title-slidetata steel slide hisarna –process innovationa new process that allows the direct use of...

SlideTata Steel

Title-slide

Industry 4.0 - Prediction is Key

Creating value from digitalized manufacturing

SlideTata Steel 2Intelligent Steel Manufacturing

Hoogovens > Corus > Tata Steel Netherlands

SlideTata Steel

From Tata Group to Tata Steel in IJmuiden

3Intelligent Steel Manufacturing

Tata Group

Communications & IT

Engineering Services Materials Energy Consumer products

Chemicals

Tata Steel Group

Tata Steel

India

Tata Steel

ThailandNatSteel

Asia

Tata Steel

Europe

Strip Products UKStrip Products

Mainland Europe

Long Products

Europe

Tata Steel in IJmuiden


Van grondstoffen naar vloeibaar ijzer


Van vloeibaar ijzer naar vast staal


Walsen

(warm en koud)


Research & Development

SlideTata SteelConfocal images showing unfinished and TM rolled

SlideTata Steel

Empty slide

First results confocal microscopes

image size

700 * 300 µm

SlideTata Steel

Image of coated tinplate showing cross linking in polymer

within the coating layer

Keyence


Duurzaam produceren

SlideTata Steel

HISARNA – Process innovation

A new process that allows the direct use of powdered raw material. No more

coke oven or ore processing required

Iron ore is melted in the

cyclone reactor

Fine coal is injected directly

into the smelter

By using pure oxygen, we get

gases without nitrogen

This makes the combination

with CO2 recovery & storage

(CCS) easier to realise

HISARNA technology will produce 20% less CO2 emission in the future with CCS 80%

iron ore

kolen

coke

Sinter

Pellets

Liquid iron

blast

furnace

Direct use of coal and ore

No coke, sinter and pellet factory required

HISARNA


Aangevoerde ruwe grondstoffen:

Met variërende kwaliteit

IJzererts

Kolen

Klanten vragen:

Gedifferentieerde producten

Gedifferentieerde service

Met de vereiste kwaliteit,

op tijd geleverd en

tegen een concurrende prijs

Smart manufacturing

SlideTata Steel

Welke uitdagingen willen we met digitalisering oplosssen?


€€

€

€

http://www.tatasteelonbrand.com/search/assetdetails.php?pageNum_Recordset1=2&totalRows_Recordset1=46&quicksearch=All+available&words=Any&division=sidemenu.php?divisionid%3D6&divisionid=6&Subject=all&UserField5=&UserField6=&assettype=all&resultsperpage=20&firsttemp=Y&return=search&assetid=239&division=6&search=Y











Sust

ain

abili

ty

Qu

alit

y

Lead

Tim

e

Pro

fita

bili

ty

He

alth

& S

afet

y

Customer orientation

Manufacturing Assets

Manufacturing Technology

Manufacturing supply chain

Areas and impact on Business Drivers

Workforce 4.0

Business Models

Through Process Models

& Integrated Logistics

Process & Control models

Machine Learning & Autonomy

Installation availability models

Predictive maintenance

Leadership profiles

Employee profiles

A lot of models !!!

THE REAL PLANT & THE VIRTUAL PLANT

‘twinning’

Do you

have a

good digital

fundament?

Tata Steel Slide

CURRENT STATE FUTURE STATE

SUPPLY of PRODUCTS

PRODUCTION SYSTEMS

process models

controls

electrical systems

mechanical systems

sensors & actuators

INTEGRATED SUPPLY of

PRODUCTS & SERVICES

PRODUCTION SYSTEMS

process models

controls

electrical systems

mechanical systems

sensors & actuators

Transition

of

Business

Models

Transition

Of

Technology

Stack

Transformation ?

Digitalisation

Connectivity

Data

Anywhere, Anytime

Tata Steel Slide


SUPPLY of PRODUCTS

PRODUCTION SYSTEMS

process models

controls

electrical systems

mechanical systems

sensors & actuators


PRODUCTS & SERVICES

Transition

of

Business

Models

Transition

Of

Technology

Stack

PRODUCTION SYSTEMS

Autonomy & Learning

Integrated

asset& process& quality

control

Collaborative Process

Route

Transformation

SlideTata Steel

Intelligent Steel Manufacturing

Rapid product & process

development by

virtual manufacturing

Connected Sensors

Digitalisation

to

create digital

fundament

Integrated

Process control

Monitoring

Diagnostics

Advanced &

predictive

Condition

monitoring

Robotics

&

Machine

Learning

High degree of autonomy by

automation & self-learning

Product

Inspection

Health

Safety

Environment

Supply Chain & Customer Interaction

A new hierarchy

23

Tata Steel Slide


SUPPLY of PRODUCTS

PRODUCTION SYSTEMS

process models

controls

electrical systems

mechanical systems

sensors & actuators


PRODUCTS & SERVICES

Transition

of

Business

Models

Transition

Of

Technology

Stack

PRODUCTION SYSTEMS

Autonomy & Learning

Integrated


control


Route

Transformation (transversal, OT <> IT)

