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

  • Warehouse
  • Material Tracking
  • Quality
  • Manufacturing
  • Maintenance
  • TPIs, KPIs, Dashboards & Analysis
  • 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
  • Integrate all Data Sources
  • Unified Data structure
  • Real-time visualization
  • Simulation
  • Performance & Outcome prediction
  • AI/ML with Big Data
  • 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
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