As part of a turnkey project, the level 3 production planning system for three electric arc furnaces, two ladle furnaces and two of the three continuous casters, as well as the maintenance section with equipment management system, were fully replaced and prepared for Industrie 4.0 with the X-Pact® MES 4.0 at Hadeed Saudi Iron and Steel. The implemented solution is scalable, so further progressive digital enhancements can be accommodated.
The key question about the modernization project at Hadeed Saudi Iron and Steel was how to prepare a steel plant with legacy equipment that partly dated back to the 1990s for Industrie 4.0, while keeping downtimes to an absolute minimum. Within a short time SMS group had already implemented a state-of-the-art automation infrastructure. The new intelligent analysis tools add leverage to Hadeed’s experience in production management, quality control, and business intelligence, including the perfect integration of pre-existing data into the new fault-tolerant database. Through the collaboration between the metallurgists from Hadeed and SMS group, a wealth of empirical experience was fed into the new self-learning process models. This has resulted in significant cost optimization. To ensure future-proof, recurring returns on investment, SMS group supplied virtualization techniques to give Hadeed independence from specific hardware components as well as great flexibility in spare parts sourcing. As a result, a comprehensive asset life cycle optimization with attractive ROI was achieved with this revamp.