Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 1 Стратегия Ядро Бизнес Процессов Самый большой в своей нише Международное Присутствие

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 2 От руды до готовой продукции, от заказа до отгрузки Интеграция, Оптимизация Управление Производством PSIintegration

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 3 PSImetals Упростите свои IT проблемы ERP (SAP) SAP NetWeaver

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 4 HomeHome - Index - We dedicate our self to the best customer solution and his successIndex Integrated Production Management with PSImetals SAP L2’s SMP L2’s HRM L2’s CRM SY CY Planning Warehouse & Transport Mgmt. Production Execution PSImetals % Factory Model PSIintegration

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 5 Summary of PES Functionality PSImetals PES Production Execution System 1. Master data /objects management 2. Production tracking 3. Quality management 4. Inventory management and dispatch 5. Tools management 7. Data gathering and reporting 8. Interfaces management 6. Production control HomeHome - Index - Summary of PES FunctionalityIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 6 Functionality of an integrated Level 3 (MES) system Level 3: Basic system for Production Management Production Management is Maintaining and Controlling all important objects of the real production world Planning of production operations Execution production operation Control and report of production Level 3 does integration of all involved systems Interface to Level 4 Interfaces to Level 2 systems Interfaces to laboratory systems and other quality systems Interfaces to weighing systems, PLC (in necessary), crane systems HomeHome - Index - Functionality of an integrated Level 3 (MES) systemIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 7 Production management: Maintaining Objects Heart of the Production Management: Factory Model. The Factory Model is the central (relational) production database having the actual and consistent status of all objects of the real production world, which are important for the production. The database also has to contain basic procedures and rules to guarantee the consistency of the objects. HomeHome - Index - Production management: Maintaining ObjectsIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 8 Production management: Maintaining Objects Important Objects for production: Material (all kind of material: Heats, Slabs, Blooms, Hot-Strip, Cold-Strip, Sheets, Bar, Wire, H-Beams….) Production order (derived from customer order: quantity, amount, product description, quality requirements, time-table information…) Production operation (production plan of the production order, description of each production step, time-table information…) Process instruction (detail information for production operation, data for Primary data input for production lines…) Production program (program or sequence for each production line, technical sequence of the material which is planned for this production line) Rules and Restrictions (technical information about rules and restrictions for planning Production Lines (actual status of each production line, factory calendar, technical performance of each line due to material and order characteristics) Stockyard information (organization of the stock yards) HomeHome - Index - Production management: Maintaining ObjectsIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 9 Production management: Planning of production Planning of the production operations: Time and capacity schedule of the WIP (work in progress, Material which is in production status) Sequencing of each individual production line, sequencing of the combined production lines (e.g. direct charging of HRM, combined pickling and annealing line, combined pickling and tandem line…) Planning of special aspects in steel industry (heat completion, mother slab generation, mother coil generation, consideration of the specific rules and technical restrictions) HomeHome - Index - Production management: Planning of productionIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 10 Production management: Production execution Execution of the production operations: Receiving of the production orders and quality master data from ERP Giving the production plan (sequences) to the production lines Prepare and transfer of the Primary data out of material information, order information, quality information and master data needed by the machinery for production Registration of the production events, planning events, production line status Registration of quality results Material tracking (material history), Production order tracking, Quality tracking, Production plan tracking Management of material stock Tracking of material location, transportation management HomeHome - Index - Production management: Production executionIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 11 Production management: Production control Evaluation of the production results Comparison of nominal and actual data of production and quality Reporting production and quality events to ERP system Reporting consumptions and times to ERP system Production decision (e.g. repair work) Quality decision (e.g. scrap decision, re-attachment of material to production order Generating shift and daily reports HomeHome - Index - Production management: Production controlIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 12 PSImetals: IT-Решения для Металлургии Примеры внедрения

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 13 ThyssenKrupp Steel today Five locations operate twelve different MES. History: Different companies has been merged Individual development of MES Software for the specific requirements of each plant Most systems operate on Tandem Hardware, one operates on IBM Mainframe Result: High maintenance costs No transparency across the production sites No possibility to compare the plants High system administration costs Duisburg Bochum Dortmund Siegerland Finnentrop

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 14 PSImetals systems PSImetals Systems at the Salzgitter Group Выплавка чугуна Сталеплавильный цехПроизводство продукции из стали ВыплавкаРазливкаГорячая прокатка Холодная прокатка Окончательная обработка Доменные печи Управление процессом на 3 доменных печах Планирование и диспетчеризация Система организации производства Автоматизация МНЛЗ Интегрированная система управления складами и транспортными потоками Перспективное и оперативное управление Система организации производства Система организации производства / Оптимизация раскроя (пореза) Перспективное и оперативное управление Система организации производства

