Consulting services for process optimization

Boris Feige:
SMS group has been much more than just a machine and plant builder for a long time. Our growing service business and activities in the field of digitalization underline this and are gaining ever-greater relevance. SMS group sees itself as a provider of solutions that relate directly to the specific challenges of our customers.

Thomas Hüper:
We were approached by a customer who is struggling with reduced quality issues with his continuous galvanizing line. He is increasingly experiencing surface defects comprising so-called \"dross pimples\" and \"black spots\", and neither he nor his team were able to identify the cause. We immediately put together a team consisting of a quality expert for galvanizing lines and an automation specialist. Within two weeks, they were on site to conduct an investigation, monitor production processes, conduct microscopic sample analyses, and inspect the line during a scheduled shutdown. The analysis showed up a number of effects that were increasing in severity, such as damage to the cold-rolled ingoing material due to relative movements of the strip and the rolls. In addition to the root cause analysis, concrete measures were subsequently drawn up and implemented, and these brought about a reduction in the number of errors.

Boris Feige:
Another interesting example is the analysis of intralogistics in the hot rolling mill, downstream pickling lines, and associated coil stores. We investigated the logistics nodes in the value chain and related weak points, which have a direct influence on the logistical parameters, deadline compliance, lead times, stocks, and capacity utilization. The greatest influencing factor was the wide range of lead times, which tie up considerable stock levels. We also identified capacity bottlenecks for the crane facilities and warehouse fill levels, with a view to increasing the production volume in future. Working in conjunction with the customer, we developed measures that increase adherence to deadlines in the production areas under review, and we tied these in with concrete savings potential to quantify the benefits and cost effects and make them tangible for the customer.

Thomas Hüper:
We always design our consulting approach based on the customer's requirements. Due to the individual wants and needs of our customers and the range of topics and issues, there is no \"one size fits all\" solution. Nevertheless, four principles, which all projects have in common and which form the basis of our philosophy, can be singled out here. 
The first principle ist "Best in class": We only staff our projects with established experts. With more than 450 specialists within SMS group, we cover the entire steel production process and can specifically rely on dedicated expertise in individual disciplines, for example operations, metallurgical process control, quality management, digitalization, intralogistics, or energy consumption optimization.
The second principle can be described as "Local": Our principle of being local whenever possible implies that we always work on the customer's issues together with him on his premises. Whether it's in Inner Mongolia, Egypt, or Brazil. We do not waste time in getting to the customer's plant and being there where he needs us. This is certainly a challenge in times of Covid-19.

Boris Feige:
Also very important is "Quantify": In providing consulting services, we see ourselves as being more than mere analysts, but rather our objective is to define concrete measures for implementation. Quantifying our activities and measures is of particular relevance for our customers. Consequently, the goal is always to bring about a concrete effect of the defined measures on the profit and loss account and to demonstrate it in this manner. This is the only way for us to achieve the necessary commitment and the customer to obtain a valid basis for corresponding implementation and investment decisions. 
The last principle is "Execute": Our consulting services do not end with the analysis and definition of measures. We also support our customers with their implementation. This is where we clearly differentiate ourselves from established strategy consultation services. We at SMS group can adapt the equipment, corresponding automation systems, and the operating parameters as and when required. In addition, we also develop and implement digital solutions to ensure the ideal operating points of our customers' facilities. We have a whole toolbox filled with options for implementation. This is how we translate consulting service theory into concrete implementation.