simulating metal coil handling

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Decision Science Forum

Multi Ton Sheet Steel Coil

Production Facility

Shipping Simulation By Greg Arneson

November 3, 2011 1 Heavy Metals Industries

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Subject Production Facility

November 3, 2011 Heavy Metals Industries 2

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Introductions


• Greg Arneson

• Started Material Handling Career

– Tasked by HP to migrate surveying Distance Meter technology into material handling position markets • Time of Flight and Phase Shift Distance Meters

• Hi tech part was patents for PID loop that tolerated loss of data

- Started promoting an HP 9825 based solution @ $50K/axis for industrial vehicles (HP 3850)

- Nuclear Refueling Cranes

- Plating Cranes

- AS/RS Cranes

- Bridge Cranes

- Transfer Cars

- Etc.

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Introductions


• 1980’s – HP retired CED, asked and was granted patents for DM PID loops

• Joined Swedish Surveying HP Competitor – Geotronics

• Started Division and co designed TCS 4000 using Geotronics DM, a stand alone integrated single axis positioning system; the next generation was the ICS 5000L

- ICS very successful, able to run cranes up to 1,100 fpm (336 mpm) @ +/- 10mm with high accelerations w perfect triangle and trapezoid motion profiles

- Could now operate with 1/3 to ½ the number of cranes for same production

- Crane OEM’s started standardizing on TCS/ICS and that's when we met AK Steel; Mark Thieman used Arena to simulate 5 large bridge cranes and 15 AGVs - Arena Simulation crane attributes for 50 ton coil cranes:

- 800 fpm (244 mpm) on 100 ft. wide 120 ton bridges with 800 mm/s²

- 600 fpm (183 mpm) on the trolleys with 800 mm/s²

- ICS’s for Bridge Skew Control, Trolley, and Collision Avoidance

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Introductions


• First Experience with Arena and Factory Simulation mid ’90s

• Met customer early 2011 teamed with crane OEM to help procure the crane order

• Once debriefed on issues, informed them of Simulation done at AK Steel with Arena

• Customer immediately wanted simulation. Informed them that

first we needed to produce a Functional Specification to define project and provide data for the formal project quote

• Customer charged me with producing Functional Specification

– First asked Mark Theisan of AK Steel if he could do the job – conflict of interest due to AK Steel competing with customer

• Contacted Simio, they were booked and they provided other companies

– After interviews, GPR selected Systems Navigator, Vincent De Gast and Maarten Kolenbrander

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Simulated Area of Facility


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Project Scope


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Truck Coil Shipping Processes


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Train Coil Shipping Processes


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Simulation SW Architecture


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Specific Queries to be addressed


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Simulation Inputs -1


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Simulation Inputs -2


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Key Performance Indicators - 1


• Throughput per area or process (Coils/hr) – Temper Line

– Galvanize Line 1

– Galvanize Line 2

– Temper Line Storage Area

– Galvanize Line 1 Storage Area


– Temper and Galvanize 1 Wrapping Machines ( Galvanize 2 internal)

– Galvanize Line 2 Walking Beam

– Temper and Galvanize 1 High Speed Coil Transfer Cars

– All Automatic and Manual Cranes

– Overall Area

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• Coil Cycle Times – amount of time each coil is in a specific storage areas and entire area lifetime, measured in hours – Temper Line Storage Area



– New Truck Shipping Bay

– Overall Area

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• Storage Area Utilization – Min/Max/% Full

– Temper Line Storage Area



– Temper Line “end of line”

– Galvanize Line 1 “end of line”

– Galvanize Line 2 “end of line”

– All Shuttles and Walking Beam Storage areas

– New Shipping Bay

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• Mechanical Asset Utilization – Min/Max/% Full

– Automated Cranes

– Manual Cranes

– Wrapping Machines

– High Speed Coil Transfer Shuttles

– Truck Loading Bays

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• Waiting Times (Lost Production) – Min/Max

– Coils • Pick up from end of line

• Pick up for wrapping

• Wrapping machine process

• Pick up from wrapping machine

• Picked up and loaded on High Speed Shuttle

• Picked up by Automatic Crane from Walking Beams

• Picked up by Automatic Crane for Truck or Manual for train level

– Trucks – Access to loading bay + being serviced by automatic crane

running in radio manual control

– (AK Steel and Protec Steel isolate the automatic cranes from manual loading operations with automatic shuttles)

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• Time Synced Data – Value of all KPI’s at regular intervals and production depreciation inputs

– Synced Data • Number of coils in New Automatic Storage Bay

• Number of coils in Temper Line Areas

• Number of coils in Galvanize Line 1 Areas

• Number of coils in Galvanize Line 2 Areas

• Current Production Level for each line

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• Event Logging

– Data • All Maintenance downtime

• All failures

• Coil generation with coil properties

• Coil Destination changes (from Truck to train and train to Truck)

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Macroscopic Results


• Results After Owning Simulation for 4 months

– Invaluable Data for: • Auto Wrapping vs. Manual Wrapping

• When Automatic Storage Bay will need to be increased in size as they move to 3 Million Tons/yr. from current 1.5 Million Tons/yr.

• How failures will cause major production constipation

• How Speed and acceleration of cranes bridge and trolley, especially the hoists, will impact production

• How settling time of unconstrained wire rope grabs impact production with skilled operator vs. electronic skew control vs. mechanical post for skew control

• How partial lifts effect production rates for the new cranes

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Simulation 3D Running Graphics


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Simulation Input Dashboard


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Simulation Output Dashboard


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Conclusions - 1


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Conclusions - 2


TL Bay is reaching its limits

Sensitive to fluctuations (day/night)

High crane utilization in TL Bay and Shipping Bay

High waiting time for wrapper

System not stable. Gradual filling of Shipping Bay

But: Galv 1 & 2 have spare capacity

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Conclusions - 3


Automated Cranes reduce utilization

Lower walking beam waiting times

Lower truck waiting times

System is still filling up

But still spare capacity in GL bays

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Conclusions - 4


Automated truck loading reduces waiting time for truck

Reduces utilization of loading bays

System is getting close to steady state

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Conclusions - 5


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THANK YOU (DANK U WEL) FOR YOUR PARTICIPATION!

Now we will watch the actual Simulation

running for a short time followed by Q & A Please refer to http://www.youtube.com/watch?v=Vv6WtdYzgxs for the movie.

November 3, 2011 Heavy Metals Presentation 31

http://www.youtube.com/watch?v=Vv6WtdYzgxs

http://www.youtube.com/watch?v=Vv6WtdYzgxs

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