OVERVIEW
COSPRO (Coil Sequencing Productivity Optimization) is a tactical tool used for the sequencing of coils in galvanization or coating lines and also in rolling mills product sequencing.
The rolling business has a high added value requiring a high level of availability in order to be productive. When a line has to be stopped for setup or maintenance or an intermediate product (intermediate coil for instance) must be used, it creates a disruption that has a direct impact on the company bottom line.
Sequencing typically requires a high degree of intelligence to take into account the complete set of transition constraints from one product to another on the production line. As each coil or slab has different properties and must be transformed into many different end products with specific characteristics, the number of possible transitions from one product to another is very large. Perfect optimisation requires far more than a simple sorting of work orders: it requires complex algorithms simultaneously taking into account each transition parameter that affects the process.
For instance, on a galvanization line, the width of the coils and their thickness is an important transition parameter. Two coils of very different widths cannot follow each other on a production line without using an intermediate coil. However, the intermediate coil causes a disruption of the process that has a financial impact on the production line productivity.
There are many other parameters to take into account on a galvanization line: the coating thickness, the temperature cycle, the texture that must be applied to the coil and the speed of the line are all examples of parameters. To further complicate optimization, a transition from coil A to coil B can be different from a transition from coil B to coil A.
COSPRO is the ideal tool to optimize transitions of the different work orders. With COSPRO you can greatly improve your production plans typically designed with a spreadsheet. The time required for optimizations reduced from hours to a few seconds. COSPRO integrates all your transition criteria and reflects your own process expertise in a flexible, parameter-driven optimization tool.
COSPRO offers a very intuitive and user-friendly User Interface that makes it possible to enter the transition criteria in a straightforward way. A major feature of the solution is that new constraints can be added or existing constraints can easily be updated by a specialist process user.
COSPRO uses multiple optimization algorithms. A first algorithm handles technical criteria, and sequences the production plan work orders in the optimal order. A second algorithm may modify that plan taking into account commercial constraints such as the date and time the coil should be available for shipment. This makes it possible to reschedule urgent orders within the plan. A third algorithm arranges the sequence of coils within a work order to optimize the cutting of output coils.
N-SIDE expertise in Steel Manufacturing optimization helps you implement COSPRO. Different aspects are covered by our experts, who typically hold a PhD in mathematics or engineering: they will help you to understand your specific problem, define its constraints, interface with the ERP system (typically work orders), assist you with training…
Also, N-SIDE is now partnering with CORTS, a well-known specialist in precision flat bearings for rolling mills, a most important technical component between chocks and housing. CORTS’ innovative solutions include flat bearing vibration sensors, which can monitor the wear of the production line. This monitoring can then be fed back to COSPRO so that transition constraints can be adapted dynamically to represent the current ability/status of the process. The benefits of such adaptable constraints are to exploit the process capabilities as far as possible, and ultimately to reduce setup downtime, which has a direct impact on rolling mill productivity.
BENEFITS
- Reduction in setup and intermediate products costs causing line disruptions
- Reduction in planning time for rolling mill Work Orders sequencing campaigns
- Increase in your rolling mill production quality
- Reduction in your rolling production lead-time
PRODUCT SHEETS & CASE STUDIES
English |
French |
 |
|
FAQ
Does COSPRO only work with galvanization lines?
No, COSPRO also works with coating lines as well as rolling mills. COSPRO is efficient in any type of complex transitions of products in a continuous production line.
Are the transition criteria’s predefined in the system?
No, you can add new transition criteria’s and define the rules for the different transitions. You can have interdependencies between the transition criteria’s as well.