Case Study – Digital Transformation of Stainless Steel Manufacturing
Customer Profile
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One of India’s Largest Steel Manufacturer
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Plant Size : 5,000,000 sq. m.
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Capacity : 1,000,000 tons stainless steel.
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More than 40,000 machine tags being tapped.
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SHS with Two Arc Furnaces, Three Casters
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HRM with Two Re-heating furnace
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CRM Four continuous CRM lines
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Complex material handling needs
The Problems
Raw Material Handling
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Handling of Incoming raw material vendor, Batch & Chemistry Management
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Mixing of different material at various stages
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Additions of Raw material at various processes
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Locating the right material in the open yard
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Optimising charge preparation according to grade
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Real time status of all in warded materials
Melt Shop
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Variance of Input raw material quality
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In process Chemistry Management
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Caster quality control
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Yield optimisation
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Power optimisation
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Maintaining of different grades quality & chemistry
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Unavailability of real time process data for subsequent operations
HSM/CRM
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Adhering different SOPs for different grades
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Unavailability of real time process data for subsequent operations
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Ad hoc changes in production planning as per business priority
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Quality control based on operating as well as input parameters
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Real time availability of slab/coil inventory
Overall
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End to End process/ batch traceability
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Maintaining Stringent Quality
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Unavailability of structured data to run the analytics
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Incomplete Defect analysis because of absence of data
Solution
- Warehouse
- Material Tracking
- Quality
- Manufacturing
- Maintenance
- TPIs, KPIs, Dashboards & Analysis
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Digitize all operations of the plants.
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Map work flows & SOPs to digital SOPs
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Enable tracking mechanisms (Mobile, Hand Held, IOT Sensors, Camera)
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Make operations Paper Less. Remove all paper based work-flows & transactions. Replace log books, maintenance logs etc.
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Bring on Smart Sensors, IOT devices for enhanced monitoring
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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
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Integrated all Silo Systems & Data. Develop relation references between data
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SAP or ERP
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Quality Systems / LMS Systems
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Warehouse Systems
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PLC , DCS , Sensors
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Enable KPIs, Dashboards, Value Stream Reports
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Enable access to relation data using API’s. Open the data for any AI/ML engine.
Benefits
End-to-end digitalization solution
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Complete plant digitalization solutions packaged into one.
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All plants, work-stations and their inter-connects, inter-dependencies modelled.
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Critical work-stations and work-SOPs digitized. Each task and its expected times, delays and other process times mapped and modelled.
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Deviations and Critical Parameters for each work-station and work SOP’s mapped and developed into automatic alert generation.
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Entire KPI’s and TPIs modelled and developed
Prescriptive Manufacturing
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Data driven process parameters and optimization
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Time and quality based real time adjustments to enable higher quality, yield and reduced energy consumptions
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Grade of steel, Grade or finishing and post processing based inputs driving the production operations starting from Melt Shop onwards.
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Real Time analytics driven on multiple data points to drive quality and energy needs optimization
Improvements
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Real-time process visibility
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Faster decisions
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Batch traceability with higher Quality and yield.
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Higher “Prime Grade” V/s “Sub Prime”
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Better maintenance and reduced down times.
Operator and operations friendly
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Better inter-departmental communications
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Time and quality based real time adjustments to enable higher quality, yield and reduced energy consumptions
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Grade of steel, Grade or finishing and post processing based inputs driving the production operations starting from Melt Shop onwards.
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Real Time analytics driven on multiple data points to drive quality and energy needs optimization
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