Redefining manufacturing execution systems with Mill Pulse®
Mill Pulse®
Why choose
Mill Pulse®?
User Friendly
Designed to simplify operations
Goals Oriented
Encourage your personnel to achieve their goals
Mobile
Responsive web interface runs on all mobile devices
Integrated
Vertically integrated with your process and ERP
Flexible
Adapted to your process
Customizable
Customizable dashboards and KPIs
Get back on the race track with
Mill Pulse®
How much time do you lose in unexpected stops and product changes? Every second counts. Like a Formula 1 driver in the pit stop, a steel mill needs to minimize the time the mill is not producing. Planning, coordination, rapid response, technology, digitalization and most importantly a great team are the ways to acquire a competitive advantage. Mill Pulse® can help you gain critical time, by optimizing the mill setup, minimizing delays and coordinating teams. Designed exclusively for steel mills, the Roll Shop and Mill Setup modules included in the Mill Pulse® Suite are digitalized tools that optimize Rolling Mill pitstops, for example during a product change.
Production management and Scheduling
Digital information that enhances the optimization in production activities, empowering plants to make proper decisions by using accurate real time data from the plant floor.
Russula MES, based on the ISA95 standard according to Manufacturing Enterprise Solutions Association (MESA).
Delivers information that enables optimization in production activities.
Empowers plant manager to take proper decisions by using accurate real time plant floor information.
Allows user to track production from raw material to finished products.
Production Orders management provides the tools to edit, dispatch and monitor different orders.
Delays Tracking
This digitalized tool tracks rolling mill delay events by automatically registering all relevant information in real time; the operator is able to add reasons and observations
for further analysis.
Time is tracked when production is down, allowing users to add relevant info and reasons to describe the situation.
A delay event is triggered when the rolling rate is below the theoretical production rate value; start time and duration of the down time are registered automatically.
Operators can indicate delay reason choosing from a predefined reasons tree.
Mill Pulse® allows users to edit, split, merge and insert the production delays.
All data is available for further analysis.
Alarms & Events
A digital way to visualize and interact with the alarms with advanced features including mobile notifications, maintenance tasks creation, statistics, reporting, and aggregation by areas or priorities.
Provides a way to visualize and interact with the alarms in a much more advanced way than the traditional HMI.
Alarms view is shown on a tree structure including main info, statistics, reporting, and aggregation by areas, groups or by priority levels.
Alarm history is filtered by area, subarea and equipment.
This module is capable to send notifications to mobile devices and generate maintenance tasks workflows.
Statistics and reporting.
Roll Shop
Enables and facilitates all tasks related to workshop activities and management of the consumable parts used by the rolling process through automated data collection.
Manages worskhop activities and consumable parts used by the rolling process.
Coordinates internal workshop activities and external activities for suppliers.
Define, query and manage existing roll stock, guides and consumable parts.
Automatic tracking of rolled tons per equipment.
Historical data of the rolls, guides and consumable parts.
Product and setup log.
Rolls and grooves machining historical records.
Automated collection of data from the PLCs (working hours, rolled tons, etc).
Mill setup
Integrates the rolling process with the workshop activities and historical consumption data (utilization, wear, etc.) of the equipment.
Enables and facilitates all tasks related to the mill equipment setup, linking rolling process and workshop.
Display availability and status of rolls and stands to preview various future scenarios, considering:
- Current rolling mill layout setup,
- Available equipment,
- Available rolls,
- Cost and setup time information.
Focus on minimizing costs, time and efforts.
Work Orders contains a list of activities to be completed before mill setup
Work Orders are created according to a predefined operation template and to previously known state and required future state.
- Current rolling mill layout setup,
- Available equipment,
- Available rolls,
- Cost and setup time information.
Recipes
Enables and facilitates all tasks related to production equipment parameters in a web-based, organized, optimized and digital way.
Enables and facilitates all tasks related to production parameters in a simple, organized, integrated and optimized way.
