehandledateveryshop
witheither
manual
decision
making
or
withtheuseofproductionmodels.
RADCONsComputerizedAnnealing
ProcessSoftware(CAPS)whichisusedtoprocessover50%ofallbatchannealedsheetsteel
inNorthAmericahandleseachoftheselayerswithdifferentsoftwaremodules. RADCONs
newestsoftwareimprovestheefficiencyofLayer3byminimizingtheprocessingtimeofcoils
withinBAFandthereforereducingworkinprocessinventory,increasingpredictabilityofthe
system,andmostimportantlymaximizingthethroughputcapacityoftheshop.
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ImprovingShopPerformancewithOptimizationModelingWhenshopmanagementishandledmanually,therearealargenumberofvariablesforthe
personneltoconsiderinordertooptimizetheoperation.Thepersonmanagingtheshopis
typicallyjusttryingtokeepeverythingmovingandhaslittletimeorabilitytodevelopand
manageaplanmuchbeyondthecurrentturn.Thelargertheshop,themoredifficultthisisto
coordinateandthemoreinefficienciesthatsneakin.
RADCONsapproachincreasesshopcapacityinsteadofjustmanagingtaskswithinthe
shop. SinceCAPShasinformationabouttheshopsuchasprocessingtimesforeachcharge,
equipmentavailability,
manpower,
as
well
as
productivity
targets,
aplan
can
be
developed
and
implementedthatnotonlykeepseverythingmovingforthecurrentturnbutreducesdelay
time,shortensprocessingtime,decreasesworkinprocessinventoryandincreasesshop
capacity.
ShopOptimizationPlanFirstanoptimizedShopPlanisgenerated.Thesoftwareusestheheating,coolingand
stackingmodeloutputstodeterminethemostefficientuseofresources.Theresourcewiththe
leastcapacityisdeterminedfromthecurrentinventoryandequipmentinformationmaintained
inCAPS.Protectingthisbottleneckresourcebecomestheprimaryfocusoftheplan.
TheShopPlanisdevelopedusingMixedIntegerLinearProgramming(MILP)whichisa
techniquefordeterminingthemostefficientmethodforallocatingresourceswhilestillmeeting
allofthesystemconstraintsorrules. InLPanobjectivefunctionisdevelopedandtheLPsolver
isaskedtoeitherminimizeormaximizethefunction.Theresultisasolution that minimizesdelay
timeofthebottleneckresourcewhichwillgivethemaximumshopthroughput.
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TheoperatorviewstheplanthroughaGantt
chartviewofthebaseoverviewscreen.This
chartshowsablendofthecurrentstatusofthe
shopalongwiththeplannedfuturearrangement
ofchargesandequipment.Theoperatoris
allowedtomodifytheplantoaccommodate
trials,maintenance,orotherspecificrequests.Figure1:ShopPlanningOverviewScreen
OperationsPlanningNowthataplanisdeveloped,itneedstobeimplemented.TheOperationsPlanningmodule
directsresourceactivitiesaccordingtotheShopPlan,suchasrealtimetaskassignmentstothe
crane,floor,andfurnaceoperators.Withtheadditionofacrane(locator),navigational
functionalityisavailablethatmaximizesefficiencyof
cranemovement.
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ThesoftwareworkslikeanavigationsystemforBAF
operation,planningthesequenceofactivitiesforthe
operators,cranes,andtransfercarstoavoidconflictsthat
woulddelaythecompletionofatask.
For
example,
in
a
shop
with
multiple
cranes,
the
crane
activitymustbecoordinatedtomakesurethattheydonot
interferewitheachotherandmoreimportantlythattheywork
Figure2:CraneTaskList
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togethertocompletethehighprioritytasks.Eachcranehasatasklistofitemstobecompleted
thatisdynamicallyupdatedbasedontaskcompletionandothereventsintheshop.Ifoneofthe
cranesistakenoutofservicethenthetasksareredistributed.
