Case Study Holistic Overview, Local Decision
PSImetals at SSAB Mobile, USA.
Since 2012, PSImetals has been in use as production management solution at SSAB Mobile (USA), a successful implementation in cooperation between PSI and SSAB IT. Increasing complexity of process demands and the requirement for a holistic planning solution were primary drivers for the system installation. Additionally, PSImetals provides the flexibility and decision support to react manually or automatically to events in the production process.
SSAB Mobile, a mini-mill in Alabama, implemented PSImetals to enhance production planning and process management. The facility includes an Electric Arc Furnace (EAF), Ladle Metallurgy Furnace (LMF), vacuum degasser, continuous slab caster, and combination rolling mill.
PSImetals was implemented to improve production planning as well as quality control, and to ensure seamless integration with existing systems.
Challenges
- Before implementing PSImetals, the SSAB Mobile facility lacked the tools to provide a holistic plant-view combined with detailed line planning.
- The addition of new production lines increased the complexity of the production flow.
- There was a need for better visibility of plant-wide scheduling, the capability to balance line capacities, and the power to create detailed line schedules in consideration of the special requirements of each individual production line.
The solutions approach
PSI implemented a comprehensive suite of solutions to address these challenges, some highlights are:
- PSImetals Order Dressing manages customer orders and prepares them for production by elaborating the specific requirements and schedules.
- PSImetals Order Scheduler provides a holistic view of all the production lines. It allows the user to define campaigns on each individual production line while having the resolution to see individual orders and the planned production dates of material assigned to that order.
- PSImetals Line Scheduler allows the user to define parameters and patterns specific to a production line in order to optimally sequence individual material according to those configurations.
- PSImetals Plate Combiner considers the order book together with the production and quality requirements to engineer slabs optimised for slab size.
Project results
- Improved visibility and control over production schedules, enabling better planning and execution.
- Minimized disruptions and ensured smooth production flows through real-time monitoring and adjustments.
- Enabled quick adjustments based on data, improving responsiveness to production events.
- Positive feedback from users on the system's ease of use and effectiveness, with improved capabilities for adjustments.
Conclusion and next steps
The implementation of PSImetals at SSAB Mobile has significantly enhanced production planning, process control, and responsiveness. The collaboration between PSI Metals and SSAB IT has delivered a robust and flexible production management system that meets the complex needs of the facility.
Moving forward, the project teams are preparing to integrate new production lines and enhance existing functionalities, ensuring the system continues to support SSAB's evolving production requirements and maintains their competitive edge in the steel manufacturing industry.
