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Quality control
One of the main problems of production of profile pipes is connected with quality control of a profile. As the director of group of the AKRA corporate ratings Maxim Hudalov told TAdviser, the traditional method of quality control assumed selective withdrawal of an element of a profile, its change and already based on these measurements making decision on quality of a profile.
{{the quote|Both the quality of the analysis, and its speed left much to be desired. Today there were IT solutions capable to carry out online the analysis of quality of a profile directly in a production process, - Hudalov.} added }
Advantages of such approach are obvious: the instant analysis of quality of a profile, early detection of possible defects when forming a profile, timely elimination of the reasons of its emergence, constant control of quality of a profile and the notification of the operator on the arisen deviations, are listed by the analyst.
Besides, Hudalov believes, constant control allows to document in details information on a production process and to estimate efficiency of the proposed innovative solutions: profile parameters arrive in the form of the ready file for processing by engineering programs of the customer at once (CAD and other)
Use of technologies of the analysis of Big Data on pipe manufacturing companies allows to analyze behavior models of metals in the course of welding and to control behavior of a weld joint, Hudalov in a conversation with TAdviser told.
 | It allows to reduce costs on defects by production of welded pipes and purification of scale, - he explained. |  |
Transition to the innovation model opens many opportunities for decrease in product cost, increase in its quality and also for the effective organization of production processes, the representative of the United Metallurgical Company (UMC) agrees with the analyst. He also added that information technologies are tools in hands of repair service, services of quality management, and behind it there is a miscalculation of cost efficiency.
Production management
OMK on average implements about 50 IT projects and initiatives annually, the representative of the company told TAdviser. The biggest and important project — creation of a single system of operational production management (MES system).
| | We began to work on it in January of last year, and we will bring a system into operation in one of workshops soon. The first start is planned for April, 2018. All project will take four years. The single platform will allow us to make products, being guided by individual needs of the client and to trace all chain — from a request before shipment. It is one of steps to so-called Real-Time Enterprise, - the metallurgist's representative told. | |
Roman Zaretsky, the Head of Department on information technologies of Chelyabinsk Tube Rolling Plant (ChTPZ), told TAdviser that the company improved a progressive tense and automated business processes exclusively by own efforts. However in 2017 the pipe company developed new IT strategy. Its task - complex business process reengineering of the company at all levels of management and their subsequent automation based on industrial solutions, Zaretsky reported.
On the practice which settled in the industry regarding constructions of a resource management system of the enterprise the company is guided by solutions of SAP company, he added.
The production line of the Zagorsk Pipe Plant (ZPP) is put into operation in November, 2015 therefore already in the "boxed" version of the enterprise it was put many technical solutions directed to increase in efficiency Svyatoslav Gvozdev, the Acting CIO of the plant reported TAdviser. The Smart Plant program acts on the enterprise. It is a complex of IT solutions which main objective is minimization of cost of an end product.
| | If the machine can perform operation with the high level of quality, but not the person – it is already interesting. It allows to redistribute human resources, without spending spare cash for wage fund. And, as a result, not to put them in pipe cost, - Gvozdev explained. | |
Control of repairs
In the field of maintenance and repair of the equipment of OMK uses technologies of Internet of Things, the representative of the company reported. The repair personnel are supplied with mobile devices, on the equipment NFC tags are set.
| | This solution automates process of arrangement of personnel on repair platforms and issue of replaceable tasks. Working plans for employees are right there transferred to mobile devices. After execution of works, repairmen scan the tags set on the checked equipment and put photos of results of a bypass or repair, - the interlocutor in the company told TAdviser. | |
A system is synchronized with ERP that allows to trace and analyze real-time operations. The solution already works in two production workshops, in 2018 the company plans its integration at all production sites.
