At the 2022 China International Intelligent Industry Expo , which opened on August 22, MCC CCID demonstrated an industrial intelligent manufacturing product - the "Metallurgical Full Process Smart Factory" system solution, and introduced the MCC CCID construction A full-process digital steel plant based on a unified industrial Internet platform - Shandong Yongfeng Lingang Smart Factory.
As the first single-platform, full-process smart factory in the global steel industry, Yongfeng Lingang Smart Factory combines "lean" and "smart" genes, allowing the entire plant's production data to gather on the same platform, setting a good example for high-quality transformation and upgrading of the steel industry. It has set a new benchmark and once again demonstrated MCC CCID's leading position in the field of intelligent manufacturing. Up to now, the first phase of Yongfeng Lingang Intelligent Factory has accumulated more than 1,800 industrial models and functional modules online. The company’s cost per ton of steel has dropped by more than 100 yuan compared with the same caliber at the headquarters, and the per capita steel output exceeds 1,500 tons per year.
Yongfeng Lingang Steel Base Intelligent Control Center
Since the world's first steel intelligent centralized control center built in 2018 was put into operation in Baowu Shaogang, China, MCC Saidi has continued to make efforts on the intelligent manufacturing track to promote China's steel industry. A new era of full-process intelligent manufacturing.
enables borderless collaboration between processes and departments
The traditional ISA95 five-level information architecture has the problems of vertical data attenuation and horizontal data islands , resulting in low collaboration efficiency. The "Water and Earth Cloud" industrial Internet platform independently developed by MCC CCID breaks the traditional information architecture and adopts a flat system architecture with independent intellectual property rights, allowing the unified industrial Internet platform that goes deep into the control layer to directly host various intelligent applications. This can efficiently collect and process massive data, allowing the data to exert its due value.
If in a five-level information architecture, information must be transmitted layer by layer to reach the "intelligent brain" of data applications, then the "Shuituyun" industrial Internet platform is like a data "neural network" extending in all directions, supporting the production of the entire factory. Applications are rooted down to the basic automation level to achieve data access and comprehensive management of the entire process, entire process, and all elements.
In the Yongfeng Lingang smart factory project, the entire steel production process and full control business are carried on a unified industrial Internet platform. The platform has access to more than 30,000 process equipment and more than 500,000 points of real-time data. Since its launch, a total of 35 billion pieces of data have been collected and stored. The platform opens up data transmission links vertically and connects various production processes and management departments horizontally. It opens the "black box" of the production process, realizes digital and transparent production, and enables borderless collaboration between processes and departments.
Yongfeng Lingang Steel Base Intelligent Control Center
makes all aspects of control and management become a unified whole
from Shaogang 's first Tiexian smart centralized control center, China Baowu Eighth Steel's first hot-rolled steel coil warehouse smart heavy-load warehousing system, and then China Baowu Zhanshan Iron and Steel's first smart raw material yard and the first UAV hot metal transportation system , the first factory-wide smart water control center, MCC Saidi continues to connect the dots in the process of promoting smart steel manufacturing. Today, the Yongfeng Lingang smart factory project once again creates a new model for the intelligence and digitalization of China's steel industry with full-process smart manufacturing based on a unified platform.
This project has built a system architecture of "Industrial Internet Platform + Intelligent Management and Control Integration, Iron Zone Integration, and Steel Rolling Integration", so that the entire production process can not only perform its own duties according to the characteristics of the unit, but also achieve unification throughout the entire plant. Scheduling. In this project, MCC Saidi developed intelligent application apps in 12 categories including production, equipment, energy, logistics, and safety and environmental protection. It is equipped with more than 1,800 industrial models and intelligent applications to support steel production from raw materials to factory, inventory, and processing. Digital support is provided in every link from the finished product to the factory, making all aspects of control and management a unified whole, realizing digital scheduling of the whole process and efficient collaboration at all levels, which greatly promotes cost reduction and efficiency improvement for enterprises.
Take temperature control as an example. Accurate and meticulous temperature control is the basis for stable steel production, and it is also one of the important starting points for improving product quality and profitability.The integrated management and control system configured in this project can track the material temperature of various processes such as blast furnace molten iron, molten steel making, tapping, post-furnace, refining in-station, and refining out-station in real time, and predict the target temperature based on the model to provide guidance for the molten iron. Provide guidance on operations such as refining, heating and temperature rise. Full-process control of factors such as rhythm and temperature enables efficient collaboration between process interfaces. Since the launch of the integrated management and control system, the company's refining power consumption has been reduced by 2 kilowatt hours per ton of steel, and the average production cycle of the converter and continuous casting has been reduced by 1 minute and 40 seconds and 3 minutes and 2 seconds respectively.
Use data to promote lean improvement for all employees
" Lean " has always been the key word for Yongfeng's development. After going through the historical period of lean foundation and lean operation, and entering the digital era, Yongfeng accelerated the transformation of momentum and joined hands with MCC CCID to open a new stage of lean intelligence.
The intelligent operation of the whole process not only improves the automation level of production at the operational level, but also provides large-scale data assets for unified management, control and collaborative linkage of the entire factory, opening up a new space for better realizing lean production . Through the window of data, every employee can use data to move towards lean improvement goals.
Traditional KPI (Key Performance Indicator) management can often only be controlled to the company level, factory level, and department level. The indicator data are all offline statistics and post-measurement. There are problems with indicators lagging behind and not being detailed enough. In the KPI dashboard created by MCC Saidi for Yongfeng, the indicators are broken down step by step from the overview of the whole factory, from the operation area, process, production line to the details of each team. This KPI management system is configured with a total of more than 600 performance indicators . These indicators are the results of real-time calculation, real-time acquisition, and real-time update, providing accurate and transparent data support for enterprise production decisions. This is a concentrated expression of the concept of lean improvement for all employees in the context of big data in smart factories. Every employee can locate problems in the data and use the data to make improvements. Through continuous lean improvement, we pursue ultimate cost optimization.
From the intelligent manufacturing of a single system unit to the creation of a full-process intelligent factory, MCC CCID has achieved many industry firsts in China and even the world's firsts with its leading intelligent manufacturing solutions, realizing the transformation of steel production from experience-driven to digital and intelligent. The transformation driven by industrialization has achieved remarkable results in reducing costs, increasing efficiency, lean production, improving labor productivity, and achieving intrinsic safety. It has vigorously promoted the intelligent transformation of the steel industry's production methods and reflected the state-owned technology enterprises' efforts to promote industrial transformation and upgrading. Take responsibility.
Based on the new era, MCC CCID will continue to implement the innovation-driven strategy, solidly promote the deep integration of intelligent big data and the real economy, and use new methods and new models to continue to create new value for the high-quality development of the steel industry.
author | reporter Tao Haiyin correspondent Zhou Xun
