Abinsk Electric Metallurgical Plant has implemented a system for managing and end-to-end control of production assets

2023: Results of the implementation of the management system and end-to-end control of production assets

The Abinsk Electric Metallurgical Plant, together with the Data Center Automatics, under a grant from the Skolkovo Foundation, has introduced a system for managing and end-to-end control of production assets during the production of metallurgical products. An infrastructure was built consisting of fault-tolerant servers, storage systems, backup tools, more than 10 km of fiber optic lines were laid. The Skolkovo Foundation announced this on June 1, 2023.

The total budget of the project exceeded 400 million rubles, of which the amount of the grant within the framework of the "national project Digital Economy of Russia" amounted to more than 194 million rubles. The implementation of the project was financed within the framework of the federal project "Digital Technologies" of the national project "Digital Economy." The Skolkovo Foundation acts as the operator of state support for projects of the first large-scale implementation of Russian solutions in the field of information technology, calculated until 2024.

The purpose of the implemented MES system is: management, dispatching and accounting of production operations, maximum automation of processes, exclusion of the human factor in accounting, formalization of technological routes, ensuring traceability of technology, construction of reports on quality, production, balance sheet reports.

The following functions of the MES system are implemented:

• obtaining regulatory reference information of process routes and process charts from the corporate PDM system;
• automation of interaction with ERP, APS systems, receipt of a portfolio of commercial or production orders, transfer of information on production facts, shipment, warehouse stocks to ERP or APS;
• in-house warehouse accounting, reception, inter-warehouse and in-warehouse movements, writing-off of materials for production, marking, packaging, formation of shipping batches, shipment of finished products;
• operational planning and rescheduling, dispatching, optimizing the load of work centers in a mode close to real time, monitoring the implementation of the production schedule;
• quality control operations and laboratory tests;
• Integration with weight controllers
• obtaining automatically generated downtime start and end times, entering the causes and culprits of downtime, calculating equipment load, generating reporting to analyze key production performance indicators, OEE.

The introduction of a system of management and end-to-end control of production assets allowed:

• combine information systems (IE) of all plant workshops into a single information circuit,
• organize the collection and centralized storage of all process data on the production process,
• Minimize equipment downtime and increase production of high-quality products.

Each unit of production will receive its own unique digital passport.

No one questions the need to digitalize production. Modern production technologies can significantly reduce the costs of the enterprise, improve the quality of products. The Skolkovo Foundation has already supported a number of projects aimed at introducing digital technologies in the industrial sector, including metallurgy. Such support contributes not only to the increase in the efficiency of enterprises that have received grants, but also to the emergence on the market of advanced Russian solutions with the potential for replication and scaling. Such projects close the need for the whole industry, which is most important for us, "said Ekaterina Stolbova, director of the project office of the Digital Economy operator of the Skolkovo Foundation.

The project was based on the DATA-TRACK company's digital platform. "DATA CENTER Automation" It allows you to combine key information enterprise systems into a single object-oriented storage. DATA-TRACK makes it possible to collect, link, analyze data and provide information to functional modules in time using a universal flexible query system. Material flows are associated with information flows to create an objective picture of the production process, so that management and personnel are always available data about how the products were produced and why the deviations occurred.

Thanks to the support of the Skolkovo Foundation and AEMZ, which were not afraid to implement a technically complex large-scale project at their enterprise, we got the opportunity to create a product that can be adapted to the parameters of any production, both discrete and process. The created intersectoral solution is already used in the digitalization of other production companies, - said Roman Uskov, General Director of DATA-CENTER Automation.

The second component of the project was the EXPERT BASE system. It allows a research analyst without an IT specialist to access global production data, build dashboards for their research, generate reports and understand production problems.

In addition to the wide functionality, it is more important for us now than ever that this is a Russian development. According to the results of the project, we can say with confidence that the domestic DATA-TRACK platform can become a worthy basis for the digital transformation of any production enterprise, "said Vladimir Fedotov, General Director of AEMZ.

2019: MES (DCA, PTG). Development and implementation of metal tracking system at newly installed rolling mill 210-2

The project includes the following technologies MES (according to MES-11): DCA (Data Collection/Acquisition) function - collection and, data storage PTG (English Product Tracking and Genealogy) - product tracking and genealogy. Provides the ability to obtain information about the status and location of an order at any time. Status information includes who is performing the task, components, materials, and their suppliers, lot number, serial number, current manufacturing conditions, process disturbance warnings, reprocessing data, and other product-related events. Real-time tracking creates historical data about the progress of production processes. This data ensures the traceability of the components and their use in each final product. The solution is based on the platform. DATA-TRACK

The created production accounting system provided:

• Real-time production data collection.
• Control of metal movement and production processes at production units.
• Filling product passports with technological parameters and events. Provision of product passports with related process information in the form of schedules. Formation of product passports and related process information.
• Transfer of information on production tasks to APCS, identification of performance of production tasks.
• Control and operating time of roll tools.