Digital Transformation of Stainless Steel Manufacturing – Vegam

Follow us on

© Vegam Solutions 2020, all rights reserved

Case Study – Digital Transformation of Stainless Steel Manufacturing

Customer Profile

One of India’s Largest Steel Manufacturer
Plant Size : 5,000,000 sq. m.
Capacity : 1,000,000 tons stainless steel.
More than 40,000 machine tags being tapped.
SHS with Two Arc Furnaces, Three Casters
HRM with Two Re-heating furnace
CRM Four continuous CRM lines
Complex material handling needs

The Problems

Raw Material Handling

Handling of Incoming raw material vendor, Batch & Chemistry Management
Mixing of different material at various stages
Additions of Raw material at various processes
Locating the right material in the open yard
Optimising charge preparation according to grade
Real time status of all in warded materials

Melt Shop

Variance of Input raw material quality
In process Chemistry Management
Caster quality control
Yield optimisation
Power optimisation
Maintaining of different grades quality & chemistry
Unavailability of real time process data for subsequent operations

HSM/CRM

Adhering different SOPs for different grades
Unavailability of real time process data for subsequent operations
Ad hoc changes in production planning as per business priority
Quality control based on operating as well as input parameters
Real time availability of slab/coil inventory

Overall

End to End process/ batch traceability
Maintaining Stringent Quality
Unavailability of structured data to run the analytics
Incomplete Defect analysis because of absence of data

Solution

Digitize all operations of the plants.
Map work flows & SOPs to digital SOPs
Enable tracking mechanisms (Mobile, Hand Held, IOT Sensors, Camera)
Make operations Paper Less. Remove all paper based work-flows & transactions. Replace log books, maintenance logs etc.
Bring on Smart Sensors, IOT devices for enhanced monitoring
Traceability of operations from Finished Goods to each work station: SMS >> HSM >> CRM

Integrated all Silo Systems & Data. Develop relation references between data
SAP or ERP
Quality Systems / LMS Systems
Warehouse Systems
PLC , DCS , Sensors
Enable KPIs, Dashboards, Value Stream Reports
Enable access to relation data using API’s. Open the data for any AI/ML engine.

Benefits

End-to-end digitalization solution

Complete plant digitalization solutions packaged into one.
All plants, work-stations and their inter-connects, inter-dependencies modelled.
Critical work-stations and work-SOPs digitized. Each task and its expected times, delays and other process times mapped and modelled.
Deviations and Critical Parameters for each work-station and work SOP’s mapped and developed into automatic alert generation.
Entire KPI’s and TPIs modelled and developed

Prescriptive Manufacturing

Data driven process parameters and optimization
Time and quality based real time adjustments to enable higher quality, yield and reduced energy consumptions
Grade of steel, Grade or finishing and post processing based inputs driving the production operations starting from Melt Shop onwards.
Real Time analytics driven on multiple data points to drive quality and energy needs optimization

Improvements

Real-time process visibility
Faster decisions
Batch traceability with higher Quality and yield.
Higher “Prime Grade” V/s “Sub Prime”
Better maintenance and reduced down times.

Operator and operations friendly

Better inter-departmental communications
Time and quality based real time adjustments to enable higher quality, yield and reduced energy consumptions
Grade of steel, Grade or finishing and post processing based inputs driving the production operations starting from Melt Shop onwards.
Real Time analytics driven on multiple data points to drive quality and energy needs optimization

chemical case study

Digital Transformation of Batch & Recipe based Manufacturing Industry

Case Study – Digital Transformation of Batch & Recipe based Manufacturing Industry Customer Profile Pioneer in Adhesive technologies...

steel

Digital Transformation of Stainless Steel Manufacturing

Case Study – Digital Transformation of Stainless Steel Manufacturing Customer Profile One of India’s Largest Steel Manufacturer Plant...

Enabling Smart Maintenance Operations in Automotive Component Manufacturing

Case Study Customer Profile Pioneer in Adhesive technologies Headquartered in Europe with Annual revenue over 20 Billion USD...

Check out all the Industries we have digitized

Other Industry?

Vegam Solutions Pte Ltd, Singapore

Aureole Technologies Pvt Ltd, Bangalore

Vegam.io Solutions Pvt Ltd, Hubli

Quality Policy | Information Security | Disclaimer | Terms | Privacy Policy Vegam.co and Vegam(TM) are copyrights of Vegam Solutions Pte Ltd | Copyrights reserved 2024