CPM in Metals CPM4Metals Production planning and execution ... · Level 1 OCS Lev 1 OCS Lev 1 OCS Level 1 OCS Manufacturing orders Order status Manufacturing order report Production

CPM4MetalsProduction planning and execution system

CPM in Metals

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CPM4MetalsCollaborative Production Management

What is CPM?CPM stands for Collaborative Production Management and is a family of solutions from ABB for information sharing, production planning and execution, reporting, asset monitoring, and process optimization (mathematical models) covering all processes from steel production, hot rolling, cold rolling to finishing and treatment in processing lines.

Typical features:• production plan optimization • plant-wide sharing of information between business systems and the shop floor• production execution (dispatch of production order data/collection of process data)• paperless production management (online information, less misprinted data, availability of instructions)• visualization of real-time production and equipment status (line stops, operating time, etc.)• production performance analysis (time-based and individual-based reporting).

CPM allows users in the organization to increase the efficiency of working by making the right decisions at the right time with fewer mistakes.This information is up-to-date and quickly accessible to users. This allows them to collaborate in a more informed way to ensure maximum productivity and quality.

Hardware and softwareCPM4Metals is the common software framework for production planning and execution systems within ABB’s Metals business. The framework forms the basis for the different Metals applications and is used for adapting base functionality to customer-specific requirements.

The CPM4Metals framework is very flexible and adaptable to different process-specific demands, which means that the system can appear in different “roles” such as Level 3, MES and Level 2.

The software package is object-oriented and is based on the MS.NET framework. The application software operates in Windows environments using standard hardware and software components.

“What and why” in your production• Do you have optimized production schedules and information at your fingertips?• Is your production integrated with your planning?• Can you back-trace your production?• Do you know the ‘what and why’ of your plant downtime?• Are you managing your line set-up parameters optimally?• Do you monitor material quality during production?

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ABB’s CPM4Metals provides the solutionThis application is engineered around ABB’s CPM4Metals Framework and provides a suite of modules, which will be tailored to your needs:• Production planning and scheduling Plant-wide production planning and short-term production scheduling for your production line, based on optimized production plans• Production data historian Data repository with long-term storage of production data for the mill output• Production performance analysis Production reports and statistics and online production data feedback• Line stop/downtime monitoring Recording and analysis of line stops/downtime detailing when, what and why• Equipment monitoring Recording of equipment operating time and cycles for planning and maintenance• Quality management Inspection, material rejection, recording and analysis of quality set-points versus measured process values• Roll management Keeps track of the rolls, monitors the roll wear and supports roll change • Set-up models and recipes Calculation of pass schedule and set-up values based on mathematical models or storage in fixed tables• Material identity tracking Tracking of individuals (pieces) along the production line.

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Roll management Line stop/downtime monitoring

Your benefits

• access to online information giving higher operational efficiency (paperless work)

• filter/search capabilities for quick access to stored information

• optimized equipment set-up for less scrapping, uniform quality and potential energy savings

• powerful tool for process and production improvement

• knowing plant availability gives improved plant utilization

• direct feedback on production and quality characteristics supports quick and correct decision-making, immediate action and correction.


Plant unit. Application package for production execution

Production planning and schedulingThe production planning is optimized at a plant-wide level from the melt shop to the finished products. The schedules are distributed to the local execution systems allowing local adjustments for unexpected situations in production.

The main production plan is maintained in the CPM/Level 3 system and a sub-set of production data relevant for the actual production line is downloaded to the CPM/Level 2 system. The list/schedule shows production orders for the coming hour(s) and day(s).

The production of the material follows a defined ‘process route’ along the production line from entry equipment to exit equipment. When the material in a production order advances along the production line, it passes through defined states. These states reflect the progress in production, providing a clear view of the order situation.

Production data historian and production performance analysisProduction- and process-related data is collected from different data sources (e.g. Level 1 process control system, lab systems, furnace control systems, etc.). The data is stored in the history database on a time and individual (material) basis.

