Steel Industry Archives » Vegam

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
Register to download Case Study
Schedule a Demo
Please fill in your details so that our experts can get in touch with you at your convenience and provide you with a comprehensive walkthrough of how Vegam helped optimize Steel Manufacturing for one of our clients
Digital Transformation of  Batch & Recipe based Manufacturing Industry
Digital Transformation of Batch & Recipe based Manufacturing Industry
Case Study – Digital Transformation of Batch & Recipe based Manufacturing Industry Customer Profile Pioneer in Adhesive technologies...
Digital Transformation of  Stainless Steel Manufacturing
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
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 Well established

Check out all the Industries we have digitized

Reach out to us

Add Your Heading Text Here

Page 1 of 3

Talk to a specialist

Please fill out the details to learn how team vegam can help you solve the challenges in your operations!
Please select meeting date and time

Vegam Sales Team

Welcome to my scheduling page. Please follow the instructions to add an event to your calendar.

Overview of Offerings of Minute

At ,
Time - ( )

Meeting scheduled

You are scheduled with Vegam Sales Team
Overview of Offerings for 30 Min
A calendar invitation has been sent to your email address.
Customer benefits shared on the page are very contextual to industry and plant size and operations. Please let us know more about your operations and our experts will reach out to you with data specific to your operations.
Please fill in your details so that our experts can get in touch with you to give you a comprehensive demo for the specific requirement at your convenience

Enter your details via

Or