Tata Steel Consulting provides a wide range of consultancy services from Mining and Technology to Human Resource Management and Corporate Services
As part of a world-class steel producer, Tata Steel Consulting is able to call upon first-hand knowledge of planning, developing, and operating an internationally competitive steel company. It is now imperative that we make our peers partners in our success story and share some of our industry leading practices.
Tata Steel Digital Journey
Our Industrial 4.0 Architecture
» Insight Platform: Visualization, Artificial Intelligence, User Apps
» Data Platform: Data & Analytics
» Infra Platform: Enterprise Applications, Sensors, Level I & II, Network, Cyber Se...SEE MORE
Tata Steel Digital Journey
Our Industrial 4.0 Architecture
Key Business Outcomes
Goals
Laurels
A Look Back at 2022 Accomplishments
Digital Consultancy
Industry 4.0 lighthouse visit
Tata Steel was quick to board the Industry 4.0 wave and had dedicated efforts to building organization wide enthusiasm for digital adoption since 2015. As the early wins started coming in, adoption picked up pace in and sizeable bottom-line impact and employee experience
enhancement has been consistently achieved. Given this early adoption and hot pursuit of business goals through digitalization, Tata Steel currently has established an early lead in Industry 4.0 maturity.
Today, Tata Steel holds the unique distinction of having three of its sites recognised as Industry 4.0 lighthouses. Its oldest and newest site in India – Jamshedpur and Kalinganagar have both been bestowed with this recognition.
A visit to Tata Steel aimed at building an appreciation of the impact that digital transformation can achieve would involve interactions with the important stakeholders to the digital transformation process, witnessing digital technologies in action and correlating the same with real world business impact brought about by adopting Industry 4.0 technologies in Tata Steel.
TSIC organizes customized Industry Visits to Tata Steel units enabling the participants to witness first-hand the impact of Industry 4.0 in a real-world setting. Participants also interact with the different stakeholders within the organization that deliver the change including line functions, Automation, IT Infrastructure and Business Process Enhancement.
Digital Negotiation Factory
Problems Addressed:
» Real time tracking of all negotiations
» Availability of structured data in a single platform
» Enable negotiation decisions based on past data (historical vendor data) ,current data (clean sheet) a...SEE MORE
1. Digital Negotiation Factory
Problems Addressed:
Impact
2. Catalogue Management System
Problems Addressed
Impact
3. Life Cycle Tracking System
Problems Addressed
Impact
4. DigiWheels
Problems Addressed
Impact
» Predictive maintenance
» Ashiyana – manufacturing or other industries in general...SEE MORE
Video Analytic Solutions for process safety
Objective:
» To ensure process/industrial safety measurements
» Social Distance
» Mask Detection
» PPE Detection
» No Man Area Zones
» Hand Rail Holding Detection
» Fire Detection...SEE MORE
Video Analytic Solutions for process safety
Objective:
To ensure process/industrial safety measurements
Feature & Benefits:
Explosive Detection System
Objective:
Detect explosives mixed with scrap on the conveyor to the shredder and alarm accordingly to ensure safety
Feature & Benefits:
Hook Vision
Objective:
Provide real-time visualization of crane hook engagement with ladle trunnion without any intervention from the crane operator
Feature & Benefits:
Remote Machines
1) RRC in Locomotives of Hot Metal Logistics
Objective: To improve safety standards and productivity in the Movement of Hot Metal Torpedoes
Features & Benefits:
2) Video Wall in Bof Converter Handling
Objective: To ensure safety at BOF Control Room by using video wall instead of glass wall
Features & Benefits:
3) Manless Cranes in Scrap Management.