The production performance analysis provides the means to follow up production performance in periodic reports (shift, daily, weekly, etc.) and individual reports (coil, plate, beam, heat, etc.).

Management of line stops/delay handlingLine Stop Management allows you to handle and classify disruptions in the plant and identify critical reasons for downtime using statistics.

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Production planning and scheduling Management of line stops/delay handling


Set-up modelsThe CPM/Level 2 system offers extensive packages of optimization models such as:• Steel Production Scrap Mix, Energy Balance, Alloys, Slag, Melt Down Control, Oxygen, DRI, Vacuum• Hot Rolling Hot Strip Mills, Plate Mills, Steckel Mills • Cold Rolling Single and Multi Stand Mills, Reduction-, Temper- and Foil-Mills Management of equipmentProduction and quality of the plant output rely on equipment, which has to function in a safe and reliable way. Equipment Monitoring and Roll Management provides support for monitor-ing operating time, cycle count and rolled tonnage as well as administering maintenance, roll logistics and roll change.

Management of quality defectsThe Quality Management allows you to effectively manage and monitor quality-related matters. This function supports the management of:• quality inspection allowing the user to handle prime/non-prime material, add text remarks and follow test instructions

• rejecting/scrapping of material allowing the user to handle reject causes, reject location, etc.• automatic monitoring of deviations in material property values versus target/nominal values.

Material identity tracking An accurate identity tracking image of material movements in the production line is crucial for correct reporting, triggering other functions and ensuring the correct setup of the process equipment.

Identity tracking reflects the material movement along the line based on different sensor signals and manual input. The user/operator always has the possibility to make corrections for sensor failure and when unexpected situations occur.

New tracking information is shown when the situation changes and therefore provides an up-to-date image/map of the actual material positions.

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Management of equipment Management of quality defects

Material identity tracking


Plant wide

Plant wide Level 3 production optimization systemsWhile Level 2 systems focus on the process optimization of one plant unit, such as one EAF or one Z-mill, CPM4Metals-based Level 3 systems provide production optimization capabilities for one production area, e.g. steelmaking and casting or cold rolling and finishing.

The main functional modules include:• manufacturing order processing• production scheduling• schedule optimization and pacing• production tracking, coordination and re-scheduling• genealogy and plant-wide reporting• inventory management.

Manufacturing order processingManufacturing orders are typically received from ERP/Level 4, or entered manually. Operation plans (production routes) are assigned, and production requests are generated for each plant unit included in the operation plan.

Production schedulingMaterial allocation is done, where applicable, in collaboration with inventory management.

Appropriate sequencing of production requests generates the production schedules, including scheduled start and end times.

Schedule optimization and pacingThe CPM4Metals schedule optimization modules aim at maxi-mizing throughput, synchronizing production, reducing energy consumption and meeting order due dates.

The module also takes into account planned maintenance stops and facilitates production schedule simulations (‘what if’ scenarios).

Pacing synchronizes production via schedule re-timing based on actual production events.

CPM4Metals therefore helps the planner and production to:• quickly and accurately generate production schedules;• optimize the production schedule for maximum throughput (up to around 2-3%) and energy savings (up to around 5-6%);• simulate various alternatives, e.g. during maintenance planning;• synchronize production in real time.

Production tracking, coordination re-schedulingLevel 3 tracks and visualizes order progress in real time, monitors deviations from defined production schedules and quality.

Re-scheduling is performed where necessary, and schedule changes are communicated to the surrounding process segments involved.

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Plant wide Level 3 production optimization systems Schedule optimization and pacing

Level 4 / ERP / SCM

CPM / Level 3

Level 2 Level 2

Level 1 OCS

Lev 1 OCS

Lev 1 OCS

Level 1 OCS

Manufacturing orders Order status

Manufacturing order report

Production requests andproduction schedule

Production data andorder status

Production requests

Production data andorder statusSetpoints Process data

Production route


Genealogy, traceability and plant-wide reportingConsolidated production reporting for the entire production process gives the manager a quick overview of the utilization and efficiency of the plant, as well as product quality.