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 15 SzFG: Production Equipment and Facilities 01 2 Coke oven batteries, 108 coke ovens, 46,0 m 3 each 02 Sintering plant – 180 m Blast furnaces, hearth Ø 11,2/10,8 m 04 3 x 220 t LD converters 05 Continuous casting machines: 2 strands 250 mm thick, mm wide 1 strand 250 mm thick, mm wide 1 strand 250 mm thick, mm wide 06 Hot strip mill 07 Continuous pickling line and push-pull pickling line 08 Hot strip cutting line 09 Cold rolling mill 10 Hot-dip galvanizing No. 1 and 2 11 Electro-zinc coating line 12 Organic coating No. 1 and 2 13 Sheet in coils 14 Surface-coated sheet in coils 15 Sheets 16 Narrow strip, rim material 17 Hot-rolled strip HomeHome - Index - SzFG: Production Equipment and FacilitiesIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 16 ThyssenKrupp Nirosta GmbH PSImetals PES for 3 stainless steel CRM The situation: Old mainframe system, high maintenance cost System structure do not support Business processes Different solution per plant The Aims: Overall Production Execution System for the entire enterprise of ThyssenKrupp Nirosta State of the art system solution System support for the special requirements of a stainless steel production Overall standardized Quality Control and Reporting PSImetals APS/ALS + PES Plant Krefeld Plant Benrath Plant Dillenburg

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 17 ThyssenKrupp Electrical Steel PSImetals PES/APS/ALS для 2 заводов Plant Bochum Plant Gelsenkirchen Ситуация: Много различных, самостоятельно разработанных систем Высокая стоимость обслуживания и поддержки Цели: Высокая степень интеграции с SAP Технический и финансовый контроль Планирование заказов, планирование на цеховом уровне

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 18 Annealing, Insulating linesPickling line, Rolling stands Cold rolled Coil (Semi) Package (Finished) Stichpla n- rechner KWR 1 Bandin- spektio n Beize Loch- suchger.UWA 1/3 Band- profil- rechner KWR 3 Loch- such- gerät EBR Loch- sucher DO 5, 6 Loch- sucher DO 4 Band- profil DO 5 Ober- flächen - inspek. DO 5, 6 Schicht dicken messg. ISA Mech. Meßpl. DO 4-6 Dehng. Magn. Meßpl. DO 4-6 Adjustage Opt.- rechner HGL picklingcold rollingannealing coating slitting Adjusting and packaging Prematerial (Raw) PLS DOfen BZKWR, UWAEBRHGLDOISAKWNLZEBZ batch annealing Lager Rechner H10,H12 Messerbaukarte SAP R/3 (PP) Shopfloor Process data/ error data Quality checking Production data acquisition +„electronic cold-strip-card“ + integration process computer Time and capacity scheduling Line sequencing Material tracking (Coils) Production data messages to SAP Cutting optimization ThyssenKrupp Electrical Steel After: PSImetals PES at EBG

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 19 PSImetals: IT-Решения для Металлургии Benefits

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 20 PSImetals APS/ALS– Benefits by the example of Arcelor EKO Stahl 90% according to schedule Steel making throughput is increased about 15% Throughput capability of cold- rolled coils is increased by about 43% Reduced coil yard inventory The whole central planning and supply chain management is handled by just 8 people HomeHome - Index - PSImetals – Benefits by the example of Arcelor EKO StahlIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 21 EKO Stahl: Plant wide Production Planning and Control Targets achieved Creation of a complete production planning, guaranteeing total planning and fulfilment of all production orders The following process optimization was achieved: reduction of throughput times optimization of all stocks improvement in plant capacity allocation high quality yield improvement in meeting the delivery schedule Execution All orders, partial orders, material stocks and production plants were fully integrated The new production planning covers all various time schedules for planning and control simultaneously Production planning integration into the underlying systems is true to time. Therefore, quick and accurate reactions to changes in day to day business are guaranteed

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 22 V4 V3 V2 V1 V8 V7 V6 V5 V74 V73 V72 V71 … CC1 Seq 4711 Heat x Heat 2 Heat 1 RF1RF2 RF3 V 70 V 170 V 71 V 171 V 72 V3V3 V 103 V1V1 V 101 V2V2 V 102 … P4P4 P3P3 P2P2 P1P1 HRM Seq 3423 P1 P2 P3 V101 V1 V102 ? … … V2 V103 Scenario Mixed Charging (1) V104 V103 V102 V101 V108 V107 V106 V105 V174 V173 V172 V171 … CC2 Seq 4712 Heat x Heat 2 Heat 1 In the first step a direct charging sequence provided by two caster is created The slabs will be distributed to two of the furnaces P4

