MES Implementation In SAIL-Bhilai Steel Plant By Arun Kumar - - PowerPoint PPT Presentation

MES Implementation In SAIL-Bhilai Steel Plant

By

• Arun Kumar
• Chandu Tembhurne
• Tejkaran Singh Hans

• 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

• utput.
• SAP ERP is difficult to configure for flat products

Why MES in BSP?

There is little bit of SAIL in Everybody’s Life

A link between Top floor and Shop floor, a Manufacturing Execution System was implemented at BSP.

Why MES in BSP?

• 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.“

Shop Floor Automation & control Supervisory control MES ERP

Business Process automation Machine automation

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

Plate Production Process

• 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

Pre MES Challenges

There is little bit of SAIL in Everybody’s Life

CTP Production Plan Quality Standard Order Progress Process Automation DAS Resource Management Quality Management Yard Management Product Scheduling & Rescheduling Operating Management DAS Process Automation Process Automation DAS Resource Management Quality Management Yard Management Product Scheduling & Rescheduling Operating Management Resource Management Quality Management Yard Management Product Scheduling & Rescheduling Operating Management SMS2 PM RSM & URM PPC, QM

SMS-II

ERP (SAP)

PM RSM

Sales & Distribute Quality Management PP Order Receipt Quality Design Order Acceptance

Configuration of MES in BSP

< Data Center >

Storage Array BSP Core Switch MES DB Server #1 ((A & P) MES AP Server #1 (A & A) Development Server

SMS2 Client PM Client RSM Client

PC HHT VMT HHT VMT HHT VMT PC PC Data Access Flow MES WEB Server #1 (A & P )

Hardware Configuration of MES

Material & Order Tracking through MES

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

Order Progress Management

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 SMS -2

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

Product Tracking at Plate Mill

• 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

Business Intelligence through MES

• Extension of MES to Newly Inaugurated Universal Rail

Mill in 2017

• ISO 9001:2015 QMS Certification to MES

Important Milestones