China 2025- How Tangsteel Deals with the Chances of ...€¦ · management data, Rule based to...
Transcript of China 2025- How Tangsteel Deals with the Chances of ...€¦ · management data, Rule based to...
China 2025- How Tangsteel Deals
with the Chances of Digitalization
ZhenRui Zhao IT Direcector
2017-5-9
2
3
Innovation
Key Points of Smart Factory
1 Review
4 Vision for the future
Brief Introduction of Tangsteel
Key member of HBIS (No.2 of Steel company of China) Located in Tangshan City
18 Million Tons per year for Tangsteel,
From ore to final products . 140 Types of products :
Water Treatment Center Iron Tapping hole
Green Tangsteel
Major Mills(Post SMP)
Plant #1
SMP HRM
Plant #2
SMP HRM
Coil Slab
long section
Plate Ltd.
SMP
+ HRM
Plate
CRM Dept.
CRM
Cold Coil G Coil A Coil
Stainles
Ltd. SMP
+ HRM
Coil Slab
High Strength
Automobile Sheet Ltd.
CRM2 in short (2014)
Cold Coil G Coil A Coil
HQ LaoTing GuYe KaiPing
Section Dept.
Section
Review the Past of IT Development of Tangsteel
2002-2007 2008-2013 2014-2015 2016 2017——
•Gigabit optical fiber backbone
network
•OA System
•Plant #1 (SMP&HRM) Sales
&production system
•ERP
•Iron/Post SMP DSS、 Plant
#1(SMP&HRM)/CRM1/Stainless Mill MES
•LMS, Quantity & Quality System
•EMS、Equipment inspection system
•BI 、E-Commercial Platform、 CRM
•Advanced Planning System(APS)
•Order Dressing System(ODS)
•Quality Management System(QMS)
•CRM2 MES
•Plant#1/Stainless Mill Melt shop Control Center(MSCC)
•Plant#1 /Stainless Ltd. MES modification
•Mill Database System(MDS)
•Plate Mill IT improvement
•ODS to cover product development phase
•Project Management
•OA improvment
•HR improvement
•Equipment Life-cycle management and on-line Diagnosis system
•CRM2 MES Phase 2 ()new lines
•CRM1 MES Enhancement
•APS、QMS function Enhancement
•LIMS
•Order negotiation system
•Stainless mill and CRM2 Smart Factory
Traditional Architecture Adjustment on Intelligent Manufacturing
Architecture
L5
L4
L3
BI/BO
ERP C S
CRM HR
CRM1 MES
MES
Plant #1MES
Plant2 DSS
Iron areaDSS
Assistant system
Logistics Train shipping
Equipment Inspection
Mesurement Managament
Quality and Quantity System
EMS
OA
Stainless Mill MES
……
Buy PP QM Sales FI/CO EM
L2 PCS
PLC L1
IT (Network/Servers/Security etc.)
Coaking DSS
WM
Legacy Architecture
Challenges on the Traditional System
FI Oriented instead of Customer oriented
-Small orders, customized SO instead of Big batch SO
-Due-Date Negotiation
Quality Control Result Adjustment mode instead of process control and Final SO Oriented
Lack connection between Automation system & Information system
Mill Coordinating Supporting instead of Flat organization Mode
2
3
Innovation
Key Points of Smart Factory
1 Review
4 Vision for the future
3 Main Lines Advancing:Integration of Production Management-Control ;Integration of whole industry SCM;Life-cycle Equipment Management
One Target:Factory Operational Excellence 1
Two Supporting System:Technical supporting system;Standardization System 2
3
Four ability promotion:Overall perception; Collaborative optimization; Forecast and early warning;Scientific decision making
4
Five Features:Digitalization;Integration; Modelling; Visualization、Automation 5
Six Core business Domain: Production management- Control、SRM、Equipment Management、Energy Management、HSE、Strategy Management 6
Key points of Smart Factory definition in “China Manufacture 2025”
China Manufacture 2025
5 layers System Architecture Defined in “Construction Guideline of National Intelligence Manufacturing standard architecture ”:
Equipment Layer:Including Sensors ,instruments and meters, bar code,RFID, equipment, machine, device etc. Material basis of production
Control Layer:Including PLC,SCADA,DCS, FCS etc.
Shop Layer: Focus on the production management of Mills/Shops,Including MES etc,
Company Layer: Focus on the company management,Including ERP,PLM,SCM,CRM etc.
Coordinating Layer:Focus on companies in the industry chain to realize the coordinating R&D, intelligent production, accurate logistics and intelligent service by share information.