Full product genealogy provides the foundation for plant-wide reporting, and allows for complete traceability of a product’s lifecycle.

Genealogy also helps you pinpoint defects upstream, and identify/isolate other potentially defective products.

Inventory managementThis CPM4Metals module covers input/raw material storages, intermediate storage, and output/finished product storage and gives you full WIP visibility and control.

The functionality provided includes handling of material entry, move, exit, inventory control and corrections.

Inventory management also collaborates with production planning to allocate materials and to generate material request lists.

The immediate benefits include reduced capital costs, improved customer satisfaction and manpower savings.

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CPM4Metals conclusions

• CPM systems bridge the gap between the shop floor and the top floor and provide concrete improvements in terms of product quality, production output, and customer service.

• ABB’s CPM4Metals systems are built on 25 years’ experience and feedback from more than 140 Metals CPM systems.

• CPM4Metals-based solutions help customers to continuously improve and helps them in their drive to become even more competitive.

• CPM4Metals solutions brings tangible benefits, in terms of increased revenues, reduced operating costs and lower capital employed.

ABB CPM4Metals helps you achieve optimal performance

Production tracking

Genealogy

ROCE Revenue – Expenses

Capital Employed

(ROCE = Return On Capital Employed)

Throughput, Prime Yield

Operating Costs, Poor Quality

Inventories, WIP


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1Argentina

ABB S.A./Metals Jose I. Rucci 1051 B1822CJU - Valentin Alsina Buenos Aires, Argentina Phone: +54 11 4229 5500 Fax: +54 11 4229 5850

Brazil

ABB Ltda./Metals Avenida dos Autonomistas 1496 Osasco, Sao Paulo, Brazil CEP 06020-902 Phone: +55 11 3688 9663 Fax: +55 11 3688 9079

China

ABB (China) Ltd./Metals Universal Plaza, 10 Jiuxianqiao Lu, Chaoyang District, Beijing 100015, China Phone: +86 10 8456 6688 Fax: +86 10 8456 7625

Canada

ABB Inc./Metals JME Division 90 Consumers Dr. Whitby, Ontario L1N 7L5 Canada Phone: +1 905 666 2251 Fax: +1 905 666 2266

Egypt

ABB Power System & Automation Technology-S.A.E/Metals 7 Dr Mohamed Kamel Hussein Str, El Nozha Elgedida-Heliopolis, Cairo, Egypt Phone: +20 2 2625 1709 Fax: +20 2 2622 2632

Germany/Italy

ABB Automation GmbH/Metals Kallstadter Str. 1 68309 Mannheim Germany Phone: +49 621 381 7159 Fax: +49 621 381 8055

India

ABB Ltd./Metals KSIIDC Building, IT/BT Park Rajajinagar Industrial Area Rajajinagar, Bangalore- 560010 India Phone: +91 80 2294 6111 Fax: +91 80 2314 8883

Japan

ABB K.K./Metals Cerulean Tower, 26-1, Sakuragaoka-cho Shibuya-ku, Tokyo 150-8512 Japan Phone: +81 3 5784 6261 Fax: +81 3 5784 6276

Russia

ABB Ltd./Metals 30/1, bld 2 Obrucheva St. 117997 Moscow Russia Phone: +7 495 9602 200 Fax: +7 495 9602 201

Sweden

ABB AB/Metals Tvärleden 2 SE-721 59 Västerås Sweden Phone: +46 21 325000 Fax: +46 21 4125 95

ABB AB/Metals Metallurgy Products Terminalvägen 24 SE-721 59 Västerås Sweden Phone: +46 21 325000 Fax: +46 21 1483 27

USA

ABB Inc./Metals 16250 W. Glendale Drive New Berlin, WI 53151 USA Phone: +1 262 354 2551 Fax: +1 262 7850 417

www.abb.com/metals

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CPM in Metals CPM4Metals Production planning and execution ... · Level 1 OCS Lev 1 OCS Lev 1 OCS Level 1 OCS Manufacturing orders Order status Manufacturing order report Production