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 23 PSImetals APS: Order combination HomeHome - Index - PSImetals APS – Material allocationIndex New combination order in PSImetals PO Routing Rolli ng Skin pass Cutti ng Finis hing Slitti ng Pack ing Rolli ng Skin pass Cutti ng Pack ing Basis production order PO1 from ERP/MES Basis production order PO2 from ERP/MES

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 24 PSImetals PES Achievement… Increased Throughput 1 extra 220t ladle/day, 1,5 – 2 % Energy Saving product reaches each stage with more precise timing reduced need to reheat ladles (cost leadership) Documented Quality full documentation on quality of every piece, to ISO 9000 standards - a key requirement in the automobile-industry Flexible & Adaptable new object-oriented system is very adaptable and easy to re-configure Easy integration of new aggregates (4th vacuum degasser, 3rd casting machine) HomeHome - Index - PSImetals PES Achievement…Index

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 25 PSI‘s Project at Böhler Steelplant, Austria The Benefits: Overall Production Execution System for the entire conventional and special melting technology as well as powder technology Integration of all production stages and all 23 facilities in one system Quality assurance by standardizing treatment practices for different grade groups High available, flexible and customizable system especially for configuration of new facilities and new characteristics Standardized data collection and long-term archiving of all production relevant data for easier evaluation Standardized and consistent production reporting and feedback to SAP for all facilities Reduction of system maintenance due to modern software technology WITH PSImetals PES.

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 26 PSI‘s Project at von Moos Steel, Switzerland The Benefits: One overall Production Execution System for the entire von Moos Enterprise including all production stages from scrap yard to the rolled product Exact time Scheduling for EAF, 3 LF, 2 VD and CCM as well as the crane leads to: increase of throughput avoidance of caster sequence breaks interrupts due to availability of the crane Energy Consumption Forecast and Control leads to: exact knowledge about energy demand reduced energy costs Standardized and consistent production reporting and feedback to SAP for all facilities Reduction of system maintenance due to modern software technology and less interfaces

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 27 PSImetals APS/ALS at Georgsmarienhütte: Improved Handling Capacity... Mill area There is now flexibility to adjust campaigns, to take account of changing order-book right up to time of rolling. Bottle-necks in the mill are minimised Testing & finishing area Throughput capacity is significantly increased -- thanks to improved HMIs, and to automatic allocation of billets to the most appropriate of the 3 lines Ability to view whole plant The entire plant is now viewed as a whole. Transit times at interfaces between areas are reduced, with benefits in lower inventory, higher throughput and precise delivery

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 28 Georgsmarienhütte: Some Extra Benefits… "Just In Time" order planning Clients now order smaller batches at greater frequency, to reduce their own inventory. So the planning system must deal with more orders, and smaller quantities per order, just to meet the same throughput tonnage. In fact, the year 2000 was a record year, with clients ordering more than ever before. But the new system successfully handled the increased loading. What is more, the new system consistently achieves great improvements in timeliness of order completion Excellent documentation Orders are now processed with clear and complete documentation, so that clients have the necessary quality documentation to meet their requirements Fast project start-up The project was completed in record time – just 10 months from order to completion. In spite of this, start-up was on time, and the new system ran smoothly from the beginning

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 29 PSImetals WTM for TKS, Beeckerwerth: Benefits TKS plant in Duisburg is a large integrated works, including steelmaking, rolling and finish processing line (5 million t/annum) Reduced Costs Increased throughput and reduced delays effective increase of 25% in storage space in the critical areas total inventory is reduced by 80% significantly fewer handling operations per coil Transport trucks now spend 25-30% less time in loading, unloading and waiting Improved quality Reduced coil damage Fewer „lost“ coils Better documentation More timely delivery HomeHome - Index - PSImetals WTM for TKS, Beeckerwerth: BenefitsIndex

Farben Buttons der Geschäftsgebiete Linienstärken 1 Punkt Städtebutton © PSI BT GmbH 2007 Slide 30 PSImetals for Blast Furnaces The task Balancing of the used materials Configurable collection and presentation of high speed process data Determination of the filling collection and representation of “burden” changes Execution of the burden calculation, model calculation Benefits Three different blast furnaces, one software Highly configurable Improvement of the operation by state-of- the-art HMI Simplification of the system structure Long term data archives of the process data for a furnace travel (approx. 15 years) HomeHome - Index - PSImetals for Blast FurnacesIndex