MES

MANUFACTURING EXECUTION SYSTEMS

One complete, fully integrated system, from customer orders
to the delivery of products, tracking and controlling:

Material used, plant/process performance, asset usage,
product quality and cost ($/Ton) and customer requirements.

PRODUCTION CONTROL MODULES

PRODUCTION PLANNING

Create Shop Orders from one or more Customer Orders that are optimum for production and determine when they should be produced to maximizes the use of the production capacity.

BENEFITS

  • Maximize Production Output

  • Meet Customers’ Delivery Requirements

  • Extra: Sets production basis for many areas

PRODUCTION SCHEDULING

Generates a Production Schedule for the Caster/Mill by finding the right combination and sequence of Order.

BENEFITS

  • Maximizes Production Output

  • Optimizes the use (production time) of Furnace-Caster-Mill

  • Maximize Yield

  • Meet Delivery Time

PRODUCTION COORDINATION

Determine in real-time how heats should be paced in the meltshop under the current melt shop conditions, to assure arriving on time at the caster with the least use/loss of energy.

BENEFITS
  • Minimize heats’ energy loss/use

  • Minimize cast sequence breaks

SCRAP CONTROL MODULES

VIU SCRAP BUYING OPTIMIZATION

Help the buyer determine the best scrap mix to buy that will contribute to produce liquid steel at the least cost ($/Ton) and meets the requirements of the Production Plan and inventory levels.

Collect, Validate and Organize data to build Process/Heat/Billet/Slab information to store, publish and distribute it for further analysis.

BENEFITS

  • Production of liquid steel at the estimated least cost with the scrap available from suppliers

COMMODITY INVENTORY SYSTEM

Keeps/Tracks the Inventory of Commodities

BENEFITS

  • Control of the usage of commodities

  • Better management of storage locations

  • Real-Time information (accurate inventory)

  • Better analysis of the quality of commodities per supplier

ONLINE SCRAP RECIPE CALCULATION

Determines the best (least cost liquid steel) Scrap Recipe for each Heat in the Heat Lineup with the scrap available in the Scrap Yard.

  • Savings producing liquid steel ($/Ton)

SCRAP HANDLING SYSTEM

Guide the Scrap Crane Operator to prepare scrap buckets according to the corresponding Scrap Recipe

BENEFITS

  • Better tracking of scrap charged into Heats

  • Better preparation of bucket scrap mix

  • Feedback and alerts about deviations from layer/charge/Heat planned weight

SUPERVISORY CONTROL MODULES

INFORMATION SYSTEM MODULE

Collect, Validate and Organize data to build Process/Heat/Billet/Slab information to store, publish and distribute it for further analysis.

BENEFITS

  • Control of the Process with Standard Practices

  • Savings in time, energy, consumables, overall cost

PRACTICE / MODULES

Guide the Operator through the Melting, Treatment, Casting and Rolling of Heats/Pieces

  • Furnace Melting Control

  • LMF/VD Heat Treatment Control

  • Casting Optimization Functions

  • Mill Setup Functions

BENEFITS

  • Control of the Process with Standard Practices

  • Savings in time, energy, consumables, overall cost

PRODUCT TRACKING

This module keeps track of all products in the Plant (melted, processed, in yards, being bundeled, etc.)

BENEFITS

  • Better Management and Control of Products

  • Better management of billet/slab yards (storage locations)

QUALITY TRACKING

This module keeps track of the quality of all products. It includes:

  • Managing Products’ Spec’s and Practices

  • Collects Quality Test results from devices and Observations from Inspectors

  • Grades (Qualifies) products based on test results and observations

  • Generates Quality Certificates

BENEFITS

  • Better Control of the Quality of Products

ASSET MANAGEMENT MODULES

ASSET LIFE TRACKING MODULE

Track the Life of Assets – keeps an inventory of assets and collects life information as it is in service. Main assets include (but not limited to):

  • Furnace Shells

  • Water Cooled Panels

  • Ladles

  • Tundishes

  • Molds

  • Strand Segments

BENEFITS

  • Get the most (Life) out of the Equipment

  • Minimize unexpected Equipment failures

  • Better management of equipment

  • Real-Time information (accurate inventory)

  • Better analysis of the life and cost of the equipment available

ASSET SCHEDULING MODULE

Schedule the use of Assets needed by the Production Schedule, by analyzing their history (constrains).

BENEFITS

  • Get the most (Life) out of the Equipment

  • Minimize unexpected Equipment failures

MAINTENANCE MANAGEMENT MODULE

Help manage (define, plan, schedule and record) work, assets and material in the Maintenance of Equipment.

BENEFITS

  • Get the most (Life) out of the Equipment

  • Optimum management of Maintenance Work

ROLL SHOP MANAGEMENT SYSTEM

PURPOSE

This system helps manage a Roll Shop. It removes the complexity by collecting and providing accurate and timely information about Arbors, Rings, Assembled and Solid Cast Rolls.

REPORTING MODULES

“PUBLISH” (ON DEMAND OR BY NOTIFICATIONS)

Production and Process Information through:

  • Web Reports

  • Scoreboards

  • Email/Text Messages

  • Mobile Devices, Smartphones and Tablets

  • Interfaces to other systems (SAP, etc.)

BENEFITS

  • Having accurate real-time information

PROCESS INFORMATIONS SYSTEM (L2)

Level 2 ApplicationElectric Arc
Furnace (EAF)		Ladle Furnaces (LF)Vaccum Oxygen Degasser (VOD)
Vaccum Tank Degasser (VTD)		Continuos Caster
Production Schedule••••
Heat Pacing••••
Scrap Charge•
Heat Tracking••••
Strand & Billet Tracking•
Billet Length Calculation•
Delay Logging••••
Event Logging••••
Material Addition••••
Chemistry Handling••••
Alloy Addition Calculation••
Quality Event Tracking••••
Life Data••••
Meltshop Overview••••
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