How to ensure round-the-clock operation at a consistently high level of plant performance? Is it possible to operate a single plant, or even an entire plant complex, fully remotely? What about the metallurgical plants remotely controlled by experts from a suitable location, meaning the ideal production site in terms of energy and logistics? What would it take to implement a genuinely holistic approach comprising everything from the sensor level to the latest developments in digitalization? To which degree should a plant be automated? What kind of AI-based assistance functionalities will shape the path to autonomous operation? That is what X-Pact® Lights-Out is all about: It is our concept for highly dynamic, resource-saving, autonomous plant operation.
X-Pact® Lights-Out concept
We have integrated X-Pact® Lights-Out concept into our philosophy and taken it a step further. Modern technologies, such as intelligent sensors and AI-assisted systems, ensure that process stability is maintained, and downtimes are minimized. They boost efficiency and generate strategic added value by providing plant owners with the right tools to future-proof their plants and keep them competitive.
Remote control and centralized operation play a crucial role here. This is an effective response, especially in regions where there is little local availability of qualified professionals. Production facilities in remote areas can be effectively controlled from urban centers, thus increasing productivity and making optimum use of employees’ skillsets.
The X-Pact® Lights-Out concept represents a paradigm shift in production plant operation. Currently, the need for operators to be physically present on-site to monitor the performance of their equipment is mostly considered essential. In the future, however, the X-Pact® Lights-Out concept could make it possible to operate individual machines or all units of a plant complex from centralized on-site or even off-site operator stations.
For large companies with various locations in different parts of the world, this could provide several benefits. Their operational expertise could be concentrated, operator training could be centralized, and the exchange of information among members of the core operations team could be intensified. It would also be possible to establish centralized training centers using digital twins and global operating centers that are always available regardless of the time zone.
The Lights-Out factory is also the future of industrial production regarding sustainability. Using the latest predictive analytics not only increases plant performance and efficiency but also helps to further reduce CO2 emissions by avoiding waste, improving the plant’s availability, and lowering overall energy consumption.
At the same time, this concept enables plant owners to sharpen their focus on strategic objectives and their core business. Unlike before, they are no longer heavily occupied and bound by operational details. Consequently, the vision of the Lights-Out factory, where plants are operated without human intervention, is not so much about replacing the entire workforce, but rather maximizing the productivity and availability of the plants and equipment. Autonomous systems are designed to operate 24/7 with minimal downtimes and maximum efficiency.
ONE pulpit:
Fully networked plant with remote pulpits
Our approach started several years ago by centralizing operating stations in a single control center within the plant – our X-Pact® One Pulpit, a single control pulpit per line or a single, integrated, and centralized operator station for the entire plant complex. We have already made significant strides, having successfully put several highly automated plants into service. For hot rolling mills or CSP® plants, which are substantial in terms of their dimensions and operated from multiple control desks, several control stations can be combined to form a single operator pulpit. This setup enables a single person to monitor and control several different subprocesses simultaneously.
Deep automation and maximum use of predictive maintenance make it possible to reduce the number of staff required on site. To this end, the various units of a plant complex are completely networked and connected to remote control pulpits. Real-time views of the plant, along with augmented reality (AR) and 3D visualizations, are displayed on large screens, along with key performance indicators (KPIs) related to plant status, product quality, energy management, and production planning. This enables centralized data management for all stages of production.
ONE team
Specialized remote control crews
With centralization, we take this idea a step further, to remote control. In a Lights-Out factory, all automation systems remain physically installed at the production facilities but are controlled centrally by a remote, highly specialized team of experts. This physical distance requires highly dynamic plant automation systems with the highest demands in IT communication capabilities for plant visualization (HMI) and also live camera views from and to the site. The remote teams and their local counterparts cooperate through the control pulpits and smart communication methods to achieve efficient operation and effective plant maintenance.
ONE view
Maximum transparency and supervision
An entire steelmaking complex, from the melt shop to the finishing lines, can be integrated into one centralized operator station – not only when building a new plant complex but also as a retrofit to existing facilities.
The X-Pact® Vision Integrated Operating Center (IOC) plays a pivotal role in this process. It consolidates all the operational expertise related to production processes in a single location, enabling a concentrated flow of information that facilitates plant and logistics management. This significantly reduces the need for human resources. All the data needed for production analysis, performance evaluation, and shift meetings is readily available at any time.
An example of an integrated operating center is a tube rolling mill in China, which employs artificial intelligence to automatically detect anomalies during the process and take appropriate action. This illustrates how intelligent technologies are capable of not only centralizing plant control but also proactively optimizing it.
ONE partner
Integrated, single-source approach
We are ideally positioned to support our customers on their way towards more sustainable and profitable operations. We are consistently pursuing our vision, with each project edging towards the goal of autonomous operation that covers everything from centralized control to full remote control. Our integrated solutions combine 150 years of experience in metallurgy and plant engineering with a deep understanding of digitalization. Our motto for this integrated approach: Our Drive – Your Performance.
Tune in to this interview and learn more about X-Pact® Lights-Out.