Development of dynamic simulation model of Cogent Orb Electrical Steels plant. The purpose of the model is to evaluate effect of upgrading critical processing centers. The model is also used to study operational and financial indicators of the plant considering high volatility of processing quality (yield losses, variable non-prime yield, etc.).
Period: February 2017 – February 2018
Industry: Metallurgy
Client / Partner: Tata Steel / Goldratt Research Labs
Project objective
- Estimate economical effect of equipment upgrading and operation improving implementation in the electrical steels plant
- Estimate operational and financial indicators of the plant considering high volatility of processing quality (yield losses, variable non-prime yield, etc.)
The main stages of work and characteristics of the model
- Performing data gathering and transformation
- Development and testing of a simulation model on the AnyLogic platform
- Verification and validation of the simulation model in cooperation with client’s team
- Technical and methodological support of the client’s team at the stage of scenario analysis
Model input data
- Information about main technological processes of rolled steel production
- Physical and chemical characteristics of raw materials
- Performance and schedule of production centers
- Capacity of storage locations of component parts
- Durations of technological operations
- Location of production centers and storage locations on the map of the plant
The main structural elements of the model
- Input data file of scenario in MS Excel format
- Simulation model with interactive presentation
- Data aggregation module that allows to generate MS Excel files with the simulation results
Model output data
- Implementation of the plan of produced products shipment
- Percentage of produced products that meet quality requirements
- Stock movement of work in progress
- Financial indicators considering dynamics of finished products quality
Project result
- Simulation-based tool for evaluation of effect of upgrading critical processing centers and implementation of operation improving
- The model is also used to study operational and financial indicators of the plant considering high volatility of processing quality (yield losses, variable non-prime yield, etc.)