Long Rolling Process Expert

The Long Rolling Process Expert is a Level 2 modular process automation for long rolling mills designed to support the production management process. Seamlessly integrated into long rolling automation concepts, the Long Rolling Process Expert automation system delivers valuable information using recorded production data monitored and collected from both the basic automation system (Level 1) and/or Production Management System (Level 3). By integrating comprehensive production planning, execution monitoring, and performance analysis data, the LR Process Expert facilitates easy assessment and optimization of the mill's performance.

The Long Rolling Process Expert automation system addresses the growing need for flexibility and efficiency in long rolling mills. It ensures that steel producers can respond quickly to new customer demands for innovative products. Reliable production data and comprehensive reports on production efficiency, equipment utilization, and downtimes are critical for achieving these goals. This adaptable and modular solution offers a wide range of functionalities for managing orders, assets, and process quality.

The system is composed of various modules that can be tailored to specific requirements. The order processing module manages work orders, allowing operators to add, remove, or adjust orders within the production schedule. It supports functionalities such as rejecting raw materials before furnace charging and managing production timelines. The production module ensures proper handling of work orders and tracks the execution of production plans, while the production sequence feature enhances flexibility and productivity by enabling operators to manage production plans effectively.

The rolling module facilitates the creation of rolling campaigns and time slots for products. It supports calculations for production throughput time, changeover time, and roll limits per profile, optimizing rolling campaigns. Material tracking ensures seamless and reliable information flow about all materials, increasing operator awareness of the production process. The measured values archive records material-related measurements, offering a detailed production overview. Shift management organizes shifts and staff teams working at the rolling line, while the delays module detects and records downtimes, providing tools for root cause analysis to reduce unplanned stoppages.

The data and setup module manages data storage and retrieval, enabling long-term analysis and reporting. It includes Level 1 setup for specific stands and products, ensuring precise control over production parameters. The reports module delivers production reports that help optimize processes and achieve overall quality and efficiency. Moreover, the standard set of modules can be expanded with optional features to enhance the evaluation and monitoring of reheating processes, product quality, roll shop inventory, maintenance history, and scheduling.

Benefits of the Long Rolling Process Expert Automation System

• Increased product quality: improves product quality through detailed analysis of rolling process data, ensuring consistent and high-standard output.
• Maximized productivity: minimizes unplanned downtimes with advanced tools for root cause analysis, ensuring higher productivity and smoother operations.
• Digital transformation for long rolling mills: facilitates the expansion and modernization of long rolling mills with advanced digital solutions for seamless automation and data-driven operations.
• Optimized production planning: enhances production planning by improving order management and reducing downtime, ensuring efficient and timely operations.
• Enhanced mill performance: boosts mill performance with reliable material tracking and real-time process monitoring for improved operational visibility.
• Sustainable efficiency and reporting: supports long-term efficiency with customized reports and data analysis, optimizing processes and maintaining quality standards.