Intelligent Manufacturing Standard Architecture
Layer
Life-cycle
Intelligent Function
Coordinating
Company Shop
Control Equipment
Resource
System integration
Inter connecting &Inter working
Information fusion
New types of business
Design
Production
Logistics
Sales
Service
New IT Architecture
PLC
L5
L3.5 Company Level APS Company Level ODS Company Level QMS
PCS
RDS MDS
L2 Enhancement in Iron
TPQC
KPI System BI/BO
L4 CRM OA SRM TBM FI Contrl
PlatForm
buy Sales PP QM WM FICO HR PM Equipment Management ERP
L3 Long Product
MES Plate MES
Stainless MES
CRM 1MES
CRM2 MES Iron MES
SMP MSCC
Plant 1# MES Meter System
EMS Inspection
CTS QAS
ISS
EBS
MMS
Train Shipping ACS Attendance
EDS
LIMS
MES Assistant System
L2.5
L2
L1
Legacy Constuction Plann 图例:
Logistics Non-
Metals
System
Innovation on the Legacy system
L3.5 Company Level
QMS
Company Level
APS
Company Level
ODS
L2.5 MDS
2
3
Innovation
Key Points of Smart Factory
1 Review
4 Vision for the future
Order-Dressing
PSR_NO: Product Specification Code
MIC_NO: Manufacture Index Code
SO
SG
User
Usage
MIC_NO
Mapping
Auto Design
Y
N
Standard
PSR_NO
Manual
Establish the Core Quality
DB:
-Product Specification DB. Mic
DB. Routing DB
Dynamic Order Dressing
Unify the Quality Standard
for all the mills
Supporting New Product
Development
APQP/FMEA
Exist?
Capacity Constrained
Planning
DDQ Supporting
Improve Decision Quality
and efficiency of Coordination
On-Time Delivery
Optimized Stock
Smart Planning Algorithm
Strategy
S&OP
Planning
Scheduling
Buy Production Logistics Sale
Iron Plan
Port Plan
Strategy Plan
Monthly material Plan Demand-modelling
DDQ
Shipping Plan
Integrated Sale-production Plan
Production Scheduling
APS
Sequence of Tundish MES
CTS
Sequence of Tundish
Real signals of L2
Pace Schelling result
For all resources Pace Schelling result
For all resources Real signals of L2
BOF L2 LF L2 CCM L2
Dynamitic Scheduling
based on the real
production
Pace Scheduling/
Temperature /Crane
Scheduling/Ladle Planning
Mixed SM Production
3BOF-3CCM ->2BOF-
>3CCM
Melt Shop Control Center(MSCC)
QMS
Product Quality
Tracing
Meeting with Product to
Meeting with standard of
Operation
On-line Control and
Off-Line Analysis
Stability Assurance
Standard Oriented to
Customer Oriented
Manually Checking
Pre-view of Coil TPQC
QMS On-line Judge
Quliaty Monitoring
Plan &Scheduling
Key performance evaluation
SO
Quality Analysis
Mill level big data,
supporting QMS’s Business
All operation data in same
Real-time DB
Re-calculation and part
operation data to Relational
DB
Algorithm mapping for the
operation data and
management data, Rule
based to support L3
Mill Database System
Unmanned CTS
3 Warehouse in CRM2
Auto Scheduling and
Auto Shipping
Unmanned CTS
Optimized on stock
assignment and
transportation
Efficiency improvement
Load Balance on Cranes
Unmanned CTS
Stock allocation automatically
Shipping Automatically
On-line Diagnostics
Life-cycle equipment
management
Spot-Checking Management
system
ERP-PM/MM
Omnidirectional and multi
dimension system equipment
management
Realize the pre-use, in use, post-use
life-cycle management of equipment
Accurate equipment book-keeping
On-line monitoring
Intelligent diagnostics and trouble-
shooting
Optimize spot-checking, maintenance,
improve equipment perfectness
Improve attachments management
Equipment Management and On-line Diagnostics
Information
integration Platform
Data Processing Hub
For Different system
Unified interface
Large scale concurrent
automatic processing
supporting
Robot Smart System
trigged by Events
会议回执--河钢唐钢 Plant#1
MES
ODS APS QMS ERP
CRM2 MES
Stainless MES
LMS
CTS
MS
LIMS
EMS
RMS CAL L2
PLCT L2
CGL L2
RC L2
Pack L2
Unified interface platform
System Integration
Value of the New Architecture
Service Oriented Manufacture
- MTO Supporting; Balance batch production and customized requirement
Know-How Consolidation
- Core Metals Quliaty DB. Product life-cycle supporting
Flexible Manufacture
- Based on the Self–organization and quick response of the production,.to
reduce the cost and Detailed FI analysis supporting
Agile Manufacture
- Based on the Quality assurance system, Design and Production integrated
2
3
Innovation
Key Points of Smart Factory
1 Review
4 Vision for the future
Vision for the Future
PLC
L5
L3.5 Company Level APS Company Level ODS Company Level QMS
PCS
RDS MDS
L2 Enhancement in Iron
TPQC
KPI System BI/BO
L4 CRM OA SRM TBM FI Contrl
PlatForm
buy Sales PP QM WM FICO HR PM Equipment Management ERP
L3 Long Product
MES Plate MES
Stainless MES
CRM 1MES
CRM2 MES Iron MES
SMP MSCC
Plant 1# MES Meter System
EMS Inspection
CTS QAS
ISS
EBS
MMS
Train Shipping ACS Attendance
EDS
LIMS
MES Assistant System
L2.5
L2
L1
Legacy Constuction Plann Notes:
Logistics Non-
Metals
System
Thanks!