Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 1 Стратегия Ядро Бизнес Процессов Самый большой

© PSI BT GmbH 2007Slide 1

Стратегия

ЯдроБизнес Процессов

Самый большой в своей нише

МеждународноеПрисутствие


От руды до готовой продукции, от заказа до отгрузки

Интеграция, Оптимизация Управление Производством

PSIin

tegr

atio

n


PSImetals

Упростите свои IT проблемы

ERP (SAP)

SAP NetWeaver

© PSI BT GmbH 2007Slide 4Home - Index - We dedicate our self to the best customer solution and his success

Integrated Production Management with PSImetals

SAP

L2’sSMP

L2’sHRM

L2’sCRMSY CY

Planning

Warehouse& TransportMgmt.

ProductionExecution

PSIm

etal

s

%Factory Model

PSIintegration

PSIintegration


PSImetals: IT-Решения для Металлургии

Примеры внедрения


ThyssenKrupp Steel today

Five locations operate twelve different MES.

History: Different companies has been mergedIndividual development of MES Software for

the specific requirements of each plantMost 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 plantsHigh system administration costs

123

54

8

67

910

Duisburg

Bochum

Dortmund

Siegerland

1112

Finnentrop


PSImetalssystems

PSImetals Systems at the Salzgitter GroupВыплавка

чугуна Сталеплавильный цех Производство продукции из стали

Выплавка Разливка Горячая прокатка

Холодная прокатка

Окончательная обработкаДоменные печи

Управление процессом на 3 доменных печах Планирование и диспетчеризация

Система организации производства

Автоматизация МНЛЗ

Интегрированная система управления складами и

транспортными потоками

Перспективное и оперативное управление


Система организации производства / Оптимизация раскроя (пореза)





SzFG:Production Equipment and Facilities

01 2 Coke oven batteries, 108 coke ovens, 46,0 m3 each02 Sintering plant – 180 m2

03 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


ThyssenKrupp Nirosta GmbH PSImetals PES for 3 stainless steel CRM

The situation:Old mainframe system, high maintenance costSystem structure do not support Business processesDifferent solution per plant

The Aims:Overall Production Execution System for the entire enterprise of ThyssenKrupp NirostaState 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 KrefeldPlant Krefeld

Plant BenrathPlant Benrath

Plant DillenburgPlant Dillenburg


ThyssenKrupp Electrical Steel PSImetals PES/APS/ALS для 2 заводов

Plant BochumPlant Bochum

Plant GelsenkirchenPlant Gelsenkirchen

Ситуация:Много различных, самостоятельно разработанных системВысокая стоимость обслуживания и поддержки

Цели:Высокая степень интеграции с SAP Технический и финансовый контроль Планирование заказов, планирование на цеховом уровне


Annealing, Insulating linesPickling line, Rolling stands

Cold rolled Coil

(Semi)

Package

(Finished)

Stichplan-

rechner KWR 1

Bandin-spektion Beize

Loch-suchger.UWA

1/3

Band-profil-

rechner KWR 3

Loch-such-gerät EBR

Loch-sucher DO 5, 6

Loch-sucher DO 4

Band-profil DO 5

Ober-flächen-inspek. DO 5, 6

Schichtdickenmessg.

ISA

Mech. Meßpl. DO 4-6 Dehng.

Magn. Meßpl.DO 4-6

Adjustage

Opt.-rechner

HGL

pickling cold rolling annealing coating slitting Adjusting andpackaging

Prematerial

(Raw)

PLSDOfen

BZ KWR, UWA EBR HGL DO ISAKWN LZ EBZ

batch annealing

LagerRechnerH10,H12

Messerbaukarte

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

ThyssenKrupp Electrical Steel After: PSImetals PES at EBG


PSImetals: IT-Решения для Металлургии

Benefits


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 inventoryThe whole central planning and supply chain management is handled by just 8 people

Home - Index - PSImetals – Benefits by the example of Arcelor EKO Stahl


EKO Stahl: Plant wide Production Planning and Control

Targets achievedCreation of a complete production planning, guaranteeing total planning and fulfilment of all production ordersThe 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

scheduleExecution

All orders, partial orders, material stocks and production plants were fully integratedThe new production planning covers all various time schedules for planning and control simultaneouslyProduction planning integration into the underlying systems is true to time. Therefore, quick and accurate reactions to changes in day to day business are guaranteed


V4V3V2V1

V8V7V6V5

V74V73V72V71…

CC1Seq 4711

Heat x

Heat 2

Heat 1

RF1 RF2 RF3

V 70

V 170

V 71

V 171

V 72

V 3

V 103

V 1

V 101

V 2

V 102 …P

4P 3P 2P 1

HRM Seq 3423

P1 P2P3

V101V1V102 ?……

V2 V103

Scenario Mixed Charging (1)

V104V103V102V101

V108V107V106V105

V174V173V172V171…

CC2Seq 4712

Heat x

Heat 2

Heat 1

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

P4


PSImetals APS: Order combination

Home - Index - PSImetals APS – Material allocation

New combination orderin PSImetals

PO Routing

Rolling

Rolling

Skinpass

Skinpass

Cutting

Cutting

Finishing

Slitting

Packing

Rolling

Skinpass

Cutting

Packing

Basis production order PO1 from ERP/MES

Basis production order PO2 from ERP/MES


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-industryFlexible & 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…


PSI‘s Project at Böhler Steelplant, Austria

The Benefits:Overall Production Execution System for the entire conventional and special melting technology as well as powder technologyIntegration of all production stages and all 23 facilities in one systemQuality assurance by standardizing treatment practices for different grade groupsHigh available, flexible and customizable system especially for configuration of new facilities and new characteristicsStandardized data collection and long-term archiving of all production relevant data for easier evaluationStandardized and consistent production reporting and feedback to SAP for all facilitiesReduction of system maintenance due to modern software technology

WITH PSImetals PES.


PSI‘s 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 productExact 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 facilitiesReduction of system maintenance due to modern software technology and less interfaces


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


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 documentationto 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


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

waitingImproved quality

• Reduced coil damage• Fewer „lost“ coils• Better documentation• More timely delivery

Home - Index - PSImetals WTM for TKS, Beeckerwerth: Benefits


PSImetals for Blast Furnaces

The task Balancing of the used materialsConfigurable collection and presentation of high speed process dataDetermination of the filling collection and representation of “burden” changesExecution of the burden calculation, model calculation

BenefitsThree different blast furnaces, one softwareHighly configurable Improvement of the operation by state-of-the-art HMISimplification of the system structureLong term data archives of the process data for a furnace travel (approx. 15 years)

Home - Index - PSImetals for Blast Furnaces

Documents

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 1 Стратегия Ядро Бизнес Процессов Самый большой