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Holistic Logistics Solutions as a Major Driver to Optimize
Productivity in a Steelworks Markus Ringhofer, Sales Manager – Industry 4.0
primetals.com
Restricted © Primetals Technologies 2019. All rights reserved. M. Ringhofer | EA I4.0
Production Flow
Online Heat Scheduling Caster
Scheduling HSM Scheduling
Slab Yard
Management
Coil Yard
Management
Coil Demand Slab
Demand
Heat
Demand Iron Demand
Through Process
Optimization
Holistic
Ironmaking
Sep 2019 Page 2
Online Heat Scheduling Caster
Scheduling
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Key Performance Indicators of
Production and Logistics
Market situation
& conditions
Planning priorities
& trade-offs
Short through-put time
Flexible product mix
Short delivery time
High equipment utilization
High production capacity
Less capital tied up
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Is the right input material being charged?
Conveyer Belt
• Analysation of emitted sounds at take over points
• Determining of material type, material quality (amount of
fines), …
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Ironmaking Expert
Efficient Coordination of Ironmaking Plants
Ore
preparation Sinter plants
Stockyard
BFs BOFs Coke plant Hot
blast stoves
Pelletizing
O2
assignment
O2
assignment
Stoves
coordination
Coke
production
& quality
Sinter production
Target sinter basicity
Burden chemistry
Hot metal production
O2 enrichment
Blast Flow
Blast Temp
Required HM Amount,
Si content, HM Temp
• Optimized production fulfilling requirements of respective downstream plants
• Cross plant coordination for optimal gas network utilization
• Transparent and traceable production decisions
• Reduction of costs and increase of production
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Understanding the scheduling
and planning constraints of the customer
Example: Complex scheduling
at single bay layout with mutually competing cranes:
• reduce ladle lead times: less energy demand & refractory wear
• high sustained production capacity without sequence breaks
• avoid blocking and delays of the cranes
• cranes to consider ladle maintenance transports in same bay
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Cranes: Different Cranes on One Crane Way
A
B
Unreachable for cranes
2 & 3
Unreachable for cranes 1 & 2
crane 1
crane 2
crane 3
1. Split crane way in three parts
2. Overlap split crane ways (creating transfer positions)
3. One crane way with three cranes (calculate best crane and if necessary displace other cranes)
1 2 3
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Crane and Yard Management
Degree of automation
Manual
No terminal in crane
cabin
Crane driver directed
by person on the
ground
Manual update of
piece location in L3 by
user
No automation
integration with coil
shuttle cars
Semi-Auto
Terminal in crane
cabin
Crane driver receives
transport orders from
L3 based on
routing/schedule
Automatic update of
piece location
x,y,z coordinates
WiFi Network
Automation integration
with coil shuttle cars
Fully-Auto
No crane cabin
Crane automation
receives transport
order from L3, No
crane driver
Fully automatic
transport order
execution
x,y,z coordinates
WiFi Network
Seamless integration
with coil shuttle cars
Transport Order
List
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Understanding the scheduling
and planning constraints of the customer
Example: Complex scheduling
at single bay layout with mutually competing cranes:
• reduce ladle lead times: less energy demand & refractory wear
• high sustained production capacity without sequence breaks
• avoid blocking and delays of the cranes
• cranes to consider ladle maintenance transports in same bay
Success factor:
• Implementation team with process know-how
• Involve actual shop floor people to capture their experience & knowledge
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Advanced Tracking System
Benefits of Ladle Detection and Tracking
• Fully automated tracking system for
metallurgical plants
• Heat counter
(How many heats on a ladle in total)
• How many heats on a ladle
since last relining
• Contact time of heat with ladle
• active/inactive ladle
(inactive means when ladle is at one of four
maintenance locations; active means
whenever tracked after dry- or preheating
station)
• mounted/installed equipment on
ladles, like slider gate, plate,…
(entered manually at maintenance shop)
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• 20% reduced costs
