X-Pact® MES 4.0Production planning and control forall production units in the plant

Industry 4.0

READY

X-PACT® MES 4.0

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X-Pact® MES 4.0Manufacturing Execution System fromSMS group makes your factory smart

For example for the facilities in:melting and refining unitscontinuous casting plantshot rolling millscold rolling millsstrip processing linesand in the long products sector.

Even parts of these plants can be flexibly equipped withindividual modules of X-Pact® MES 4.0, whether as part ofmodernizations, expansions or complete new installations.The special features of the various types of materials, fromsimple carbon steels to stainless steel and aluminum, arealso considered.

The challengeThe SMS group as partner to industry has answers tothese major issues of the future:

customization of products with consistently high qualityminimization of the lead time in productionensuring punctuality in deliveryoptimum use of resources: personnel, material andenergyand stocks reduction.

X-Pact® MES 4.0 is the complete modular solution for planning and control of the whole metallurgical processchain and all production facilities. From receipt of the customer’s order until the finished product leaves the works -the customized concept of X-Pact® MES 4.0 leads the way.

X-Pact® MES 4.0 modules.

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The SMS group solution

Complete plant equipment, technology and automationfrom one supplierIntegrated overall solution for the customerComplete planning solution from capacity planning, pro-duction sequencing up to short reschedulingAvailable know-how with regard to material flow, produc-tion processes, equipment, and quality controlprocessesOptimized integration between process control andcommercial systems.Analysis of “big data” for identification of improvementpotentials

Optimized integration between other plant-wide solu-tions from SMS group for product quality and cost effi-ciency

X-Pact® MES 4.0 integrates harmoniously into the existingIT landscape.

The functional modules are logically categorized into:PlanningSupport & OptimizationSupply & DispatchReporting

X-Pact® MES 4.0 as a means of linking and flawlessly integrating the business system and the plant.

X-Pact® MES 4.0 application.

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Modules overview

Technical Order Generation Automatic generation of production order

Generation of extensive primary data sets for Level 2systems with specific production instructionsAchievement of reproducible production conditions Simple administration of production rules

Capacity PlannerCapacity and time planning

Punctual scheduling of ordersLoad distribution over alternative routes, establishmentof order priorities and campaignsContinuous monitoring of planning-relevant eventsIntegration of available plant capacity, production deviations, standstills, etc.

Production SequencerSemi-automatic advance planning ofthe production sequence

Algorithm for creating of optimized productionsequencesAlgorithm-based checking of technological and plant-specific limitations, availability of charge materials/process media Provision of an intuitive user interface

Meltshop PacerAutomatic generation of optimized timeschedules in melt shops

Optimized routing of heats and determination of plannedtreatment timesContinuous monitoring of actual and planned treatmenttimesRerouting of heats in case of considerable delays orunforeseen plant unit stoppage

Planning

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Support & Optimization

Short ReschedulerSemi-automatic rescheduling shortly before execution of production sequence

Automatic reaction to planning-relevant disruptions inthe production processIdentification of production order alternatives

Plant Condition ManagerMonitoring of plant condition

Inclusion of plant condition as a further criterion in theplanningRecording of relevant plant conditionCentral monitoring of the plant condition on the basisof aggregated information

Considerably relieving the burden on the control roompersonnel

Delay ManagerManagement of standstill times

Planning of standstills with respect to the scheduleCentral recording of unscheduled delaysRecording of standstills and their cause

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Modules overview

Master Data Manager Management and distribution of master dataand process instructions

Central administration of:production practicessteel grade specificationmaterial and equipment characteristicsintermediate and final product definitionquality management instructions

Quality ManagerCentral management of quality aspectsduring production

Inclusion of product quality as a further criterion inthe planningRecording of relevant product qualityManagement of samples and inspections, dependingon specifications, forecastsIdentification of quality deviations

Energy ManagerEnsures efficient use of energy

Inclusion of plant condition as a further criterion in theplanningRecording of relevant energy consumptionEnergy forecast based on production planning

Warehouse ManagerWarehouse Management System tailored for steel and aluminum

Creation and display of transport instructionsOptimization of storage based on intake sequences andfurther production sequencesMature visualization of stored product, for examplecoils, slabs, plates, tubes, and long products

Support & Optimization

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Inclusion of inventory as a further criterion in theplanningRecording of relevant inventory Forecast of inventory requirements on the basis ofthe production planning and history

Information & Dispatch ManagerManagement of communication with thecustomer and dispatch

Filtered provision of tracking and production informa-tion to customersRecording and notification of order modifications bythe customerManagement of the dispatch

Inclusion of material availability as a further criterionin the planningRecording of relevant material stocks Forecast of material requirements on the basis of theproduction planning and history Automatic purchase order request and recording ofstocks

Inventory Manager Management of relevant productionequipment

Resource ManagerManagement of relevant charge materials

Supply & Dispatch

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Modules overview

Business Intelligence-Mobile Display of web-based reports on tablet orsmartphone

Mobile access everywhere and any timePossibility to interact with dynamic applications,dashboards and analysis

Special management apps via Intranet (Wifi) and/orInternet

Reporting

Intelligent and up-to-date reporting with X-Pact® Buiness Intelligence.

