rhythm 2.0 Metal Industry Solution
rhythm 2.0
Metal Industry Solution
rhythm 2.0 Metal solutions are specifically carved out of the Platform and pre-configured for Metal Sector. All metal nuances like specs. and size based Planning, Material Allocation and Execution have been considered. Plant specific schedulers have been configured to meet Heat, Slab, Plate, Hot Strip, Cold Strip, Ingot, Finished Products needs.
Key Modules and Metals Use Cases
- Order Promise - Generates Promise dates against the requested delivery date based on the current Order booking and based on the Plant Capacity. Evaluates technical feasibility of an Order and suggests the Impact of booking an Order on the other Orders.
- Production Planning - Generates End-to-end Production plan from Steel Making to Plate or Hot Strips to Cold Rolled Products in one step. Synchronizes capacities across processes and maximizes Asset utilization while considering the Campaign Requirements.
- Material Allocator - Clubs child items optimally to create optimal parent dimensions and minimizes yield losses. Creates Optimal HR width and thickness from CR specifications, Optimal Mother plate length and width from Child plate specifications and Optimal Slab dimensions from HR Coil and Mother Plate dimensions.
- Production Scheduling - Generates the Loading sequence for all Equipment based on process specific Scheduling rules and ensures minimization of Free Stocks. Key schedulers include Steel Melt Shop Scheduler with Heat Sequencing capability, Plate and Hot Strip Mill Schedulers with Round Building capability and CRM Scheduler.
- MES Production Tracking - Computes & Downloads PDI to Level 2 and Validates PDO results. Enables Manual Production Capturing for each process. Tracks Inventory, Order Progress Status, End-to-end Material Genealogy, Production defects, delays, production losses etc. Enables optimal shop floor decisions in real time & reduction of free inventory.
- MES Quality Tracking - Test management system for tracking chemical, mechanical, physical and surface Properties with ability to capture and validate Test result, track Defects, Sample status etc. Auto suggestion and diversion in case of problems.
Level 5
Level 4
Level 3
Level 2, SCADA, IoT Systems
Metal Flow Example
Some Case Studies
A producer of Steel Slabs, Plates, Coils & Finished Products with over 5 Mio Tons capacity completely automated and optimized Production Planning, Scheduling and Execution to save over USD 10 million annually and Improve Delivery Performance by over 10%.
End to end MES implementation along with other Planning modules to enable a completely automated and optimized Integrated Steel Factory with flat and long products.
