Optimizing the Plants of the Future thanks to Smart Data ... · Optimizing the Plants of the Future...
Transcript of Optimizing the Plants of the Future thanks to Smart Data ... · Optimizing the Plants of the Future...
Steel
June 2017
Yannick LEPRETRE
Fives — Group Chief Innovation and Digital [email protected]
Optimizing the Plants of the Future
thanks to Smart Data & Services
Future Steel Forum
Steel
Fives, an international industrial engineering group
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‒ Aerospace
‒ Aluminium
‒ Automotive
‒ Cement
Fives designs and supplies
process equipment and
production lines for the world’s
largest industrial suppliers
‒ Energy
‒ Glass
‒ Logistics
‒ Steel
Steel
Industry of the Future at the heart of Fives activities
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Digitalisation
of the value
chain
Automation
and robotics
Control and
monitoring
Energy
efficiency and
environment
IoT
CybersecurityAvailability
Handling
Enhancedrobotics
Sensorsnetwork
Non destructive control
Production and storage
Energy recovery
Composites,
and new
materials
Composite
manufacturing
In process
control
Parts assembly
New
manufacturing
technologies
CompositeMetallic 3D
printing
JV with
Michelin
Human in the
factory
Augmentedreality
Cobotics
The Steel division benefits from group
Fives developments in all its activities
Steel
Digital factory – Fives analytics platform
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Data
Acquisition Data
Storage
Data Analytics
Connected Sensors
Smart Gateway
Field Bus
Local
Cloud
AnalyticsPrediction
Data Mining
Machine Learning
WEB
Dashboarding
Configurable
Steel
Digital factory – Fives analytics platform
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Comprehensive Suite for Data Analytics:
— Acquisition Storage Treatments Alerts
— Encrypted / Secured Access and Data Transfer
— Applicable on both new and existing equipment
Steel
New digital business models? Stick to the basics!
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Plant
manager
focus
OEE
Costs
Capability
improvement
Raw material, consumables, …
Energy, fluids, …
Spare parts, services, …
Availability
Efficiency
Quality
Industrialization of new products
Improvement of process
performance
Digital brings new tools to improve
operational excellence in the plants
Steel
Process know-how embedded in quality control software
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— Evaluation of yield improvement: 1.2M profit for a 3% increase
of the prime shipment for galvanizing line 400 000 mt/year
— Monthly licence fee and consulting
EyeronTM Web application, based on data storage and
analysis, for steel quality control to guarantee
quality, time delivery and save costs
Smart line development
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Combustion process optimization with Virtuo®
Virtuo®, Furnace Level 2 Thermal Solution
for reheating, treatment and processing lines
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— Maximize production rate with guaranteed quality
— Ease of use with reduced manpower
— Optimize product delivery
— Reduced gas consumption
— Improved yield performance
— Prevention of production losses
— Meet environmental constraints
Gas flow stabilized
on a 450 t/h furnace
at Çolakoğlu
Metalurji - Turkey
Virtuo® benefit for reheat furnaces:
energy savings up to 22%
Steel
Planned
Maintenance
Break
downReactive
Maintenance
What about predictive maintenance?
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Component health status
Time
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Break
down
Maintain
standard status
Steel
Manage your mill with your finger tip
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TPM
Maintain standard status
OEE / costs / process dashboards
Remote control
and helpdesk
Video feeds
Component Health
check and predictive tools
Periodic recommandations
for optimization
Process optimization
Tools
Make technical
documentation available
On line parts catalogue
Much more …
Steel
Online catalogue for spare parts
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≈ 30 Assembly drawings for a
tube cut-off machine
— Easy identification of the parts
— Direct link to 2D drawings or 3D models
— Click to move to the basket and order
— Risk of misunderstandings and delivery
of wrong parts is almost zero
Old way
Fives way
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Predictive maintenance for a tube cut-off machine
Improvement of blade lifetime
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— Optimize broken blade stops
— Increase blade life with adaptive
behavior parameters
— Partnership with Parma University
(sensorless approach and 3D signals
(noise analysis)
→Monitoring of slack belt status
Tension monitoring and dection of the
excessive tension
Steel
Conclusion
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Digital technologies are powerful tools to improve operational efficiency
The key point to make them successfull is to consider them
as tools that support good manufacturing methodologies
Fives’ digital philosophy is to provide a comprehensive
approach of industrial excellence:— Edge equipement technology
— Smart automation and data infrastructure
— Consulting in process and maintenance optimization
— In-house experts and data analytics
— Powerfull softwares
— Hands on ability to firmly root progress in the daily
operations
SteelFives - Future Steel Forum 16
Yannick LEPRETRE
Fives — Group Chief Innovation and Digital Officer
3 rue Drouot
75009 Paris - FRANCE