Many customers expect from Big River Steel as a newcomer in the market very high flexibility with regard to product quality, product dimensions, lot sizes and delivery time. On account of the best plant dimensioning in every process step and the digitalization of the whole plant, all these expectations can be met at a mean lot size of only 7 coils. Almost 50 percent of the strips produced have a width of more than 1500 mm.
The CSP® plant is of decisive importance for the flexibility of Big River Steel. Within one sequence, considerable changes of the strip width can be effected. Strip thickness variations of more than 10 mm are realized from strip to strip.
Moreover, in the case depicted here, four different steel grades are cast within the sequence. This flexibility is a decisive factor of success for Big River Steel. On one hand it is a benefit yielded by the CSP® technology due to temperature homogeneity and CVC plus® technology and on the other hand it is economically feasible due to advanced functionality to reduce the length and the number of transition slab or strips like the flexible analysis approach implemented in the Level 3 system X-Pact® MES 4.0. It reduces the number of transfer slab by more than 50 percent and saves BRS millions of dollars already during the first two years.
Within an implementation period of 8 weeks, the PQA® system was able to do its job and is now fully utilized in the day to day dispatching. The fundamental benefit of the PQA® system is that only products without defects leave the plant, which is very important for the development of a long-standing customer-supplier relationship.