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Concept of Industry 4.0 for the Metals Concept of Industry 4.0 for the Metals

Concept of Industry 4.0 for the Metals - PowerPoint Presentation

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Concept of Industry 4.0 for the Metals - PPT Presentation

Industrie Třinec 30 Nov 2016 Restricted Primetals Technologies 2015 All rights reserved primetalscom Digitalization is driven by new customer requirements and ID: 547216

page herzog data 2016 herzog page 2016 data plant technologies steel quality production system tracking maintenance expert primetals metals process customer automation

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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