Industry Prediction is Key
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- Quentin Harmon
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1 Tata Steel Slide Industry Prediction is Key Creating value from digitalized manufacturing
2 Intelligent Steel Manufacturing Tata Steel Slide 2 Hoogovens > Corus > Tata Steel Netherlands
3 Intelligent Steel Manufacturing Tata Steel Slide 3 From Tata Group to Tata Steel in IJmuiden Tata Group Communications & IT Engineering Services Materials Energy Consumer products Chemicals Tata Steel Group Tata Steel India Tata Steel Thailand Tata Steel Europe NatSteel Asia Strip Products UK Strip Products Mainland Europe Long Products Europe Tata Steel in IJmuiden
4 Intelligent Steel Manufacturing Tata Steel Slide 4
5 Intelligent Steel Manufacturing Tata Steel Slide 5
6 Intelligent Steel Manufacturing Tata Steel Slide 6 Van grondstoffen naar vloeibaar ijzer
7 Intelligent Steel Manufacturing Tata Steel Slide 7
8 Intelligent Steel Manufacturing Tata Steel Slide 8 Van vloeibaar ijzer naar vast staal
9 Intelligent Steel Manufacturing Tata Steel Slide 9
10 Intelligent Steel Manufacturing Tata Steel Slide 10 Walsen (warm en koud)
11 Intelligent Steel Manufacturing Tata Steel Slide 11
12 Intelligent Steel Manufacturing Tata Steel Slide 12 Research & Development
13 Tata Steel Confocal images showing unfinished and TM rolled Slide
14 Tata Steel Slide First results confocal microscopes image size 700 * 300 µm
15 Tata Steel Slide Image of coated tinplate showing cross linking in polymer within the coating layer Keyence
16 Intelligent Steel Manufacturing Tata Steel Slide 16 Duurzaam produceren
17 Tata Steel Slide 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 CO 2 recovery & storage (CCS) easier to realise iron ore kolen Sinter Pellets coke Direct use of coal and ore No coke, sinter and pellet factory required blast furnace HISARNA Liquid iron HISARNA technology will produce 20% less CO2 emission in the future with CCS 80%
18 Intelligent Steel Manufacturing Smart manufacturing Tata Steel Slide 18 Klanten vragen: Gedifferentieerde producten Gedifferentieerde service Met de vereiste kwaliteit, op tijd geleverd en tegen een concurrende prijs Aangevoerde ruwe grondstoffen: Met variërende kwaliteit IJzererts Kolen
19 Intelligent Steel Manufacturing Tata Steel Welke uitdagingen willen we met digitalisering oplosssen? Slide 19
20 Sustainability Quality Lead Time Profitability Health & Safety Intelligent Steel Manufacturing Tata Steel Slide 20 Customer orientation Manufacturing supply chain Business Models Through Process Models & Integrated Logistics Manufacturing Technology Manufacturing Assets Process & Control models Machine Learning & Autonomy Installation availability models Predictive maintenance Do you have a good digital fundament? Workforce 4.0 Leadership profiles Employee profiles A lot of models!!! Areas and impact on Business Drivers THE REAL PLANT & THE VIRTUAL PLANT twinning
21 Tata Steel Slide Transformation? CURRENT STATE SUPPLY of PRODUCTS Transition of Business Models FUTURE STATE INTEGRATED SUPPLY of PRODUCTS & SERVICES PRODUCTION SYSTEMS process models controls electrical systems mechanical systems sensors & actuators Transition Of Technology Stack PRODUCTION SYSTEMS process Digitalisation models Connectivity controls electrical Data systems Anywhere, Anytime mechanical systems sensors & actuators
22 Tata Steel Slide Transformation CURRENT STATE SUPPLY of PRODUCTS Transition of Business Models FUTURE STATE INTEGRATED SUPPLY of PRODUCTS & SERVICES PRODUCTION SYSTEMS process models controls electrical systems mechanical systems sensors & actuators Transition Of Technology Stack PRODUCTION SYSTEMS Autonomy & Learning Integrated asset& process& quality control Collaborative Process Route
23 Tata Steel Slide 23 A new hierarchy Intelligent Steel Manufacturing Supply Chain & Customer Interaction High degree of autonomy by automation & self-learning Rapid product & process development by virtual manufacturing Digitalisation to create digital fundament Integrated Process control Diagnostics Advanced & predictive Condition monitoring Robotics & Machine Learning Product Inspection Health Safety Environment Connected Sensors
