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Production Unit Tracking SystemIntroduction
The Production Unit Tracking System (PUTS) is an accumulator,
aggregator and disseminator of the various components of production
information process, product and resources, which are received from
the individual plant units of the Steel Melt Shop, the Caster and
the JSW HTS during production. The main functionalities include the
following:
Collecting extensive event based and cyclic process information
from individual plant units during production and the JSW HTS.
Processing (validating, storing, relating, aggregating) of the
process information collected thus
Hot metal tracking Heat tracking Disseminating this information,
real-time and on-line, to all plant units and JSW HTS, thus
enabling heat pacing at the individual plant units Generation
(both, time-based automatic and user-requested) of reports User
authorized access to the data entry/modification windowsInformation
CollectionThe backbone of the functioning of the PUTS is the
receipt of timely and correct process information from the
corresponding Level 2 systems of the individual plant units. This
information includes not only cyclic and event-based data, but also
the specific manual information entered into the Level 2 system by
the operator. PUTS also communicates with the JSW HTS to receive
schedule information as well as the analysis data from laboratory.
The information collected include among others:
Schedule and analysis information from JSW HTS
Actual heat start / end and other process event times from
individual plant units
Detailed batch-wise material, energy and other utilities
consumption and their actualization time
Process measurements and their actualization time
Delay information
Equipment renewal informationInformation ArchivalAll information
received from the various partners are validated, co-related and
archived in a logical format in the PUTS relational database.
For faster retrieval purposes some commonly accessed aggregate
data are already processed and stored accordingly.
Hot Metal Tracking
The hot metal is tracked by the hot metal ladle. The tracking
starts when a ladle with hot metal arrives at the HMPTS or HMDS for
treatment and continues till the ladle is charged into the BOF.
Heat Tracking
Each heat is tracked in the steel melt shop and caster. Heat
tracking starts from BOF charging and continues till finish of
cutting of last slab of a heat at the CCM.
Information Dissemination
Proper and timely distribution of process and control
information is the foremost responsibility of the PUTS. As such,
the relevant portions of all data which have been collected from
various plant units and the JSW HTS are transmitted to all the
relevant plant units (a PUTS HMI terminal is located in each of the
plant unit control room to display this information). The
information displayed includes:
Process information
An overview of the current state of production at each plant
unit in the entire shop
A detailed information about the current state of production at
any individual plant unit
Product information
Expected heat arrival time at the next planned processing unit.
This helps the Level 2 system for the individual plant units to
pace the current heat under production at its unit. The history and
progress details of sequential processing of a heat at the various
plant units
Real-time and on-line heat-wise progressive analysis
information
A Gantt chart showing the planned vs. actual progress of heats
at the various plant units
Resources information Providing real-time and on-line equipment
life information
Reports
The following category of reports will be provided:
Heat Reports (individual heat plant-wise, individual heat
overall history-wise)
Production Summary Reports (shift-wise, daily, weekly,
monthly)
Analysis Reports (heat-wise)
Consumption Reports (heat-wise, plant unit-wise : shift-wise,
daily, weekly, monthly) Delay Reports (heat-wise, plant unit-wise :
shift-wise, daily, weekly, monthly) Productivity Reports Quality
Deviation Reports
Equipment Availability Reports
Energy and Utilities Usage Reports
Operations Visibility Report Retrospective vs. Current
Operations Performance Report Retrospective vs. Current
The reports are also reported as trends, generated from the
above information. These reports are available on a crew-wise,
shift-wise, daily, weekly, monthly basis or over any selectable
period of time (< last 90 days). These reports may be viewed
on-line as well.
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