MES Implementation In SAIL-Bhilai Steel Plant By Arun Kumar Chandu Tembhurne Tejkaran Singh Hans
Why MES in BSP? SAP ERP system implemented in BSP on 1 April 2009 ERP system provided enterprise-wide collaboration and real-time reporting capabilities which enabled the Top Management to take better and informed decisions. ERP lacks in managing activities on the shop floor. Is more concerned with the input and output of the production activities rather than the operations that take place on the shop floor to transform the input into the output. SAP ERP is difficult to configure for flat products There is little bit of SAIL in Everybody’s Life
Why MES in BSP? A link between Top floor and Shop floor , a Manufacturing Execution System was implemented at BSP.
Business Process automation Machine automation ERP MES Supervisory control Shop Floor Automation & control Manufacturing Execution Systems (MES) are Computerized systems used in Manufacturing. MES can provide the right information at the right time and show the manufacturing decision maker “how the current conditions on the plant floor can be optimized to improve production output.“
Plate Production Process A Made to Order (MTO) process i.e. each plate is produced according to the requirements and Technical Delivery Conditions (TDC) of a particular order. Various Steps involved in the process before MES are – Order Receipt Order Design Scheduling Production Dispatch
Pre MES Challenges Islands of Information in Different Systems VAX, OPEX,ERP , BTS, LRTS Non Availability of Order Progress information in Real Time Basis Difficulty in managing large number of Sampling Schemes for different Grades and Technical Delivery Conditions(TDC) Difficulty in Product analysis, NCO, defects analysis Inability to perform Reallocation in timely manner Material Tracking on the Shop Floor (PM and SMS2) was poor There is little bit of SAIL in Everybody’s Life
Configuration of MES in BSP Sales & Quality ERP (SAP) PP Distribute Management Quality PPC, QM Standard CTP Production Plan Order Receipt Order Acceptance Quality Design Order Progress SMS2 PM RSM & URM Resource Product Scheduling Resource Product Scheduling Resource Product Scheduling Management & Rescheduling Management & Rescheduling Management & Rescheduling Operating Management Operating Management Operating Management Quality Yard Quality Yard Quality Yard Management Management Management Management Management Management SMS-II PM RSM Process Process Process DAS DAS DAS Automation Automation Automation
Hardware Configuration of MES BSP < Data Center > Core Switch MES MES MES AP DB WEB Server Server Server Development #1 #1 #1 Server (A & A) ((A & P) (A & P ) Storage Array VMT VMT VMT PC HHT PC HHT PC HHT SMS2 Client PM Client RSM Client Data Access Flow
Material & Order Tracking through MES
Order Progress Management
Order Progress Management Better planning and Scheduling of Production Activities Automatic Daily Steel Order (DSO) creation Preventing Over Production or Under Production against any order. Timely Reallocation of Diverted Material to save NCO generation and Handling Faster Dispatch of material to its Destination through allocation Better Decision making at CMO level
Product Tracking at SMS -2
Product Tracking at SMS -2
Product Tracking at SMS -2 Integration with level 2 automation systems to capture process data Raw Material Consumption can now be computed for each and every Heat Processing Cost for various Work Centers computed for each and every heat. Critical resources like Steel Ladle, Convertor Lance etc. are also tracked through MES. Finished/Unfinished stocks of Slab/Bloom on real time basis. Yard Management Module also helps in tracking Slab and Blooms stacked in Yard which is helpful while Dispatch.
Product Tracking at Plate Mill
Product Tracking at Plate Mill Data is captured from more than 25 workstations for each plate. Real time status of Furnaces and Roller table is available Plate Status associated with each and every Plate Reduction in NCO burden through Reallocation the plate to a different compatible order at different stages of Plate Production
Business Intelligence through MES Seamless Integration with SAP ERP through interfaces Various MIS, E-mail, SMS Alerts are generated through MES Costing of individual Heat, Slab or Plates now possible through MES Plate size calculator and Order Minimum Size Calculation for CMO Branches Order Lead time analysis possible through MES
Important Milestones Extension of MES to Newly Inaugurated Universal Rail Mill in 2017 ISO 9001:2015 QMS Certification to MES
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