Influence of the natural aluminium oxide layer on ... - ALU-WEB.DE

Fig. 2: Optimized raw material calculation using a LP solver always considering given restrictions and
optimization targets
loying module which can be used by <strong>the</strong> production
planning, scheduling or execution. For
calculating <strong>the</strong> optimized raw material supply
<strong>the</strong> actual situation, all scheduled batches or
production orders are taking into account.
The calculating is down by feeding a LP (linear
programming) solver. Fig. 2 shows <strong>the</strong> schedule
generation inclusive material supply. In
<strong>the</strong> first stage <strong>the</strong> melting and casting batches
are built up and sequenced for each device.
With <strong>the</strong> second stage <strong>the</strong> material supply for
every scheduled batch is calculated.
Managing energy
The energy costs are getting more and more
into <strong>the</strong> focus. The complexity <strong>of</strong> <strong>the</strong> regionally
different influences and restrictions makes
it difficult to manage. The forecasting and procurement
<strong>of</strong> energy and even <strong>the</strong> reactivity in
adopting <strong>the</strong> production on a short term notice
to a different energy situation are <strong>the</strong> challenges
for <strong>the</strong> future.
PSImetals provides <strong>the</strong> functionality for
consider <strong>the</strong> various aspects <strong>of</strong> increasing
energy efficiency, forecasting and production
control:
Tracking and short term control
• High level <strong>of</strong> transparency in energy
Fig. 3: Energy management to track and control
<strong>the</strong> energy consumption in production
consumption
• Early warning system to avoid violations
<strong>of</strong> contractual limited peak loads
• Predicted overall energy consumption for
operational decision support
Energy consumption in planning
and scheduling
• Energy consumption values – part <strong>of</strong>
production order routings
• Consumption forecast for different
time-frames
• Support for contract negotiation with
energy supplier
Summary
Potential benefits are summarized in <strong>the</strong> following
overview:
Transparency and online material genealogy
• Decrease <strong>of</strong> reaction time and efforts
• Integrated alloying
• Optimized material supply <strong>of</strong> all
scheduled batches
• Decrease in production costs
• Secured alloying process
• Reduced alloying adjustment steps
(~ 1,1 steps in average)
• Support in deviation handling
• Decrease in material costs by over 10%
Fig. 4: Managing <strong>the</strong> load peaks <strong>of</strong> your energy
demand to avoid limit violation costs
MEASURING & CONTROL
• Additional benefits by adopted
procurement strategies
Integrated energy management
• Minimizing energy costs
• Basis for new business model ‘selling
control power’
Next steps
For fur<strong>the</strong>r improvements in adopting <strong>the</strong>
ma<strong>the</strong>matical models to <strong>the</strong> real world ‘Qualicision’
will be used. Qualicision is an extended
fuzzy logic based optimizing module which
leads to more human way <strong>of</strong> decision by recalculating
<strong>the</strong> different parameters <strong>of</strong> <strong>the</strong> linear
programming model. With <strong>the</strong> Qualicision
module shows how this level as a qualitative
decision level will be integrated into <strong>the</strong> system
structure:
About PSI Metals
PSI is <strong>the</strong> leading IT supplier for production
management solutions in <strong>the</strong> metals industry
combining supply chain management,
advanced planning and scheduling, production
execution and logistics optimization.
For more than 40 years, we have been delivering
added-value solutions to maximize <strong>the</strong>
plant performances <strong>of</strong> numerous metals producers
around <strong>the</strong> globe. PSImetals s<strong>of</strong>tware
solutions enable producers <strong>of</strong> <strong>aluminium</strong>,
steel and copper products to ensure <strong>the</strong>ir competitive
edge by delivering products as agreed
in quantity, quality and time whilst considering
inventory, productivity and performance
targets.
The PSImetals solution line is an end-toend
approach for <strong>the</strong> overall supply chain caring
for all <strong>the</strong> needs <strong>of</strong> <strong>the</strong> metals industry.
From your supplier to your customer, PSImetals
<strong>of</strong>fers powerful and tailor-made products
to support all processes from planning to
execution within your supply chain always
considering <strong>the</strong> complexity <strong>of</strong> metals production:
• Planning level to support all planning processes
from Business Planning via Production
Planning to Detailed Scheduling
• Execution level to monitor and control production
activities as well as to assure quality
• Level <strong>of</strong> material- and transport logistic to
optimise all transports requested to keep production
running
• Energy management level
• Cross-application KPI and production
monitoring functions.
All information is based on an integrated
factory model for consistent real time plant
status information.
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ALUMINIUM · EAC CONGRESS 2011 27