due to better logistics
• Reduced rental cost for
rail wagons
Cost
Reduction
Yard Management
Typical Benefits
• By integration of planning
and logistics
• By improved shipment
Reduced
Inventory
• Better use of available yard area
• Bottleneck of shipment yard eliminated by an increased throughput of 25%
Reduced
Storage Space
• 100% material location and
identification with Yard
Managment
Improved
Material
Tracking
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Yard Management
Reference: ATI Allegheny-Ludlum – USA
• No Personnel
• Automatic Coil Car unload
• Automatic Coil storage
• Automatic rail car loading
• Automatic saddle loading/unloading
• Automatic coil ferry loading
• Storage Strategies, Rules
• Full Integration
• Coil Shuttle Car System
• Yard Management
• HSM Automation
• Crane Automation
• Safety System
• 100% accurate inventory
Fully Automatic Yard Management
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Yard Management
Reference: ATI Allegheny-Ludlum – USA
• Fully automatic coil transport from
HSM coilers to storage yards
• Integrated system
• Warehouse Management
• Mill Automation
• Coil Shuttle Cars
• Safety
• Target location finding by WMS
• Automatic pick up by crane
Sep 2019 M. Ringhofer | EA I4.0 Page 15
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RFID Labels Marking Machines
QR Code
Product identification at any product stage of production
provides more secure traceability of products
Additional RFID Labels can
support the tracking of products in
the yard.
Marking via alphanumeric
characters Painted, stamped or on
labels.
Additional marking of products with
a QR Code for identifying.
Reading of marking via crane or installed reading station: The marking of the product will be identified during pick up of the slab with a camera system or RFID reading
unit which is installed on the crane. The Data will be interlinked with the overall Yard management system.
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Production Management Solution
A comprehensive approach
Sep 2019 M. Ringhofer | EA I4.0 Page 18
QUALITY
• Comprehensive quality from definition through quality
control
• Seamless integration and application of Through-
Process Optimization
• Handling of quality deviations by integration of
deviation management with production control
PRODUCTION MANAGEMENT
• Order-based production
management
• Manufacturing execution
• Raw-material and stock management
• Production tracking
• Management of production equipment
LOGISTICS
• Stock management
• Order-based transport coordination
• Transport optimization and execution
• Shipping and delivery
PLANNING AND SCHEDULING
• Anticipation of future demand
• Material-flow optimization
• Capacity utilization
• Material allocation
• Order and line scheduling
• Evaluation of planning, KPIs
BENEFITS
• Optimal plant and equipment utilization
• Reduced order-turnaround time
• Reduced inventory
• Reduced logistics costs
• Improved delivery performance
• Higher product quality
• Lower production costs
• Lower energy costs
Restricted © Primetals Technologies 2019. All rights reserved.
The information (including, e.g., figures and numbers)
provided in this document contains merely general
descriptions or characteristics of performance based on
estimates and assumptions which have not been verified.
It is no representation, does not constitute and/or evidence a
contract or an offer to enter into a contract to any extent and
is not binding upon the parties. Any obligation to provide
and/or demonstrate respective characteristics shall only
exist if expressly agreed in the terms of the contract.
These estimates and assumptions have to be analyzed on a
case-to-case basis and might change as a result of further
product development.
Primetals Technologies excludes any liability whatsoever
under or in connection with any provided information,
estimates and assumptions. The provided information,
estimates and assumptions shall be without prejudice to any
possible future offer and/or contract.
Any use of information provided by Primetals Technologies to
the recipient shall be subject to applicable confidentiality
obligations and for the own convenience of and of the sole
risk of the recipient.
Contact
Sep 2019 M. Ringhofer | EA I4.0 Page 19
Dr. Markus Ringhofer
Sales Manager – Industry 4.0
Primetals Technologies Austria GmbH
Turmstrasse 44
4031 Linz
Austria
T +43 (732) 6592-9358
M +43 (664) 6150708
primetals.com
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