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Slide1
Concept of Industry 4.0 for the Metals Industrie
Třinec, 30. Nov. 2016
Restricted © Primetals Technologies 2015 All rights reserved.
primetals.comSlide2
Digitalization
is
driven
by
new customer requirementsand enabled by
new technologies30.11.2016
K.Herzog
/ EA I4.0
Page
2
New Technologies
Customer
requirements
Communication Technologies
Computational
power
Internet
technologies
Cloud technologies
Big data analytics
Self-learning systems
Mobile devices
Augmented reality
End-customer integration
Lot-size 1
New business models
Know-How management
Supplier integration
New steel grades
Availability of information
Ergonomy / Operator support
Achieved
by Holistic AutomationSlide3
A digitalized plant is like an orchestra – The Metals Orchestra30.11.2016
K.Herzog / EA I4.0Page
3Slide4
Metals OrchestraTeach your players to play better30.11.2016
K.Herzog / EA I4.0Page
4Slide5
Smart Sensors help to improve data availability
Page 5
Scrap
Chute
Tracking
Ladle
Tracking
with
RFID
Pallet
car
tracking
with
RFID
ICE-Tag
Protection
Measurement Identification Communication Tracking
Scrap
Weight
Wireless
transmition
Temperatures
Ladle
history
Identification
Tracking
Improved
Tracking and Input
Data for
the
Process
Models & Data Analytics
30.11.2016
K.Herzog / EA I4.0Slide6
RoboticsLiquiRob
Page
6
EA ISC
Temperature
measurement
Shroud
handling
Oxygen
lancing
Lock out
of
personnel
from
hazardous
working
areas
Ensures
reliable
production
Quality
improvement
due
to
reproducible
procedures
Minimal
maintenance
required
Customizable
robot
tasks
to
guarantee
high
flexibility
Highly
scalable
(i.e.
basic
systems
to
highly
sophisticated
implementations)Slide7
Steel Expert Process ModelsA digital twin of the real plant30.11.2016
K.Herzog / EA I4.0Page 7
Precalculation of complete heat
Preview of blowing process
Adaption of treatment
practice
Online tracking of steel and
slag analysis
, temperature and
weight
Steel Expert
Supervision
FCC First Charge Calculation
SCC Second Charge Calculation
Inblow
(Sublance model),Reblow ; Alloy
Steel Expert Setpoint
Dynamic blow end controlbased on off-gas
dataDynacon
Steel Expert Prediction
Tapping
Hot metal and scrap order
Model-
based
Control
Modelling
Simulation
Optimization
s
upported
by
Smart
sensors
and
Automatic
Functions
:
Advanced
Tracking System (
Ladles
,
Scrap
chutes
,
Slag
pot
)
Wiplant
(HM
weight
,
Scrap
weight
,
Slag
weight
on
transfer
cars
)
LOMAS – Low
maintenance
offgas
analysis
system
Ignition
guard
Slagmon
(
Slag
warning
system
for
tapping
)
Automatic
tappingSlide8
BOX CONCEPT
One Source One centralised
Condition
Monitoring System
Mechatronics
Technological controls (Level 1)
Process models (Level 2)
Vibration
monitoring
3
rd
-Party
Information
BOX Concept
Informationbroker
Condition MonitoringSystem
Iron and Steel- making
Caster
Rolling
mill
Process-ing LinesUtilities
supplyM2M
InterfaceSingle sourcew
ith plant wide data collection
Maintenance/ ProcessTeam
Process
Plant-Equipment
Automation30.11.2016
K.Herzog / EA I4.0Page 8Slide9
Smart Work Augmented reality supports maintenance personnel
Page 9
E
fficient
troubleshooting and fast, direct access to the required
information
Shortens search
times, and reduces errors and mistaken
identities
Reliable
identification of plant components
with
RFID tags or QR codes
Checking
the precise installation location of sensors and actuators in 3D displays
Checking sequences
in animated
displays
Retrieving live and diagnostics data from the automation system
Retrieving online documentation
Seamless linking of data from the HMI,
condition monitoring
,
diagnostics
, automation
system
30.11.2016
K.Herzog / EA I4.0Slide10
Acoustic
Expert
Data
Based
Services
Cloud Service
Benefits
Automatic detection of equipment malfunction
Maintenance support
Island
system – no access to plant network from outside possible
Secure
/
encrypted
data transmission
Comparison of different plants possible
Automation
30.11.2016
Page
10
K.Herzog / EA I4.0
UMTS
Plant
InternetSlide11
The Digital Unity – The Conductor of the Metals Orchestra30.11.2016
K.Herzog / EA I4.0Page
11Slide12
The Digital Unity – The Conductor of the Metals Orchestra30.11.2016
K.Herzog / EA I4.0Page 12Slide13
The Digital Unity – The Conductor of the Metals Orchestra30.11.2016
K.Herzog / EA I4.0Page
13
PMS
dynamically plans and
tracks your production to utilize your production facilities in an optimized way, from the customer order down to each individual production step.
It optimizes productivity and ensures maximum flexibility to your customer requests.
TPOpt
provides know-how based identification of non-conformities, identifies the related root-cause and provides corrective and compensational actions through-
out the entire production chain.
It effectively helps to achieve
the intended product
specifi
-cations
and supports your quality management.
Maintenance Managementassists you manage and execute your maintenance in an entirely new way. Built in know how generates actionable items, according to your strategy, increases efficiency of your maint-enance personnel and unleashes the true value of you assets. Slide14
Quality along the entire production chainThrough-Process Optimization (TPOpt)Page
14
Complete genealogy from heats to finished products.
Product quality conformance checks for the entire production
chain
Many different data sources
Quality monitoring functionality
Know How
documentation
Defect Classification & Corrective Actions (feed forward & feedback)
Big Data storage for
analysis
Solution
Quality management support
Reduced manual
inspection
, rework and downgradesSupport for quality certification
(ISO/TS16949)Reduced influence of human-factor
Benefits
TPOpt is an important element for the horizontal integration in the Smart
Factory
PRIMETALS TPOpt = Quality Management +Root-Cause Identification +Corrective
Action
Data analysis is combined
with an rule-based expert systemChallenge
Product Genealogy across the entire production chain
30.11.2016
K.Herzog / EA I4.0Slide15
Summary and ConclusionPage 15
Industrie
4.0 Strategy
Industry
4.0 will not be available “off the shelf
”
Digitalization started years ago and will not be finished within a few years
Each
steel plant must
define their own particular implementation strategy
Primetals
Technologies will actively assist plant operators in the digital transformation of their production plants with portfolio elements and
services
Primetals
Technologies supports
Developments in all directions: Quality, Productivity, Flexibility
Industry 4.0 Readiness
Immediate
customer value
Implementation step-by-step
, e.g. in Modernization
Projects
30.11.2016
K.Herzog / EA I4.0Slide16
30.11.2016K.Herzog / EA I4.0
Page 16Slide17
Contact
30.11.2016
K.Herzog / EA I4.0
Page
17
Kurt Herzog
Head of
Industrie
4.0
Primetals Technologies Austria GmbH
Turmstrasse
44
4031 Linz
Austria
T
+43 (732) 6592-6781
M +43 (664) 6151208
kurt.herzog@primetals.com
primetals.com