Already a top provider of enterprise software to the steel sector, Aptean acquired Asset Point in 2016 and with it the TabWare enterprise asset management system.
TabWare is designed to help companies maximize asset performance, increase equipment uptime, and reduce maintenance and operational costs. It is based on pre-configured, industry-wide best practices, can be configured to an organizations specific work processes and is easily integrated into existing applications.
TabWare compliments Apteans flagship enterprise resource planning (ERP) system called Axis, which was designed specifically for metals producers, processors, and service centers. Axis integrates production, sales, financial management and analytics around a single base of information.
In metal-processing, the constant challenge is maximizing asset performance, increasing uptime and controlling costs. With heavy equipment and expensive facilities, metal processors must use aggressive asset performance management to maintain equipment and ensure production availability.
Aptean was able to integrate TabWare with Axis quickly in 2016, and configure the two together for industry-specific functions including equipment management, asset information history, tracking, and hierarchy along with work process management, including initiation of work orders through work planning, scheduling, execution, and completion. The integration of TabWare and Axis extend the joint systems capabilities into areassuch as preventive maintenance and inventory managementthat typically pose challenges to steelmakers.
In preventive maintenance, the joint system can now generate work orders that can be scheduled based on time and/or units with descriptions of the resources and materials required. Maintenance business intelligence features allow instant insight into industry-standard, key performance indicators and metrics with the capability to drill down into areas of concern. In inventory management the combined software can track inventory and maintain cost and transaction history to determine the optimum stocking levels for operations. Users can perform all work activities while in the field, and improve data accuracy with point-of-execution data-capturing capabilities.
ArcelorMittal is Canada's largest steel producer, making flat-rolled and tubular steels, as well as laser‐welded blanks from facilities in Canada, the United States and Mexico. It produces 4.5 million tons of steel annually from a 750‐acre steelmaking complex in Hamilton, Ontario and features some of the most technologically advanced facilities in North America.
ArcelorMittal Dofasco implemented planning systems by Quintiq that allowed the complex to combine orders to improve the coil-slitting process, and, as a result, reduce the volume of steel purchased to satisfy orders. At the same time maintenance teams can be proactive in their workforce planning and better manage work order backlogs.
Dofasco required an integrated scheduling system to make decisions in real time, while anticipating demand and being able to react to schedule disruptions. The system is designed to allow maintenance teams to be proactive in their workforce planning, manage work order backlogs and minimize the amount of time a machine is out of service.
The Quintiq system is designed to streamline maintenance scheduling. Delivery compliance and due-date determination, based on customer demand and forecast orders, can be increased and products can be allocated across multiple production routes. The system also visualizes and offers the potential to monitor all planning decisions as well as the current status of orders, allowing optimized coordination between individual departments, (e.g., production and shipping), and improving communication and traceability between planning and production.
Changes in production due to shutdowns and maintenance work, for example, are taken into account, allowing for real‐time reporting, continuous process analysis and feedback in the form of key performance indicators.
Quintiq notched a banner year in steel in 2016, expanding its relationships with several major steelmakers across the globe.
Notably, the company built on its decade-long relationship with Outokumpu by launching a fully integrated supply-chain planning system after earlier sealing a successful corporate license deal with the company.
Italys Acciaieria Arvedi went live with Quintiq to improve customer service across its entire supply chain. The steelmaker was also able to improve the production efficiency and flexibility of its continuous casting and rolling process.
Severstal continued its strong relationship with Quintiq in 2016 by enhancing its supply-chain optimization processes. Quintiq provided a unified scheduling platform for Severstal to cut overall inventory costs, speed lead times, reduce work-in-progress inventory and improve delivery performance. The system synchronizes workflows at the production sites to improve productivity, increase overall yield and reduce inventory.
Refined over the past 15 years, Quintiqs approach to work-order planning features telescoping periods, daily in the near term, weekly further out. Similarly, there is detailed input for the short term and rougher input for the long term. Operational lead times may be configured for higher or lower accuracy and increased focus on resources that are important for a particular supply chain.
A linear programming optimizer plans all orders simultaneously. The optimizer generates an executable plan and will continue refining that plan toward optimality for as long as it is allowed to run. The optimizer can reach a point where the plan is indistinguishable from the optimal and able to ensure performance. Once the optimizer creates the backbone of the schedule, planners may add the finishing touches. Traditionally, metals scheduling focused only on quality and productivity. Gains from Quintiqs hybrid approach include improved machine occupation of several percent, increased adherence to planned dates by 10 percent or more, and maintained or improved hot-charged ratio.