Browse the list of recipes with tools for sorting, filtering, and searching by user, product or recipe name.
Allow users to create a new recipe from scratch or create a new recipe copying the information from an existing one.
Review the usage log for each recipe with detailed information about when the recipe has been used.
Attach additional information to the recipe (pdf, doc, or excel files).
Recipes are classified by the current status: draft, approved, active, superseded.
Combining efficiency and accuracy
Roll Shop and Mill Setup Benefits
- Preview future production scenarios
- Visibility of available equipment for scheduled production
- Fast and effective decision making with cost and setup-time analysis
- Preventive maintenance is simple and easy
- Taking decisions based on reliable real time data from rolling mill
- Full native integration with Mill Pulse®
- Fast and effective decision making with cost and setup-time analysis, previewing future production scenarios through a user-friendly comparison tool.
- Online addition of workshop information shows availability and status of the assembled stands, rolls, guides, and consumable parts.
- User can rapidly access a status list for all the roll shop activities and available equipment for the scheduled production requirements.
- Preventive maintenance is simplified by making decisions based on the real rolling tons and equipment issues. Maintenance activities can also be previewed through Mill Pulse® warnings and notices about equipment wear life.
- All information related to change in layout of the rolling mill stands is registered in Mill Pulse® database, so the Historic and Traceability data is built from various dimensions, being able to be contextualized to Production Orders, Events, Delays, and other relevant info about production.
- Roll Shop and Mill Setup are fully integrated with Mill Pulse® and are also open to integrate with other systems.
- Human errors are minimized in the Setup process due to e-checks and work orders that are generated automatically. The setup process is supervised and controlled though Mill Pulse®, which minimize human mistakes when preconditions are forgotten to be checked.
- Checklists are fast and easy to complete for the user, some of them are automatically checked within the automation system.
- Mill Pulse® integrates data collection from the automation system (working hours, rolled tons, etc.) and manual data inputted by the operations in the form of checklists, notes and observations. Altogether the data makes up the Mill Setup workflow process, giving supervisor a global panorama of the setup time and enhancing future analysis.
RUSSULA'S
Roll Shop Management
Management of workshop activities, machining historical records for rolls and grooves. and also those related with consumables such as pinch rolls guides, water cooling nozzles, equalization troughs, turn down guides and laying head pipes. Useful life is automatically registered and updated by the rolling process.
- Management of workshop activities and the consumables parts used by the rolling process.
- Coordinates internal workshop activities and also for external suppliers.
- Definition, querying and management of the existing stock of rolls, guides and consumable parts.
- Automatic tracking of rolled tons per equipment.
- Historical data of the rolls, guides and consumables parts.
- Log of products and setups
- Scheduled assembly plan for rolls and consumables.
- Rolls and grooves machining historical records.
- Tracking capability to record rolls lifetime when there are multiple grooves for slitting.
- Automated collection of data from the PLCs (working hours, rolled tons, etc.)
- Tracking of consumables parts as pinch rolls guides, water cooling nozzles, equalization throughs, turn down guides and laying head pipes
- Native integration with the other Mill Pulse® modules.
RUSSULA'S
Mill Setup
Mill Setup harmonizes and facilitates all tasks related to the current mill equipment setup, empowering the plant to make decisions when equipment changes are required by coordinating and integrating the necessary activities for the rolling mill and workshop.
- Mill Setup enables and facilitates all tasks related to the mill equipment setup, linking rolling process and workshop.
- Mill Setup could be requested due to production schedule (business priorities), due to incidentals or due to wear.
- Mill Setup consider management of Work Orders for activities on the roll shop in order to execute a Mill Setup.
- A detailed Checklist is automatically generated with all the activities on the product change.
- Check list helps production staff to verify activities to do, simplifying and minimizing errors during product changes.
- Optimization of the decisions based on availability, setup time and costs.
Finish first with Mill Pulse®
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