Control of employees
On ZTZ there is a final stage of integration of a system of a radio communication into the operating telephone network of the company, Svyatoslav Gvozdev told. A system is intended for operational management of personnel on the sections which are not provided with communication, he explained.
| | Also at the plant the possibility of monitoring of location of employees by a triangulation method on base stations with a recording capability of control points of passing, record of negotiations of the employees using corporate mobile communication is implemented, - Gvozdev told. | |
In 2017 on ZTZ the single centralized system of video surveillance was implemented: more than 100 cameras with a possibility of storage of archive to 60 days were mounted. According to Gvozdev, it allowed to test the system of video analytics.
| | She assumes face recognition, control of intersection of lines, the sabotage detector, the detector of fire and smoke, the detector of the left objects, quick search in Active Search archive, a possibility of end-to-end tracking of movement of personnel. These works are taken on perspective, - he explained. | |
Artificial intelligence technologies
Artificial intelligence technologies helped OMK with ServiceDesk development where all appeals of employees to technical support arrive. Together with a small startup the company developed an AI system (Artificial Intelligence, artificial intelligence) — Gog.
| | The company receives 50,000 requests monthly. They come on different channels — phone, the Internet, a corporate portal. Speed of accomplishment of addresses in many respects depends also on that, how correctly and quickly they are routed, i.e. go to profile specialists. After several months of work it became clear that the system of artificial intelligence copes with such work better, than the person, - the representative of OMK told. | |
Gog is analyzed by the text of the letter and makes the decision on the basis of earlier executed addresses. Besides, a system is capable to samoobuchatsya, so, the more in its base of the processed addresses, the it becomes "more smart".
In four months of work of 92% of addresses Gog classified unmistakably, the representative of the company added.
Effective administration
In 2017 ChTPZ started a pilot series of the program of projects on personnel management, payroll, preparation of the consolidated statements according to IFRS and preparation of the management reporting.
| | To speak about results of implementation so far early – transition to commercial operation on a pilot series is planned for the second quarter 2018. Meanwhile, the company already managed to fulfill structure of the project, structure and formats of the project documentation, the organization of management and many other methodological and organizational moments which will not slow down implementation of the subsequent stages of implementation of the program, - Roman Zaretsky told TAdviser. | |
Plans for 2018
OMK in the laboratory mode began to investigate also use of drones. The company is going to apply technologies of throne shooting to monitoring of thermal leaks, status monitoring and fixing of breakdown of service of roofs of buildings and adjacent objects in the territory of the enterprise, the representative of the metallurgist of TAdviser reported.
The technology will allow to detect losses in the online mode, to prevent possible destructions, to predict process of aging of coverings taking into account weather conditions, he explained.
| | One more project is based on use of machine vision and neuronets. It is aimed at determination of grade and a blockage of scrap for steel production. Due to installation of cameras and training of a system using a big array of the existing data, the company is going automatically, to define types of scrap and percent of a blockage without participation of the person, - the interlocutor in OMK told. | |
In 2018 the company will begin to build Data Lake. Experience in the field of use of Big Data showed that just automated data collection is not enough, and it is necessary to create the platform for quick access to them, to provide proper collecting and data storage for researches, the representative of the company added.
In 2018 ChTPZ is going to start the following series of the program: financial accounting, creation of a system of operational production management (the company studies possibilities of world leaders in creation of such systems and we make the choice). An important component of IT strategy of the company is development of the APCS systems, Zaretsky added.
| | ChTPZ signed the strategic agreement with Siemens company for implementation of this project, - he reported. | |
The beginning of works on creation of schedule systems and modeling of activity is planned for 2019 at the metallurgist.
| | The company has an intensive program of projects and there is no time for "swing". Accomplishment of such large-scale reorganization of processes requires harmonious and hard work of department on information technologies and all business divisions, - Zaretsky emphasized. | |
At the end of February, 2018 ZTZ is going to implement the system of fixing of numbers of cars and control of loads with ability to integrate with SAP/MES, Svyatoslav Gvozdev told. "The tender is already held and the agreement is already signed", - he added.
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