24 Tata Steel Slide Transformation (transversal, OT <> IT) CURRENT STATE SUPPLY of PRODUCTS Transition of Business Models FUTURE STATE INTEGRATED SUPPLY of PRODUCTS & SERVICES PRODUCTION SYSTEMS process models controls electrical systems mechanical systems sensors & actuators Transition Of Technology Stack PRODUCTION SYSTEMS Autonomy & Learning Integrated asset& process& quality control Collaborative Process Route
25 Tata Steel Slide CURRENT STATE SUPPLY of PRODUCTS Transition of Business Models FUTURE STATE INTEGRATED SUPPLY of PRODUCTS & SERVICES PRODUCTION SYSTEMS process models controls electrical systems mechanical systems sensors & actuators Transition Of Technology Stack PRODUCTION SYSTEMS Autonomy & Learning Integrated asset& process& quality control Collaborative Process Route
26 Tata Steel Slide Vertical Integration 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
27 Control & Control & Control & Tata Steel Slide 3 silo s in Plant operation Reaction based on MALFUNCTION Reaction based on ALARM TRENDS Reaction based on DEVIATION Current situation: Silo-ed response to operational situations No decision support In-efficient learning Installation Sensors Process Measurement s Product Inspection
28 Control & Control & Control & Tata Steel Slide Integration Architecture 1th step: DASHBOARD Data Integration Data Synchronisation Data Visualisation acquire & integrate & synchronise & visualise relevant data Installation Sensors Process Measurement s Product Inspection
29 Control & Control & Control & Tata Steel Slide EXAMPLE DASHBOARD Vibration Data Integration Data Synchronisation Data Visualisation Bearings Speed Hardness Installation Sensors Process Measurement s Product Inspection
30 Control & Control & Control & Process performance Tata Steel Slide Visualise operational health status 30 DASHBOARD Vibration Data Integration Data Synchronisation Data Visualisation Product quality Bearings Speed Hardness Installation Sensors Process Measurement s Product Inspection
31 Control & Control & Control & Process performance Tata Steel Slide Identify source by analysis 31 DASHBOARD Vibration Data Integration Data Synchronisation Data Visualisation Product quality Bearings Speed Hardness Installation Sensors Process Measurement s Product Inspection
32 Control & Control & Control & Process performance Tata Steel Slide Drill down to root cause 32 DASHBOARD Vibration Data Integration Data Synchronisation Data Visualisation Product quality Bearings Speed Hardness Installation Sensors Process Measurement s Product Inspection
33 Control & Control & Control & Tata Steel Slide Include intelligence and autonomy DASHBOARD Data Integration Data Synchronisation Data Visualisation Analysis Diagnosis Support Learning support solution support solution (operator) Action (engineer) Action reaction support solution (expert) Action Installation Sensors Process Measurements Product Inspection
34 Tata Steel Slide Vertical Integration 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-theloop) Improved prediction of process-route availability Value created : - Maintaining process capabilities with a deteriorating installation - Reduction of maintenance costs - Improved OTIF
35 Tata Steel Slide Digitalised Asset management Tata Steel Use Case (). Tata FIELD LAB LIVING LAB Supplier Ecosystem
36 Intelligent Steel Manufacturing Tata Steel Slide 36 And finally about Artificial Intelligence? AI does smart things. But that does not mean it is intelligent! 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 Source:Scyfer
37 Intelligent Steel Manufacturing Tata Steel Slide 37 How about Jobs? Dangerous Dirty Dull WORK solve with 3.0 Complex Stress full Error prone Isolated WORK Solve with 4.0 Plant stability, performance and continuous optimisation by analysis, diagnosis, learning and simulation Solve with 4.0 The human task perspective The business task perspective NOW FUTURE
38 Intelligent Steel Manufacturing Tata Steel Slide 38 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
39 Intelligent Steel Manufacturing Tata Steel Slide 39 THINK BIG START SMART / SMALL ACCELERATE Thank you! Any questions? Do you have any questions?
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