optimizing the plants of the future thanks to smart data ... · optimizing the plants of the future...

Steel

June 2017

Yannick LEPRETRE

Fives — Group Chief Innovation and Digital Officeryannick.lepretre@fivesgroup.com

Optimizing the Plants of the Future

thanks to Smart Data & Services

Future Steel Forum

Steel

Fives, an international industrial engineering group

Fives - Future Steel Forum 2

‒ Aerospace

‒ Aluminium

‒ Automotive

‒ Cement

Fives designs and supplies

process equipment and

production lines for the world’s

largest industrial suppliers

‒ Energy

‒ Glass

‒ Logistics

‒ Steel

Steel

Industry of the Future at the heart of Fives activities

Fives - Future steel forum

Digitalisation

of the value

chain

Automation

and robotics

Control and

monitoring

Energy

efficiency and

environment

IoT

CybersecurityAvailability

Handling

Enhancedrobotics

Sensorsnetwork

Non destructive control

Production and storage

Energy recovery

Composites,

and new

materials

Composite

manufacturing

In process

control

Parts assembly

New

manufacturing

technologies

CompositeMetallic 3D

printing

JV with

Michelin

Human in the

factory

Augmentedreality

Cobotics

The Steel division benefits from group

Fives developments in all its activities

Steel

Digital factory – Fives analytics platform

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Data

Acquisition Data

Storage

Data Analytics

Connected Sensors

Smart Gateway

Field Bus

Local

Cloud

AnalyticsPrediction

Data Mining

Machine Learning

WEB

Dashboarding

Configurable

Steel

Digital factory – Fives analytics platform

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Comprehensive Suite for Data Analytics:

— Acquisition Storage Treatments Alerts

— Encrypted / Secured Access and Data Transfer

— Applicable on both new and existing equipment

Steel

New digital business models? Stick to the basics!

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Plant

manager

focus

OEE

Costs

Capability

improvement

Raw material, consumables, …

Energy, fluids, …

Spare parts, services, …

Availability

Efficiency

Quality

Industrialization of new products

Improvement of process

performance

Digital brings new tools to improve

operational excellence in the plants

Steel

Process know-how embedded in quality control software

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— Evaluation of yield improvement: 1.2M profit for a 3% increase

of the prime shipment for galvanizing line 400 000 mt/year

— Monthly licence fee and consulting

EyeronTM Web application, based on data storage and

analysis, for steel quality control to guarantee

quality, time delivery and save costs

Smart line development

Steel 9

Combustion process optimization with Virtuo®

Virtuo®, Furnace Level 2 Thermal Solution

for reheating, treatment and processing lines

Fives - Future Steel Forum

— Maximize production rate with guaranteed quality

— Ease of use with reduced manpower

— Optimize product delivery

— Reduced gas consumption

— Improved yield performance

— Prevention of production losses

— Meet environmental constraints

Gas flow stabilized

on a 450 t/h furnace

at Çolakoğlu

Metalurji - Turkey

Virtuo® benefit for reheat furnaces:

energy savings up to 22%

Steel

Planned

Maintenance

Break

downReactive

Maintenance

What about predictive maintenance?

11

Component health status

Time

Fives - Future Steel Forum

Break

down

Maintain

standard status

Steel

Manage your mill with your finger tip

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TPM

Maintain standard status

OEE / costs / process dashboards

Remote control

and helpdesk

Video feeds

Component Health

check and predictive tools

Periodic recommandations

for optimization

Process optimization

Tools

Make technical

documentation available

On line parts catalogue

Much more …

Steel

Online catalogue for spare parts

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≈ 30 Assembly drawings for a

tube cut-off machine

— Easy identification of the parts

— Direct link to 2D drawings or 3D models

— Click to move to the basket and order

— Risk of misunderstandings and delivery

of wrong parts is almost zero

Old way

Fives way

Steel 14

Predictive maintenance for a tube cut-off machine

Improvement of blade lifetime

Fives - Future Steel Forum

— Optimize broken blade stops

— Increase blade life with adaptive

behavior parameters

— Partnership with Parma University

(sensorless approach and 3D signals

(noise analysis)

→Monitoring of slack belt status

Tension monitoring and dection of the

excessive tension

Steel

Conclusion

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Digital technologies are powerful tools to improve operational efficiency

The key point to make them successfull is to consider them

as tools that support good manufacturing methodologies

Fives’ digital philosophy is to provide a comprehensive

approach of industrial excellence:— Edge equipement technology

— Smart automation and data infrastructure

— Consulting in process and maintenance optimization

— In-house experts and data analytics

— Powerfull softwares

— Hands on ability to firmly root progress in the daily

operations

SteelFives - Future Steel Forum 16

Yannick LEPRETRE

Fives — Group Chief Innovation and Digital Officer

yannick.lepretre@fivesgroup.com

3 rue Drouot

75009 Paris - FRANCE