Figure
4:
Operator
Receiving
Message
on
PDA
SimilarinformationisprovidedtotheflooroperatorviaahandheldPortableDigital
Assistant(PDA).Sincetheinformationisavailabletotheoperatorwhiletheyareontheshop
floor,theyareabletospendmoretimecompletingassignedtasksinsteadofconstantly
checkingbacktothecontrolroomtodecideonthenexttask.Also,sincethecomputeris
determiningthetasksequencetheoperatorwillbeassignedthepropertasksrequiredtomeet
theShop
Plan
requirements.
ThePDAisalsousedtocollectinformationrelatingtotheoperators
activity.Coilsarescannedtoavoididentitymixupsandmanualtaskssuch
asverifyingtanklevelsorsafetychecksareinputfromthelocationthatthe
activityiscompletedinsteadofrecordedlater.Thisallowseachoperatortobe
moreproductivewhichcanreducethenumberofoperatorsnecessarytorun
theshop.
Figure5:OperatorScanningCo
Identification
Layer3optimization,withRADCONsShopOptimizationandOperations
Planningmodules,providesthehighestutilizationofhumanandequipment
assetsintheBAF. LikealloftheCAPSmodels,ShopOptimizationincreases
throughput,decreases
operating
costs,
and
improves
product
quality.
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BokaroBAFBokaroSteelPlant,aSteelAuthorityofIndiacompany,locatedinJharkhand,INDIAis
currentlyinstallingacompletehydrogenbelltypebatchannealingfacilitythatwillbethemost
advancedBAFintheworld,intermsofoverallproductivityefficiency.Whencompleted,the
facilitywillprocess860,000tonsperyearofcoldrolledsteel,primarilydestinedforthe
automotivemarket,usingonly47bases. Theproductmixofgradesisasfollows:
Mix[%] Grade Description
10 CQ CommercialQuality
20 DQ DrawingQuality
30
DDQ
Deep
Drawing
Quality
20 EDDQ ExtraDeepDrawingQuality
10 IF InterstitialFree
5 HSLA HighStrengthLowAlloy
5 BH BakeHard
RADCONisoverseeingthecompleteproductionandturnkeyinstallationofthecompanys
H2SHC(100%HydrogenSuperHighConvection)annealingsystemconsistingof:
47baseswith2mchargediameterand6.5mstackingheight;
26mixedgasfiredfurnaces;
20air/watercoolers;
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49basepostcoolingfacilityfordehumidifiedair
cooling;
o Allassociatedcontrols.
Theprojectfeaturesthetalleststackfor508mmIDcoils,utilizingRADCONsuniquehigh
pressureSuperHighConvectionsystem.ThesystematBokarocombinestheleading
convectionsystemwiththeleadingthermalmodelingsystem,CAPS. TheShopOptimization
systemmergesequipmentandmodels,tomaximizeoutputofthecombination.Inadditionto
productivity,thematchingofcoilsatscheduletimealsoreducesvariabilitygivingconsistent
qualitythatshouldgivepausebeforecommittingtosystemsbasedonCAL.
Managinganannealshopofthissizerequiresdetailedandsophisticatedsystemsand
controls. Therefore,asanintegralpartoftheproject,theBokarofacilitywillutilizeCAPS
OptimizationSoftware,tocontroltheentireannealprocess. Thecompletesoftwaresuite
includesCAPS
models
for,
Stacking,
Heating
and
Cooling
as
well
as
the
new
Shop
Optimization
model. CAPSinterfaceswiththefacilityslevel3datatoscheduleeverymovementofeach
coilfromthetimeitpassestheannealbaydoorsthrougheveryphaseoftheprocessincluding
instructionsforcranesandcoilcaroperatorstoensurefullutilization. Thesoftwarewillprovide
Bokarowithoptimizedcoilselectionandstackcharging,reducedcycletimesandmaximum
facilityandmanpowerproductivity.
AlargeannealingshopliketheoneoperatedatBSLrequiresdiligenceinordertofullyutilize
theassets.Planningfortheutilizationofthe47bases,26furnacesandcoolers,threecranes,
multipletransfercars,anddifferentlevelsofpersonnelisdonewithRADCONsShop
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OptimizationmoduleinCAPS.
