AIST 2011 Presentation April 25
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Transcript of AIST 2011 Presentation April 25
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Copyright ArcelorMittal 2011
Scott BaylisSenior Specialist
Danny PavanSenior Specialist
Automation Technology SolutionsArcelorMittal Dofasco
The Application Of Simulation Modeling atArcelorMittal Dofasco
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Computer Simulation Modeling
What is it?
The methodology for using computer models to:
Imitate the operation of real-world processes orfacilities.
Draw conclusions about their performance.
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Computer Simulation Modeling
Why to use it?
Model Complex Dynamic Systems You can incorporate the variables, interactions and rules that define a system.
Model Random Variability over Time You can model variation over time by describing system behaviors using
probability distributions.
What-if Analysis
You can run experiments to estimate key performance measures for proposedsolutions and alternative system designs.
Visualization of the system You can provide an animated visual representation of the system.
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Demonstration
The Problem with Averages - Simulation versus Calculation
Averages Model
Grabau, M.R. (2001) Averages kill (or how to sell business process simulation). InProceedings of the 2001 Winter Simulation Conference (pp 1263-1265).
Hot Metal Delivery to Electric Arc Furnace Model
Objective:With a new practice of delivering hot metal to the Electric Arc Furnacedetermine if additional transporters or ladles are required.
(Model Demonstration)
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Hot Metal Delivery to Electric ArcFurnace Model
Objective:With a new practice of delivering hot metal to the Electric Arc Furnace
determine if additional transporters or ladles are required.
Outcome:
A single transporter and a single hot metal ladle was capable of
servicing EAF requirements for hot metal. The purchase of anadditional transporter was not required.
Sample Results
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Summary
Simulation modeling provides the unique capability
of creatingDynamic, Visualrepresentations ofComplexreal-world systems that includes theinherentRandom Variabilityof the systems.
Computer Simulation Modeling
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Simulation At ArcelorMittal Dofasco
Computer simulation modeling has been employed for over30 years.
Current team is three simulation specialists.
Where ever possible we utilized the simulation methodologyin our capital projects evaluation process.
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Models are designed to answer specific questions.
Defining the system to be modeled is a collaborative effort between: simulation specialists process experts
IT specialists (system input data) decision makers
Models are the translation of the system definition into the simulationsoftware.
Model scope and detail as well as the level of animation detail aredependant on questions to be addressed.
Typically simulation development is an iterative process.Model> Simulate> Learn> Revise
Model Development
Simulation At ArcelorMittal Dofasco
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Flexsim Software
Powerful and flexible tool that allows for large scale model customization,visualization and analysis of a wide array of processes.
Rapid prototype model development.
New users can build simple basic models very quickly.
Experienced users can develop more complex, sophisticated models relativelyquickly.
The 3D graphics are integrated with model development.
can be tailored to needs visual verification enhanced credibility, understanding, acceptance
Multiple specialist are able to simultaneously develop portions of the same large,complex models.
Simulation At ArcelorMittal Dofasco
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Sample
Simulation Projects
Simulation At ArcelorMittal Dofasco
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Sample Projects
Hot Mill Slab Yard Logistics Capability StudySlab Storage Yards, Transfer cars, Cranes, Hot Mill Depiler, Reheat FurnaceCharge Tables and Entry Doors
Objective:
Determine if existing slab handling equipment is capable of performingall slab sorting and delivery responsibilities at increased throughputlevels and to help identify potential bottlenecks and logisticsimprovement strategies.
Outcome:
Determined that slab handling equipment is capable at targetedproduction rates and anticipated future warm charge levels. Identifiedopportunities to develop strategies to balance crane work loads.
(Model Demonstration)
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Central Shipping New Axial Wrapper EvaluationCoil storage racks in adjacent buildings, Truck/transporter access lanes, AxialWrapper, Coil Preparation Area, transporter decks, customer trucks, Coil StackerCranes
Objective:Determine if the cranes in adjoining buildings are capable servicing aproposed coil axial wrapper at target throughput rates while maintainingadequate service levels for incoming customer truck and coil transporterdeck traffic.
Sample Projects
(Model Demonstration)
Crane Results
WorkElements
Summaries
Time Series Analysis ofCrane Utilization
Utilization Distribution frommultiple model runs
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Central Shipping New Axial Wrapper EvaluationCoil storage racks, Truck access lanes, Axial Wrapper, Coil Preparation Area,transporter decks, customer trucks, Cranes
Objective:
Determine if the cranes in adjoining buildings are capable servicing aproposed coil axial wrapper at target throughput rates while maintainingadequate service levels for incoming customer truck and coil transporterdeck traffic.