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Interactive dashboards KPI analysisSmart decision making Detailed overview of the entire processTrend analysis also for long period of time

Security ShieldAll software components ensure high levelof data security

Plant-wide material and order tracking using a factorymodelExtensive control room visualizationCentral coordination and management of the commu-nicationCentral user administrationSupervision of various software modules

Easy interpretation of large volume of dataEasy way of sharing informationConsolidation of relevant data from various sources

Business Intelligence-Analysis Interactive analysis of production foridentification of improvement potentials

Business Intelligence-ReportingWeb-based production reports

Production ControllerMonitors and controls any particularoperation in shop floor

X-Pact® Cloud Centralized storing of relevant data in com-pany network

Basis

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ReferencesYour benefits at a glance:

Lean and efficient production planningOptimum production sequence with minimum set-uptime and efficient energy consumptionOptimum targets for the production of maximum qualitywith efficient utilization of materials and the saving ofplant resourcesIntelligent strategies for alternative measures in cases of malfunctionsComprehensive data collection and evaluation for creation of potential improvements

CSP® plantArcelorMittal, Sestao, SpainSeverstal Columbus, USABig River Steel, USA

BOF converter shopVisakhapatnam Steel, IndiaKardemir - Karabuk Demir Celik San ve Tic AS, Turkey

Ladle furnaceSeverstal Columbus, USAVisakhapatnam Steel, IndiaPervouralsky Novotrubny Works - OJSC, RussiaSiderúrgica National (SN), VenezuelaSaudi Iron & Steel Co (Hadeed), Saudi ArabiaBig River Steel, USA

DegasserSeverstal Columbus, USAVisakhapatnam Steel, IndiaBig River Steel, USA

Electric arc furnaceSeverstal Columbus, USAPervouralsky Novotrubny Works - OJSC, RusslaSiderúrgica National (SN), VenezuelaSaudi Iron & Steel Co (Hadeed), Saudi ArabiaBig River Steel, USA

Coil yardJinan Iron and Steel Group Corp, ChinaChina Steel Corporation, TaiwanBig River Steel, USA

Continuous slab casterSiderúrgica National (SN), Venezuela

Continuous billet casterPervouralsky Novotrubny Works - OJSC, RussiaVisakhapatnam Steel, IndiaSaudi Iron & Steel Co (Hadeed), Saudi ArabiaKardemir - Karabuk Demir Celik San ve Tic AS, Turkey

Billet yard, bloom yardPervouralsky Novotrubny Works - OJSC, Russia

Pickling lineArcelor Mittal Sestao, SpainJinan Iron and Steel Group Corp, China

Tandem mill couples with pickling lineSeverstal Columbus, USABig River Steel, USA

Hot Strip MillsHabas Sinai Ve Tibbi Gazlar Istihsal Endüstrisi AS, Turkey

Heavy plate mill, Steckel plateVyksa Steel Works, RussiaSiderúrgica National (SN), Venezuela

Compact Cold MillJinan Iron ans Steel Group Corp, China

Slab yardArmurmetal, RussiaArcelorMittal Poland S.A., PolandSiderúrgica National (SN), Venezuela

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Annealing and coating lineChina Steel Corporation, Taiwan

Hot-dip galvanizingSeverstal Columbus, USABig River Steel, USA

Shearing line (heavy plate mill)Vyksa Steel Works, RussiaSiderúrgica National (SN), Venezuela

Coil yardJinan Iron ans Steel Group Corp, ChinaChina Steel Corporation, TaiwanSiderúrgica National (SN), VenezuelaBig River Steel, USA

Plate storeSiderúrgica National (SN), Venezuela

Tube Finishing LinesPervouralsky Novotrubny Works OJSC, Russia

Large Diameter Pipe PlantPipe Mill Tscheljabinsk CHTPZ Group, RussiaAl Gharbia Pipe Company LLC, United Arab Emirates

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“The information provided in this brochure contains a general description of the performance characteristics of the products concerned. The actual products may not always have thesecharacteristics as described and, in particular, these may change as a result of further developments of the products. The provision of this information is not intended to have and will nothave legal effect. An obligation to deliver products having particular characteristics shall only exist if expressly agreed in the terms of the contract.”

SMS group GmbH

Electrics/AutomationIvo-Beucker-Strasse 4340237 Düsseldorf, GermanyPhone: +49 211 881-5895Telefax: +49 211 881-775895automation@sms-group.comwww.sms-group.com