PSImetals

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PSIintegration
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ERP (SAP)
PSImetals
SAP NetWeaver
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Integrated Production Management with PSImetals
SAP
PSIintegration
ProductionExecution
Planning
PSImetals
Warehouse TransportMgmt.
PSIintegration
L2sHRM
L2sCRM
CY
L2sSMP
SY
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customer solution and his success
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Summary of PES Functionality
PSImetals PES Production Execution System
1. Master data /objects management
2. Production tracking
3. Quality management
4. Inventory management and dispatch
5. Tools management
6. Production control
7. Data gathering and reporting
8. Interfaces management
Home - Index - Summary of PES Functionality
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Functionality of an integrated Level 3 (MES)
system

• Level 3 Basic system for Production Management
• Production Management is
• Maintaining and Controlling all important objects
  of the real production world
• Planning of production operations
• Execution production operation
• Control and report of production
• Level 3 does integration of all involved systems
• Interface to Level 4
• Interfaces to Level 2 systems
• Interfaces to laboratory systems and other
  quality systems
• Interfaces to weighing systems, PLC (in
  necessary), crane systems

Home - Index - Functionality of an integrated
Level 3 (MES) system
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Production management Maintaining Objects

• Heart of the Production Management Factory
  Model.The Factory Model is the central
  (relational) production database having the
  actual and consistent status of all objects of
  the real production world, which are important
  for the production. The database also has to
  contain basic procedures and rules to guarantee
  the consistency of the objects.

Home - Index - Production management Maintaining
Objects
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Production management Maintaining Objects

• Important Objects for production
• Material (all kind of material Heats, Slabs,
  Blooms, Hot-Strip, Cold-Strip, Sheets, Bar, Wire,
  H-Beams.)
• Production order (derived from customer order
  quantity, amount, product description, quality
  requirements, time-table information)
• Production operation (production plan of the
  production order, description of each production
  step, time-table information)
• Process instruction (detail information for
  production operation, data for Primary data input
  for production lines)
• Production program (program or sequence for each
  production line, technical sequence of the
  material which is planned for this production
  line)
• Rules and Restrictions (technical information
  about rules and restrictions for planning
• Production Lines (actual status of each
  production line, factory calendar, technical
  performance of each line due to material and
  order characteristics)
• Stockyard information (organization of the stock
  yards)

Home - Index - Production management Maintaining
Objects
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Production management Planning of production

• Planning of the production operations
• Time and capacity schedule of the WIP (work in
  progress, Material which is in production status)
• Sequencing of each individual production line,
  sequencing of the combined production lines
  (e.g. direct charging of HRM, combined pickling
  and annealing line , combined pickling and tandem
  line)
• Planning of special aspects in steel industry
  (heat completion, mother slab generation, mother
  coil generation, consideration of the specific
  rules and technical restrictions)

Home - Index - Production management Planning of
production
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Production management Production execution

• Execution of the production operations
• Receiving of the production orders and quality
  master data from ERP
• Giving the production plan (sequences) to the
  production lines
• Prepare and transfer of the Primary data out of
  material information, order information, quality
  information and master data needed by the
  machinery for production
• Registration of the production events, planning
  events, production line status
• Registration of quality results
• Material tracking (material history), Production
  order tracking, Quality tracking, Production plan
  tracking
• Management of material stockTracking of
  material location, transportation management

Home - Index - Production management Production
execution
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Production management Production control

• Evaluation of the production results
• Comparison of nominal and actual data of
  production and quality
• Reporting production and quality events to ERP
  system
• Reporting consumptions and times to ERP system
• Production decision (e.g. repair work)
• Quality decision (e.g. scrap decision,
  re-attachment of material to production order
• Generating shift and daily reports

Home - Index - Production management Production
control
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PSImetals IT-??????? ??? ???????????

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ThyssenKrupp Steel today
Five locations operate twelve different MES.

• History
• Different companies has been merged
• Individual development of MES Software for the
  specific requirements of each plant
• Most systems operate on Tandem Hardware, one
  operates on IBM Mainframe
• Result
• High maintenance costs
• No transparency across the production sites
• No possibility to compare the plants
• High system administration costs