Objective: To eliminate Human-machine interface in the operation of cranes inside Steel Melting shop
Features & Benefits:
Remote Sprinkler for Stock Yards
Objective: To eliminate human presence for operating sprinklers in stockyards
Issues & Concerns:
Benefits:
Plume Dispersion System
Objective: Estimation and visualization of pollutants deposition (PM, SOx, NOx) in real time to demonstrate the environmental impact
Solution:
Developed a real-time process model using Gaussian distribution methodology for estimation of plume dispersion and deposition
Benefits:
Auto Pelletizing Disc
Objective:
» Develop an automated pellet size control system using Level II Automation System parameters to control the size distribution of green pellets
Result & Benefits:
» Elimination of manual inspection of discs to ident...SEE MORE
Auto Pelletizing Disc
Objective: Develop an automated pellet size control system using Level II Automation System parameters to control the size distribution of green pellets
Result & Benefits:
Auto Pellet Tester
Objective: To provide a completely autonomous process of testing pellets without any delay in the process
Issues & Concerns:
Benefits:
Grate Scan
Objective: To develop an automated defect logging, tracking & positioning system for Pallet Cars thus enabling faster detection and maintenance of defective cars which lead to loss of pellets while transport
Automated system is required for
Key Features:
Sinter Sizing Estimation
Objective: Image-Analytics-based system to calculate the Sinter size distribution in real-time
Novelty: Using a CNN based Object detection + Instance segmentation model for estimating size distribution
Benefits:
Sinter Plant Level II System
Objective: A complete Level II system for process improvement and an overall increase in productivity at sinter plant through effective operation, management & visualization with analytical models
COSMOS (Coke Oven Scheduling & Heating Monitoring System) - Coke Oven Level II System
Objective:
» Heating, scheduling & machine coordination in coke oven battery which leads to improved productivity, battery life, energy efficiency and quality of coke...SEE MORE
COSMOS (Coke Oven Scheduling & Heating Monitoring System) - Coke Oven Level II System
Objective:
Heating, scheduling & machine coordination in coke oven battery which leads to improved productivity, battery life, energy efficiency and quality of coke under reduced emission
Process:
KPI improves:
Online Flue Temperature Measurement of Coke Ovens
Objective: To eliminate manual measurement and provide an online temperature of each flue
Solution:
Benefits:
Tie Rod Load Cell Measurement in Coke Ovens
Objective: To provide Load changes that take place during different events of Oven operation
Solution: To install a high-temperature Loadcell on the tie rod
Benefits:
Tuyere Eye
Objective: Visualizing the pulverized coal injection with analytics and eliminating manual observation of the tuyer platform
Solution:
Benefits:
Wireless Dip Lance
Objective: Wireless enabled measurement of hot metal temperature at the cast house
Features & Benefits:
Provide BF (Process Visualization & Data Evaluation for Blast Furnace) : Blast Furnace Level – II System
Objective: Visualisation, Simulation & Optimisation of BF processes which improve operational efficiency, furnace health and quality of hot metal
Smart Raking System
Objective:
» To facilitate the removal of slag optimally from molten iron
Solution:
» IR camera differentiates steel and slag.
» Imaging algorithm detects the endpoint of raking
Feature & Benefits:
» Improved yield
» Indep...SEE MORE
Smart Raking System
Objective:
To facilitate the removal of slag optimally from molten iron
Solution:
Feature & Benefits:
Slag Detection System
Objective:
To avoid slag carryover into the ladle during tapping
Solution:
Feature & Benefits:
Opti BOF: SMS Level II System
Objective:
Consistency in the end blow chemistry and temperature through different models which provides assistance in the planning of heats
Benefits:
Slab Auto De-grader for SMS
Objective:
An automated ML model with gradient boosting algorithm to determine the best possible alternate for unplanned transitions/degradation due to chemistry
Innovation:
Benefits:
Scrap Yard Management System
Objective:
Auto scrap loading information system eliminates manual-based data logs of scrap charged in BOF and other manual practices coupled with autonomous scrap charging to improve overall productivity
Features & Benefits:
Casting Online Diagnostics system (Break out prediction system)
Objective:
CODS continuously monitors the embedded thermocouple values in real time and generates early alarms to arrest potential sticker breakouts
UPS:
Gives a breakout ability factor
Improved KPIs:
Improved KPIs, 80% true/false sticker alarms
Slab Dimension Measurement System
Objective:
To develop a system that comprehensively measures various casting parameters like Length, Width, Thickness, Bulging and Taper to provide real-time feedback to the operation about the casting quality
Previous Practice:
Length (Auto-Encoder based), Width (Manual), Thickness (Manual), Taper (None), Bulging (None)
New Initiative:
A hybrid of Machine Vision and Laser technology has been developed to measure Slab dimension
Features & Benefits:.
