Essar Steel
The second largest private sector steel producer in India has an integrated steel complex at Hazira, Gujarat. Plant comprises Hot Briquette Iron (HBI) - Electric Arc Furnaces (EAF) - Continuous Caster (CC) - Hot Strip Mill (HSM) route to strip making. The plant is capable of manufacturing high value added non-commercial flat products. With regard to its product quality and specifications, the plant offers tremendous flexibility in charge mix, lot size and product mix / range. Operations are highly automated to improve operational efficiency and productivity. It has high level of automation for both process and business applications. It has a state of art hot rolled coil (HRC) plant with a capacity of 2MMPTA. It is the only mill in India capable of rolling up to 2000-mm wide coils.
Business Challenges
- High Volume and a large variety of product types.
- Changing market demand and prices required plant management to change product mix and schedule in near real time to improve profitablity
- Automation and technology at different levels was a major challenge. Technology was sourced from various suppliers globally resulting in data islanding.
Solution Offered
- Solution as a step towards establishing an integrated real time information system on the plant floor using Windows platform.
- Solution to Integrate with wide variety of Process Controllers like Cegelac, GeFanuc Honeywell, Siemens, Allen-Bradley, L&T and Siemens was offered and technology was brought on a single unified platform.
- Information was logged without any manual interventions and errors.
- Timely corrective actions were ensured and much needed co-ordination between various departments was achieved.
- Satisfied by the performance and support by KLG, Essar has offered a MES (Manufacturing Execution System) system study and prototype project for material and ladle tracking in Ladle Furnace, VD& Ferro Alloy Store Area.
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