Tata Steel Slide


SUPPLY of PRODUCTS

PRODUCTION SYSTEMS

process models

controls

electrical systems

mechanical systems

sensors & actuators


PRODUCTS & SERVICES

Transition

of

Business

Models

Transition

Of

Technology

Stack

PRODUCTION SYSTEMS

Autonomy & Learning

Integrated


control


Route

Tata Steel Slide

Connected (data available anywhere, anytime) instrumentation & smart measurements

Diagnostic systems to indicate installation health (condition based & predictive)

Integrate installation condition, process performance and product quality variations into

dashboard based on open systems

Embed advanced analytics and diagnostics in real-time (supervisory) control to enable

sustainable ergonomics, effective and efficient learning and

Integrate product quality variations into process control (also feedforward)

Create dashboards for sustainable ergonomics based on open platforms

Vertical Integration

Tata Steel Slide

Reaction

based onMALFUNCTION

Con

tro

l &

Mo

nito

rin

g

Con

tro

l &

Mo

nito

rin

g

Con

tro

l &

Mo

nito

rin

g

Installation

Sensors

Process

Measurement

s

Product

Inspection

Current situation:

• Silo-ed response to

operational situations

• No decision support

• In-efficient learning

Reaction

based onALARM

TRENDS

Reaction

based onDEVIATION

3 silo’s in Plant operation

Tata Steel Slide

DASHBOARD

Data Integration

Data Synchronisation

Data Visualisation

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tro

l &

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nito

rin

g

Con

tro

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nito

rin

g

Con

tro

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nito

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g

Installation

Sensors

Process

Measurement

s

Product

Inspection

Integration Architecture

1th step:

acquire &

integrate &

synchronise &

visualise relevant data

Tata Steel Slide

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tro

l &

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nito

rin

g

Con

tro

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rin

g

Con

tro

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rin

g

Installation

Sensors

Process

Measurement

s

Product

Inspection

DASHBOARD

Data Integration


Data Visualisation

Bearings Speed Hardness

VibrationVibration

EXAMPLE

Tata Steel Slide

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Con

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Installation

Sensors

Process

Measurement

s

Product

Inspection

DASHBOARD

Data Integration


Data Visualisation


VibrationVibration

30

Product qualityPro

cess

perf

orm

ance

Visualise operational health status

Tata Steel Slide

Con

tro

l &

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nito

rin

g

Con

tro

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rin

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Con

tro

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Installation

Sensors

Process

Measurement

s

Product

Inspection

DASHBOARD

Data Integration


Data Visualisation


VibrationVibration

31

Product qualityPro

cess

perf

orm

ance

Identify source by analysis

Tata Steel Slide

Con

tro

l &

Mo

nito

rin

g

Con

tro

l &

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nito

rin

g

Con

tro

l &

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nito

rin

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Installation

Sensors

Process

Measurement

s

Product

Inspection

DASHBOARD

Data Integration


Data Visualisation


VibrationVibration

32

Product qualityPro

cess

perf

orm

ance

Drill down to root cause

Tata Steel Slide

DASHBOARD

Data Integration


Data Visualisation

Con

tro

l &

Mo

nito

rin

g

Con

tro

l &

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nito

rin

g

Con

tro

l &

Mo

nito

rin

g

Installation

Sensors

Process

Measurements

Product

Inspection

Analysis

Diagnosis

Support

Learning

(operator)

Action

support

solution

(engineer)

Action

(expert)

Action

support

solution

support

solutionreaction

Include intelligence and autonomy

Tata Steel Slide

Integrating predictive asset health data and process data and product

quality data will:

Improve diagnosis of incidents

improved discriminating capabilities by combined data for root cause

analysis

Adequate and quicker reactions/decisions

in (complex) events & situations advice to operators (human-in-the-

loop)

Improved prediction of process-route availability

Value created :

- Maintaining process capabilities with a deteriorating installation

- Reduction of maintenance costs

- Improved OTIF

Vertical Integration

Tata Steel Slide

• ….

FIELD LAB

LIVING LAB

Tata Steel Use Case ()

Supplier Ecosystem

Tata

Digitalised Asset management


Tijmens rules:

Artifical Intelligence will help you when:

1) You want the computer to perform a (repetitive) task

2) There are a lot of examples

3) Each example has a label (action/prediction/class)

4) The samples have complex data as input

And finally about Artificial Intelligence ?

Source:Scyfer

AI does smart things.

But that does not mean it is intelligent!

SlideTata Steel

How about Jobs?

The human task perspective

Dangerous

Dirty

Dull

WORK

solve with

3.0

Complex

Stress full

Error prone

Isolated

WORK

Solve with 4.0

The business task perspective

Plant stability,

performance and

continuous

optimisation

by

analysis, diagnosis,

learning and

simulation

Solve with 4.0

NOW FUTURE

Intelligent Steel Manufacturing 37

SlideTata Steel

How does the working day life look in a digitalized plant ?


Understand process performance & stability

Predict maintenance needs

Analyse and solve disruptions

Analyse performance and improve

Permanent education

Challenges:

1. Autonomous and self-learning processes

2. Expertise and skills in the workforce 4.0

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Do you have any questions?

THINK BIG

START SMART / SMALL

ACCELERATE

Thank you !

Any questions?

title-slidetata steel slide hisarna –process innovationa new process that allows the direct use of...

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