Rhomboidity Measurement System
Objective:
Real-time, precision vision machine for Rhomboidity measurement of Billets/Blooms to improve yield by a reduction in downstream rejects & reduce man-machine interface
Features & Benefits:
Roll Shop Management System
Objective:
» The Roll Management monitors the usage of grooves, rolls, roll sets, roll modules and guide boxes in terms of the rolled tonnage and indicates when set limits are reached
Digital Features:
» Application migra...SEE MORE
Roll Shop Management System
Objective:
The Roll Management monitors the usage of grooves, rolls, roll sets, roll modules and guide boxes in terms of the rolled tonnage and indicates when set limits are reached
Digital Features:
Mill Chatter detection System
Objective:
Chatter marks on coils generated in Cold Rolling Mill often lead to rejection and downgrade downstream. In absence of an online chatter detection system, chatter defects are not detected in real-time which may take upto some days of actual rolling. So, no corrective action can be taken immediately and material rolled with this defect is always exposed to chatter defects
Product Features:
V.Eye (An eye for crop optimization)
Objective:
Real-time vision-based system for accurate computation of cut profile of the head and tail ends of Transfer Bar to reduce yield loss due to crop cut. The system also provides accurate speed measurement of the hot strips to assist precision cutting by crop shear
Principle of operation:
Benefits:
Tru-Span
Objective:
Based on stereo photometry and triangulation principles, Tru- SPAN measures the hot/cold coil widths with immaculate precision. Powered by a line laser, the new generation Tru-SPAN is also capable of carrying out width compensation in presence of a moderate bow in the surface
Improved KPIs:
Surface Quality Inspection System
Objective:
Discretion alarms are raised only for significant defects missing zero defects and resulting in accurate classification and revised gradation standards
Principle of operation:
Hole Detection System (HDS)
Objective:
A precision vision machine that will not let go of any holes undetected. Built on image processing, sophisticated and efficient algorithms are used to detect holes on the fly. Salient features include triggering of Audio/Visual alarm, customized report generation, and advanced analysis of hole defects
Benefits:
Torpedo Ladle Tracking System
Objective:
» Efficient coordination of torpedo ladles for serving Hot Metal “capacity buffers” for the Blast Furnaces and “feed buffers” for the Steel Making Shops
Improved KPIs:
» Efficient & optimum management...SEE MORE
Torpedo Ladle Tracking System
Objective:
Efficient coordination of torpedo ladles for serving Hot Metal “capacity buffers” for the Blast Furnaces and “feed buffers” for the Steel Making Shops
Improved KPIs:
Efficient & optimum management of hot metal movement
Generic Yard Management System
Objective:
Solution for smart Material Handling
Features:
Benefits:
Smart Solutions
Objective:
It helps enable devices on the network, data streaming, data analysis, MIS reports/exceptions, & control/enhance business operations
Process Flow:
Smart Devices >> Cloud Search >> Web Applications
Connected Workforce
Objective: Smart solution for identification & tracking of manpower deployed inside plants
The Solution has 4 critical components – Lora Wan, BLE Beacons, Android / IOS Mobile App & Cloud application
Smart Barricade
Objective:
Remotely controlled smart access control systems deployable at any Process hazard areas
Features:
Benefits
Smart Fleet Management System
Objective:
E-Tracking and Optimization of mobile equipment
Key Functions:
Benefits:
Enhanced Tracking and Optimization
UniLORD (Universal Lora wan Solutions)
Objective:
Implementation of smart solutions under LoRaWAN network for effective operation and monitoring on real-time basis.
Application:
Centralized Condition Monitoring System
Objective:
The CCMS improves equipment reliability by automatically diagnosing and alerting equipment faults
Benefits:
DC Motor Spark Monitoring System
Objective:
Real-time monitoring of Sparks in DC motors
Improved KPIs:
Pipe Conveyor Monitoring System
Objective:
An online system capable of measuring the Overlap & Sway of the Pipe conveyor is needed which can trigger the alarm for corrective action
Features & Benefits:
Track Rail Inspection System (Trains)
Objective:
To develop an automatic Inspection system to measure multiple inspection parameters, and process and visualize rail track on the fly
Key features:
Our Team is Here to Help.
For More Details Contact Us.
0657 662 5253
Or write to us at tsic@tatasteel.com
LET'S TALK