CoilsarereceivedfromthePickleLineTandemColdMill(PL/TCM)andElectrolyticCleaning
Line(ECL)conveyorsandtrackedbyCAPSuntilthecoilsareremovedbytheSkinPassMill
(SPM)fromthesoftcoilstoragearea.AllequipmentandcoillocationsaremaintainedinCAPS
throughcommunicationtoandfromthecranesandtransfercars.CAPScoordinatesthe
activitiesfortheentryconveyors,cranes,andtransfercarstomovecoilstothedifferent
processingandstoragelocations.
Coilsareautomaticallybuiltintothermodynamicallyefficientchargestoimprove
throughputandalsoreducecoiltocoiltemperaturevariability,givingthemostfavorable
mechanicalpropertyperformance. ThechargesareplannedonabasebytheShopOptimization
Modelandasdiscussedabove,tasksaredistributedtotheappropriatecraneandfloor
personneltoprocessthecharge.
AtBokaromostoftheoperatortasksareautomaticallyverifiedbythesystemwithoutthe
needfor
operator
input
of
information
into
CAPS.
For
example,
when
the
operator
is
asked
to
disconnectthefurnace,thePLCnotifiesCAPSwhenthetaskiscomplete.Thisallowsthe
OperationsPlannertopermitthecranetomovethefurnace.CAPSalsoknowstheexact
locationofthefurnaceandsincethecranehasapositioningsystem,CAPSsendsthefurnace
coordinatestothecraneandthecraneissenttothatlocation.Thiseliminatesthepossibilityof
movingafurnacethathasnotbeendisconnectedandalsominimizesthewaittimebetweenthe
tasks.
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ConclusionTheintroductionoftheShopOptimizationmodeladdressesthefinalBAFlayer
managementoftheshoptomaketheshopequipmentandpersonnelasproductiveand
efficientaspossible. ThesoftwareallowstheBAFtooperatewithfeweremployees,provides
significantlyimprovedcommunicationandassignmentoftasks,reducesincidentsofhuman
error,improvesequipmentandmanpowerutilization,increasesthroughputcapacity,lowers
productioncosts,andimprovesqualitylevels. Inaddition,BAFproductionbecomesmore
predictableandeffectivewhichenhancestheefficiencyandeffectivenessofdownstream
operations. TheShopOptimizationmodelcanbeaddedtoexistingshopsornewRADCON
installationsthatutilizeCAPSHeating,CoolingandInventoryManagementmodules.
AlloftheCAPSmodelshelptoimprovemechanicalproperties.TheHeatingModel
accuratelycalculatescoretemperatureofeachcoilinthechargeanddynamicallyendsthe
heatingphasewhenthecriticalcoilhasreceivedenoughheat.TheStackingModelbalancescore
temperaturerequirementstobuildchargeswiththeleastvariationattheendoftheprocess.
Finally,ShopOptimizationsynchronizesmanandmachinetoensurethatfurnacesarenotleft
onbasestoovercookthesteel.
TheRADCONsuppliedBAFandCAPSoptimizationsuitewillallowBokaroSteeltoprovide
highlyconsistentproductqualitytotheautomotivemarketatlowerdeliveredcostthan
competitorsusingContinuousAnnealLines(CAL). Bokaroswillingnesstoembracethisnew
technologyis
indicative
of
Indias
progressive
approach
and
the
resulting
industrial
growth
that
ishelpingtoraisetheworldoutofitsrecession. FortheIndiansteelcompanies,thisgrowthwill
meanopportunitiestodevelopnewmarketsandexpandproduction.Theinevitableadditionof
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coldrollingcapacitywilldrivethedevelopmentofassociatedannealingfacilitieswhichwill
significantlybenefitfromimprovedcontrolandoptimization.
RADCONhasaprovenrecordofprovidingeffectiveoptimizationsoftwareforBAFs.The
ShopOptimizationModelcontinuesthattraditionwithnextgenerationprocessmanagement.
www.RAD-CON.comPhone: +1.440.871.5720Fax: +1.216.221.1135
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