optiMize Plant Wide Automatic Process & Production Diagnostics - PowerPoint PPT Presentation

optiMize – Plant Wide Automatic Process & Production Diagnostics Hot Cold Foil Levelling Slitting Coating Casting Heating Testing Casting Automatic tracking of material and machine performance through the whole process Finishing Benefits  Automatic detailed analysis of EVERY slab or coil  Robust interface to machine data logging systems  Tracking of material throughout the process  Detection of network issues and allowing checks and cross checks at each stage of automatic recovery System Automatic process using one dedicated system Management Diagnostics  Secure long term data storage in  Rapid automatic detection of process faults and database identification of the root causes  Extensive system configuration  Early detection of quality failures and tools performance degradation  Better use of valued process engineering resources Detailed Production Analysis Reporting  Detailed and flexible tools to view  Automated communication with production & and analyse process data for process engineers via emails individual slabs/coils or large groups  Powerful search and filter features Custom Dashboards  Automatic web based production reporting  Dedicated analysis tools for key for production and process engineers process variables like profile, gauge, flatness, coating, temperature and elongation  Machine type specific analysis for  Flexible web based dashboard system for custom casters, furnaces & reversing mills reports presentable on all platforms  Mill dynamics analysis  Live streamed process and production data as well as  User interfaces to configure custom machine status alarms and calculations  Scheduled emails with links & attached PDF report

optiMize - Plant Wide Automatic Diagnostic System

optiMize – Objective  The optiMize system provides automated analysis and diagnostic facilities plant wide, from casting, pre-heating, hot rolling, cold rolling through to finishing processes like edge trimmers, slitters and coating lines, delivering clear feedback to machine operators & supervisors, production & process engineers  optiMize system provides:  Automatic detailed analysis of EVERY slab or coil processed in the machines connected to the system  Tracking of material throughout the process allowing checks and cross checks at each stage of process using one dedicated system  Rapid automatic detection of process faults and identification of the root causes  Early detection of quality failures and performance degradation  Automated communication with process engineers and production management via email  Extensive graphical tools for process and production engineers and managers to assist in diagnosing the fault conditions quickly  Automatic reporting (shift, day, weekly) to production and process engineers via email containing links to web based reports  Automatic feedback to key performance indicators to L3 production systems (SAP etc.)  Better use of valued process engineering resources The purpose is to generate valuable information out of data!

optiMize – System Overview  ONE solid data tracking & automatic diagnostic system for ALL machines in the plant Core System Configuration Multi Machine Configuration Customer (IT Room) optiMize Server (IT Room) optiMizeClient & optiMize WebReport Users User: optiMize Server (IT Room): * optiMize Client * optiMize Database (MySQL) * optiMize WebReports * optiMize System Manager * optiMize Dashboards optiMize System Manager * optiMize Diagnostics Plant Network * optiMize Web Reports (Web server) * optiMize Dashboards (Web Server) * optiMize Signal Configuration * optiMize Client Switch Switch Switch Switch Switch Switch Switch Switch Plant Network VLAN VLAN VLAN VLAN VLAN VLAN VLAN VLAN Firewall Annealing Casting Hot Mill Cold Mill Leveller Slitter HOM Pre-Heat Furnaces Data Logging Data Logging Data Logging Data Logging Data Logging Furnace Furnace Data Logging Data Logging Data Logging Machine Network optiMize Machine Manager Data Logging PC: * optiMize Machine Manager * optiMize Live Server * optiMize Signal Configuration

optiMize – Core Applications Data Visualisation optiMize Client optiMize Dashboards optiMize Production Reports Data Storage optiMize Database Automatic Process & Production Diagnostics optiMize Diagnostics System Management optiMize Live Server optiMize Machine Manager optiMize System Manager optiMize Signal Configuration

optiMize – Plant Integration  The optiMize system can be integrated into a plants production planning system and provide key processes indicators used by the production planning system to validate pieces or coils for further processing. Production Planning (ERP) MES (L2) Control System Data Logging

System Management

optiMize – System Management: Diagnostics Control  optiMize System Manager application is controlling the automatic diagnostics for all connected machines  Robust communication between optiMize applications and machine data logging including automatic recovery from network failures User: optiMize Server (IT Room): * optiMize Client * optiMize Database (MySQL) * optiMize WebReports * optiMize System Manager * optiMize Dashboards * optiMize Diagnostics * optiMize Web Reports (Web server) * optiMize Dashboards (Web Server) * optiMize Signal Configuration * optiMize Client optiMize System Manager Plant Network Watch dog Hand shake Firewall Machine Network optiMize Machine Manager Data Logging PC: * optiMize Machine Manager * optiMize Live Server * optiMize Signal Configuration

optiMize – System Management: Data Storage Database Data Storage  Centralised storage of automatic diagnostic configuration parameters , alarms limits as well as traces and calculated results for all connected machines  Secure long term data storage using relation database (MySQL)  High lossless data compression for high resolution traces  Database replication available as option  Built-in clean up and table optimisation

optiMize – System Management: System Configuration Signal Configuration Automatic Diagnostics Configuration  Data logging traces as well product and process information (PDI) to be  Parameters and limits controlling the automatic process and used by the optiMize system are configured using a configuration tool production diagnostics are configured using intuitive user interfaces

Automatic Diagnostics - optiMize Diagnostics

optiMize – Automatic Diagnostics Data Generation & Management Database Interface (IN) Data File Interface PDI & Trace Validation Database Management Machine and Instrumentation Dependent Analysis Casters Furnaces Hot Mills Cold Mills Foil Mills Levelling Lines Coating Lines Slitting Lines Casting Furnace Rev. Mill Stat. Auto Slow Down Elongation Coating Gauge DC HOM Temperature Mill Dynamics Flatness Gauge Production T. EMC Profile Component ID Pre Heating Gauge Flatness Annealing Flatness Gauge Gauge Roll Tracking Roll Tracking HGC Analysis HGC Analysis Production Tracking Additional details as example of analysis Material Testing Alarm Generation & Custom Evaluation External/Customer Interface Database Interface (OUT) Report Generation

optiMize – Automatic Diagnostics: Gauge Analysis [Head Length] Detailed Specification Specific Analysis

optiMize – Automatic Diagnostics: Production Tracking Detailed Specification Specific Analysis

optiMize – Automatic Diagnostics: HGC Analysis Detailed Specification Specific Analysis

optiMize – Alarm Generation & Custom Evaluation Alarm Generation Custom Evaluation  Built-in industry standard alarms for key parameters like gauge,  Feature to create custom:  Alarms speed, tension etc. are configured using intuitive user interfaces  Warnings  Email sent to designated individuals  Calculations  Events  Alarm summary in email text for quick alarm review  Basic or complex process and production parameter  Alarm report (pdf) sent with email for quick alarm review evaluations are created using an intuitive user interface  Emails can be sent to designated persons  Results can be viewed and analyse in the optiMize data visualisation tools

Detailed Analysis - optiMize Client