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Duisburg
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3
Bochum
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5
Dortmund
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Siegerland
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Finnentrop
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PSImetals Systems at the Salzgitter Group
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SzFGProduction Equipment and Facilities
01 2 Coke oven batteries, 108 coke ovens,
46,0 m3 each02 Sintering plant 180 m203 3
Blast furnaces, hearth Ø 11,2/10,8 m04 3 x 220 t
LD converters05 Continuous casting machines
2 strands 250 mm thick, 1.100 - 2.000 mm wide
1 strand 250 mm thick, 2.000 - 2.600 mm wide
1 strand 250 mm thick, 850 -2.100 mm wide06
Hot strip mill07 Continuous pickling line and
push-pull pickling line08 Hot strip
cutting line09 Cold rolling mill10 Hot-dip
galvanizing No. 1 and 2 11 Electro-zinc coating
line12 Organic coating No. 1 and 213 Sheet in
coils14 Surface-coated sheet in coils15
Sheets16 Narrow strip, rim material17
Hot-rolled strip
Home - Index - SzFG Production Equipment and
Facilities
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ThyssenKrupp Nirosta GmbH PSImetals PES for 3
stainless steel CRM

• The situation
• Old mainframe system, high maintenance cost
• System structure do not support Business
  processes
• Different solution per plant
• The Aims
• Overall Production Execution System for the
  entire enterprise of ThyssenKrupp Nirosta
• State of the art system solution
• System support for the special requirements of a
  stainless steel production
• Overall standardized Quality Control and
  Reporting

PSImetals APS/ALS PES
Plant Benrath
Plant Krefeld
Plant Dillenburg
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ThyssenKrupp Electrical Steel PSImetals
PES/APS/ALS ??? 2 ???????

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Plant Bochum
Plant Gelsenkirchen
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ThyssenKrupp Electrical Steel After PSImetals
PES at EBG
SAP R/3 (PP)
Shopfloor

• Process data/ error data
• Quality checking
• Production data acquisition
• electronic cold-strip-card
• integration process computer

• Time and capacity scheduling
• Line sequencing
• Material tracking (Coils)
• Production data messages to SAP
• Cutting optimization

Adjustage
Stichplan-rechner KWR 1
Bandin-spektion Beize
Loch-suchger.UWA 1/3
Band-profil-rechner KWR 3
Loch-such-gerät EBR
Loch-sucher DO 4
Schichtdickenmessg. ISA
Mech. Meßpl. DO 4-6 Dehng.
Magn. Meßpl.DO 4-6
Opt.-rechner HGL
PLS DOfen
Lager Rechner H10,H12
Loch-sucher DO 5, 6
Band-profil DO 5
Ober-flächen-inspek. DO 5, 6
Cold rolled Coil (Semi)
Package (Finished)
Prematerial (Raw)
pickling
cold rolling
annealing
BZ
KWR, UWA
EBR
HGL
DO
ISA
KWN
LZ
EBZ
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PSImetals IT-??????? ??? ???????????

• Benefits

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PSImetals APS/ALS Benefits by the example of
Arcelor EKO Stahl

• 90 according to schedule
• Steel making throughput is increased about 15
• Throughput capability of cold-rolled coils is
  increased by about 43
• Reduced coil yard inventory
• The whole central planning and supply chain
  management is handled by just 8 people

Home - Index - PSImetals Benefits by the
example of Arcelor EKO Stahl
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EKO Stahl Plant wide Production Planning and
Control

• Targets achieved
• Creation of a complete production planning,
  guaranteeing total planning and fulfilment of all
  production orders
• The following process optimization was achieved
• reduction of throughput times
• optimization of all stocks
• improvement in plant capacity allocation
• high quality yield
• improvement in meeting the delivery schedule
• Execution
• All orders, partial orders, material stocks and
  production plants were fully integrated
• The new production planning covers all various
  time schedules for planning and control
  simultaneously
• Production planning integration into the
  underlying systems is true to time. Therefore,
  quick and accurate reactions to changes in day to
  day business are guaranteed

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Scenario Mixed Charging (1)
V74
CC1 Seq 4711 Heat x Heat 2 Heat 1
V174
CC2 Seq 4712 Heat x Heat 2 Heat 1
V73
V173
V72

• In the first step a direct charging sequence
  provided by two caster is created
• The slabs will be distributed to two of the
  furnaces

V172


V71
V171
V8
V108
V7
V107
V6
V106
V5
V105
V4
V104
V3
V103
V2
V102
V1
V101


V 1
V 101
V 2
V 102
P 4
V 3
V 103
P 3
P 2
V 70
V 170
V 71
V 171
V 72

P 1
?
V103
V2
V102
V1
V101
P3
P4
P1
P2
RF1
RF2
RF3
HRM Seq 3423
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PSImetals APS Order combination
Basis production order PO1 from ERP/MES
PO Routing
Packing
Rolling
Skinpass
Cutting
Slitting
New combination order in PSImetals
Rolling
Cutting
Skinpass
Skinpass
Rolling
Cutting
Packing
Finishing
Basis production order PO2 from ERP/MES
Home - Index - PSImetals APS Material allocation
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PSImetals PES Achievement