Outcome:
Determined that cranes are capable of servicing axial wrapper whilemaintaining truck service requirements.
Sample Projects
WorkElementsSummary
UtilizationDistributionfor multiplemodel runs
Axial Wrapper Performance Results
Throughputperformance
Distribution formultiple model
runs
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Sample Projects
21 Bay Coil Storage and ShippingCoil Shuttle Cars, Temper Mill Exit, Cranes, Coil Storage fields , TransporterDeck Locations, Galvanize Line coil consumption
Objective:
Assess cranes capability to service coil movement and storage withinthe bay under various throughput and bay layout scenarios. Also to testcoil storage field capacity allocations
Outcome:Identified limitations in crane capacity under various material volume
and routing scenarios. Also identify areas where planned storage fieldcapacities required modification. Provided follow-up analysis of varioussolution proposals.
(Model Demonstration)
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Temper Mill Exit Conveyor StaggeringTemper Mill Entry an Exit Indexing Coil Conveyors and Mandrels, New AutomatedPackaging equipment (Banders and Stencilers)
Objective:Determine if the practice of staggering coils on the exit conveyor of theTemper Mill in order to physically accommodate new automatedpackaging equipment would cause unforeseen throughput/bottleneckissues.
Outcome:
Determined that there were no detrimental flow effects or throughputeffects using coil staggering practice.
Sample Projects
(Model Demonstration)
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Sheet Mill A Building Model#2 CPCM, #1 Batch Anneal, Open Coil Anneal, Coil Transporters, Coil Shuttle Cars
Crane Utilization Project
Objective:Assess existing cranes capability of servicing coil movement
requirements within the bay at expected increased throughput levels.Outcome:
Determined that a third crane was required to meet projectedproduction demands.
Coil Movement Logistics Evaluation
Objective:Evaluate existing systems ability to support shorter term increasedthroughput requirements in order to determine if a significant capitalproject designed to support longer term goals could be deferred.
Outcome:Determined that a major $500,000 transporter doors installationexpenditure could be deferred.
Sample ProjectsModels with Multiple Applications
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Sample ProjectsModels with Multiple Applications
Hot Metal Delivery System Model(Blast Furnaces, Desulph Station, KOBM Pour Pit, EAF Pour Pit, Coffin Facility, Dekish,Railroad System (Locomotives, torpedo cars, logistics logic))
Steelmaking Improvement ProjectObjectives:
Determine if Metal Delivery System is capable of supporting targeted increasedproduction levels at #2 Melt Shop.
Evaluate multiple torpedo fleet configuration scenarios in support of blast furnacehigh productivity trials.
Outcomes:
Validated that the Hot Metal Delivery System could support the targetedincreased #2 Melt Shop levels.
Supported the blast furnace high productivity trials by analyzing multipleoperating scenarios to ensure that torpedo car fleet configurations wereadequate for the increased production.
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Hot Metal Delivery System Model contdHot Metal to EAF Proof-Of-Concept Study
Evaluated feasibility of supplying EAF facility with hot metal under a 3 blastfurnace operation.
Key justification to move forward with this initiative.
Precipitated several further analysis requests relative to this proposedoperating context:
Torpedo Car Puller Study Desulph Bag House Capability Study Fleet Size Analysis Pig Machine Location and Quantity Analysis
Sample ProjectsModels with Multiple Applications
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Hot Band Gantry Yard Simulation ModelHot Mill Coil Exit Conveyors, Gantry Cranes, Coil Storage Yards, Coil Carriersand Tractors, roadways, Coil Decks, coil arrival logic, coil storage logic, exiting
coil load logic.
Objective:
Assess Hot Mill exit coil conveyor throughput capabilities at
anticipated increased levels.
Outcome:
Determined that exit end of the Hot Mill is capable under normaloperating conditions.
Sample ProjectsModels with Multiple Applications
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Summary of Benefits
Simulation modeling has provided the capability to answernumerous complex questions.
Specific Outcomes:
Cost avoidance.
Highlighting of deficiencies in proposed system designs. Productivity improvements. Improved equipment utilization. Efficient allocation of resources. Resolution of material handling concerns.
General Benefits:
Avoidance of risk by changing virtual process versus actual processes. Proof-of-concept capabilities. Improved collective understanding of processes. Cost effective evaluation of alternative investment scenarios.
Th k Y
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Scott Baylis-Senior Specialist
Danny Pavan-Senior Specialist
Automation Technology SolutionsArcelorMittal Dofasco
Thank You