NatSteel smart plant in Sydney (Australia) is made by a “Reta 20” straightener with quick wire change, tilters and chain conveyor for two Robomaster and three railways for straight bars, where each has another three rails. The production speed of this machine is 8TN /hour continuous cycle at low speed 100m/sec with “spooled coils” and up to 300m/sec with hot-rolled coils.
The plant is controlled at all times by our software Optiflow. This software module is integrated with the customer via web service ERP that uses a SQL database.Optiflow has a two-way communication with the customer's ERP. On one side the ERP communicates with Optiflow and sends the list of positions needed for the production orders in accordance to the needs and priorities, all accessible directly from the Optiflow interface.
After selecting the positions to produce, the OPTIFLOW controls in real time the status of the plant. This way the system automatically changes the flow of work between straight and bent, in this way there’s always continuous work of the bending machines and straight bars when the bending machines are occupied, so as to obtain the highest performance.
Since the production sequence of the positions varies depending on the needs of the plant, the label printing is performed on board machine, communicating via web services between Optiflow and the customer's ERP. When a bundle of bars is cut and sent to the chain conveyor, labels are immediately printed to identify the package, allowing the operator to tie properly before sending the material to its destination.
Moreover through web services the software Optiflow notifies the ERP every status of each position and order, the time when a label is produced, when it has finished producing and when it is downloaded from the plant, allowing the customer’s ERP to quantify the timing for the calculation of costs. As well as providing in real time the status of their orders performance.
The cutting and bending plant “Dongkuk Steel” produces about 21,000 tons/month. The plant began working only with bars and then expanded in 2015 to coil processing. The installation of the plant has two main cutting lines “shearline 500”, 3 bending Robots, 4 Smart Bar, 8 Barwiser and 8 manual Japanese Toyo cutting and bending machines.
The system Graphico acts as a gateway for the machine’s production. It receives information from the customer central system with Oracle Database 10.x and processes all infos as production orders. The person on charge of the production manages the production of the machines with Graphico optimizing and planning the production for each machine.
The central system and the software Graphico are connected with all Schnell machines via TCP-IP. This allows the operators to work the optimized lists directly from the numerical control machines considering the priority orders.
When the machines produce labels we return this information to the central system through the Data Pro software. The solution that Schnell Software has implemented allows the customer to know in real time the production of the plant and the machine’s productivity.
The customer Dongkuk has requested that the information received in our system are sent back in real time to their ERP system with Oracle database 10.x. Schnell Software and Dongkuk Department carried out a study of the needs and an integration plan and update of the customer's ERP system has been studied.
Schnell Software is connected with Oracle database and updates the production of the plant in real time. The system Data Pro sends all the necessary data to know the status of each label, operator, machine and if the cutting or bending processes were performed according to the production timetable. The customer can thus calculate the production costs of each order, and the scrubs.
The project has been completed in two months, analysis, development and system implementation included.