1. Decision Science Forum
Multi Ton Sheet Steel Coil
Production Facility
Shipping Simulation
By Greg Arneson
Hosted by:
November 3, 2011 Heavy Metals Industries 1
3. Introductions
• Greg Arneson
• Started Material Handling Career
– Tasked by HP to migrate surveying Distance Meter
technology into material handling position markets
• Time of Flight and Phase Shift Distance Meters
• Hi tech part was patents for PID loop that tolerated loss of data
- Started promoting an HP 9825 based solution @ $50K/axis for
industrial vehicles (HP 3850)
- Nuclear Refueling Cranes
- Plating Cranes
- AS/RS Cranes
- Bridge Cranes
- Transfer Cars
- Etc.
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4. Introductions
• 1980’s – HP retired CED, asked and was granted patents for
DM PID loops
• Joined Swedish Surveying HP Competitor – Geotronics
• Started Division and co designed TCS 4000 using Geotronics
DM, a stand alone integrated single axis positioning system;
the next generation was the ICS 5000L
- ICS very successful, able to run cranes up to 1,100 fpm (336 mpm) @ +/- 10mm
with high accelerations w perfect triangle and trapezoid motion profiles
- Could now operate with 1/3 to ½ the number of cranes for same production
- Crane OEM’s started standardizing on TCS/ICS and that's when we met
AK Steel; Mark Thieman used Arena to simulate 5 large bridge cranes
and 15 AGVs - Arena Simulation crane attributes for 50 ton coil cranes:
- 800 fpm (244 mpm) on 100 ft. wide 120 ton bridges with 800 mm/s²
- 600 fpm (183 mpm) on the trolleys with 800 mm/s²
- ICS’s for Bridge Skew Control, Trolley, and Collision Avoidance
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5. Introductions
• First Experience with Arena and Factory Simulation mid ’90s
• Met customer early 2011 teamed with crane OEM to help
procure the crane order
• Once debriefed on issues, informed them of Simulation done
at AK Steel with Arena
• Customer immediately wanted simulation. Informed them that
first we needed to produce a Functional Specification to define
project and provide data for the formal project quote
• Customer charged me with producing Functional Specification
– First asked Mark Theisan of AK Steel if he could do the job – conflict of
interest due to AK Steel competing with customer
• Contacted Simio, they were booked and they provided other companies
– After interviews, GPR selected Systems Navigator, Vincent De
Gast and Maarten Kolenbrander
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15. Key Performance Indicators - 1
• Throughput per area or process (Coils/hr)
– Temper Line
– Galvanize Line 1
– Galvanize Line 2
– Temper Line Storage Area
– Galvanize Line 1 Storage Area
– Galvanize Line 2 Storage Area
– Temper and Galvanize 1 Wrapping Machines ( Galvanize 2 internal)
– Galvanize Line 2 Walking Beam
– Temper and Galvanize 1 High Speed Coil Transfer Cars
– All Automatic and Manual Cranes
– Overall Area
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16. Key Performance Indicators - 2
• Coil Cycle Times – amount of time each coil is in a specific
storage areas and entire area lifetime, measured in hours
– Temper Line Storage Area
– Galvanize Line 1 Storage Area
– Galvanize Line 2 Storage Area
– New Truck Shipping Bay
– Overall Area
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17. Key Performance Indicators - 3
• Storage Area Utilization – Min/Max/% Full
– Temper Line Storage Area
– Galvanize Line 1 Storage Area
– Galvanize Line 2 Storage Area
– Temper Line “end of line”
– Galvanize Line 1 “end of line”
– Galvanize Line 2 “end of line”
– All Shuttles and Walking Beam Storage areas
– New Shipping Bay
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18. Key Performance Indicators - 4
• Mechanical Asset Utilization – Min/Max/% Full
– Automated Cranes
– Manual Cranes
– Wrapping Machines
– High Speed Coil Transfer Shuttles
– Truck Loading Bays
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19. Key Performance Indicators - 5
• Waiting Times (Lost Production) – Min/Max
– Coils
• Pick up from end of line
• Pick up for wrapping
• Wrapping machine process
• Pick up from wrapping machine
• Picked up and loaded on High Speed Shuttle
• Picked up by Automatic Crane from Walking Beams
• Picked up by Automatic Crane for Truck or Manual for train level
– Trucks – Access to loading bay + being serviced by automatic crane
running in radio manual control
– (AK Steel and Protec Steel isolate the automatic cranes from manual
loading operations with automatic shuttles)
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20. Key Performance Indicators - 6
• Time Synced Data – Value of all KPI’s at regular intervals
and production depreciation inputs
– Synced Data
• Number of coils in New Automatic Storage Bay
• Number of coils in Temper Line Areas
• Number of coils in Galvanize Line 1 Areas
• Number of coils in Galvanize Line 2 Areas
• Current Production Level for each line
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21. Key Performance Indicators - 7
• Event Logging
– Data
• All Maintenance downtime
• All failures
• Coil generation with coil properties
• Coil Destination changes (from Truck to train and train to Truck)
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22. Macroscopic Results
• Results After Owning Simulation for 4 months
– Invaluable Data for:
• Auto Wrapping vs. Manual Wrapping
• When Automatic Storage Bay will need to be increased in size as
they move to 3 Million Tons/yr. from current 1.5 Million Tons/yr.
• How failures will cause major production constipation
• How Speed and acceleration of cranes bridge and trolley,
especially the hoists, will impact production
• How settling time of unconstrained wire rope grabs impact
production with skilled operator vs. electronic skew control vs.
mechanical post for skew control
• How partial lifts effect production rates for the new cranes
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23. Simulation 3D Running Graphics
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26. Conclusions - 1
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27. Conclusions - 2
TL Bay is reaching its limits
Sensitive to fluctuations (day/night)
High crane utilization in TL Bay and Shipping
Bay
High waiting time for wrapper
System not stable. Gradual filling of
Shipping Bay
But: Galv 1 & 2 have spare capacity
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28. Conclusions - 3
Automated Cranes reduce utilization
Lower walking beam waiting times
Lower truck waiting times
System is still filling up
But still spare capacity in GL bays
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29. Conclusions - 4
Automated truck loading reduces waiting
time for truck
Reduces utilization of loading bays
System is getting close to steady state
.
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30. Conclusions - 5
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31. Now we will watch the actual Simulation
running for a short time followed by Q & A
Please refer to http://www.youtube.com/watch?v=Vv6WtdYzgxs for the movie.
THANK YOU (DANK U WEL)
FOR YOUR PARTICIPATION!
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November 3, 2011 Heavy Metals Presentation 31