• Increased Throughput
• 1 extra 220t ladle/day, 1,5 2
• Energy Saving
• product reaches each stage with more precise
  timing
• reduced need to reheat ladles (cost leadership)
• Documented Quality
• full documentation on quality of every piece, to
  ISO 9000 standards - a key requirement in the
  automobile-industry
• Flexible Adaptable
• new object-oriented system is very adaptable and
  easy to re-configure
• Easy integration of new aggregates (4th vacuum
  degasser, 3rd casting machine)

Home - Index - PSImetals PES Achievement
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PSIs Project at Böhler Steelplant, Austria

• The Benefits
• Overall Production Execution System for the
  entire conventional and special melting
  technology as well as powder technology
• Integration of all production stages and all 23
  facilities in one system
• Quality assurance by standardizing treatment
  practices for different grade groups
• High available, flexible and customizable system
  especially for configuration of new facilities
  and new characteristics
• Standardized data collection and long-term
  archiving of all production relevant data for
  easier evaluation
• Standardized and consistent production reporting
  and feedback to SAP for all facilities
• Reduction of system maintenance due to modern
  software technology

WITH PSImetals PES.
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PSIs Project at von Moos Steel, Switzerland

• The Benefits
• One overall Production Execution System for the
  entire von Moos Enterprise including all
  production stages from scrap yard to the rolled
  product
• Exact time Scheduling for EAF, 3 LF, 2 VD and CCM
  as well as the crane leads to
• increase of throughput
• avoidance of caster sequence breaks
• interrupts due to availability of the crane
• Energy Consumption Forecast and Control leads to
• exact knowledge about energy demand
• reduced energy costs
• Standardized and consistent production reporting
  and feedback to SAP for all facilities
• Reduction of system maintenance due to modern
  software technology and less interfaces

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PSImetals APS/ALS at Georgsmarienhütte Improved
Handling Capacity ...

• Mill area
• There is now flexibility to adjust campaigns, to
  take account of changing order-book right up to
  time of rolling. Bottle-necks in the mill are
  minimised
• Testing finishing area
• Throughput capacity is significantly increased
  -- thanks to improved HMIs, and to automatic
  allocation of billets to the most appropriate of
  the 3 lines
• Ability to view whole plant
• The entire plant is now viewed as a whole.
  Transit times at interfaces between areas are
  reduced, with benefits in lower inventory, higher
  throughput and precise delivery

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Georgsmarienhütte Some Extra Benefits

• "Just In Time" order planning
• Clients now order smaller batches at greater
  frequency, to reduce their own inventory.
• So the planning system must deal with more
  orders, and smaller quantities per order, just to
  meet the same throughput tonnage.
• In fact, the year 2000 was a record year, with
  clients ordering more than ever before. But the
  new system successfully handled the increased
  loading.
• What is more, the new system consistently
  achieves great improvements in timeliness of
  order completion
• Excellent documentation
• Orders are now processed with clear and
• complete documentation, so that clients
• have the necessary quality documentation
• to meet their requirements
• Fast project start-up
• The project was completed in record time
• just 10 months from order to completion.
• In spite of this, start-up was on time, and
• the new system ran smoothly from the beginning

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PSImetals WTM for TKS, Beeckerwerth Benefits

• TKS plant in Duisburg is a large integrated
  works, including steelmaking, rolling and finish
  processing line (5 million t/annum)
• Reduced Costs
• Increased throughput and reduced delays
• effective increase of 25 in storage space in the
  critical areas
• total inventory is reduced by 80
• significantly fewer handling operations per coil
• Transport trucks now spend 25-30 less time in
  loading, unloading and waiting
• Improved quality
• Reduced coil damage
• Fewer lost coils
• Better documentation
• More timely delivery

Home - Index - PSImetals WTM for TKS,
Beeckerwerth Benefits
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PSImetals for Blast Furnaces

• The task
• Balancing of the used materials
• Configurable collection and presentation of high
  speed process data
• Determination of the filling collection and
  representation of burden changes
• Execution of the burden calculation, model
  calculation
• Benefits
• Three different blast furnaces, one software
• Highly configurable
• Improvement of the operation by state-of-the-art
  HMI
• Simplification of the system structure
• Long term data archives of the process data for a
  furnace travel (approx. 15 years)

Home - Index - PSImetals for Blast Furnaces