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Tenova in the Industry 4.0
The Microsoft -Tenova partnership
Tenova in Additive Manufacturing
Francesco Memoli
Executive Vice President
Tenova Inc.
November 2017
The four industrial revolutions
November 2017Tenova in the Industry 4.0 1
WHY WE CALL IT INDUSTRY 4.0
Industry 4.0 Steel Plant Vision
• New Field Data generator: Sensors, measurement devices etc.
• A unique Interconnecting Platforms
• “Whole Process” Data Analysis & Optimization
• Business Level Optimization
Today’s Challenges
November 2017Tenova in the Industry 4.0 2
WHAT WE HAVE TO OVERCOME AND IMPROVE IN THE MINING AND METAL SECTOR
Volatility Efficiency Productivity
Understand the
exposure at every stage
of the value chain. Avoid
risks arising from timing
differences between the
selling price of steel and
purchasing price of raw
materials.
Understand the
operational efficiency of
the value chain. Reduce
errors, downtime, improve
product quality, expand
faster beyond markets
and reach customers
quicker.
Understand the
production capacity of
the value chain. Improve
performances by monitor
the OEE, forecast market
supply and demand by
proactively plan key
activities.
- Risks - Errors + Performances
Industry 4.0
CapabilitiesCloud Computing Big Data Internet of Things Advanced Analytics
Today’s Challenges
November 2017Tenova in the Industry 4.0 3
WHAT WE HAVE TO OVERCOME AND IMPROVE IN THE MINING AND METAL SECTOR
Volatility
Business Challenges KPIs
Produce actionable
insights for supply chain
Develop more effective
procurement strategies
Efficiency
Digitizing the equipment to
streamline operations
Monitor machineries to
reduce errors and failures
Productivity
Detect inefficiencies and
increase process quality
Increase the overall
equipment efficiency
- Risks
% of expenditures saving
by predictive maintenance
% of expenditures saving
by forecast inbound stocks
- Errors
% of expenditures saving
by digitizing spare parts
% of revenues by
increasing the plant OEE
+ Performances
% of efficiency related to
MTTBF and MTTF
% of performance by
control the equipment
Industry 4.0 Capabilities
Cloud ComputingOpen standard platform,
able to compute tons of data
Big DataHeterogeneous data sets to
serve real-time analysis
Internet of ThingsCollect data from field
gateways and devices
Advanced AnalyticsData insights to drive
business actions
Partnership with Microsoftxx
Cloud computing, IoT, and machine learning: three key ingredients of Industry 4.0 that will change the way of creating
value in the near future. To make this happen in the metal Industry, Tenova and Microsoft combined efforts and
launched a partnership in May 2017 to develop a new platform which will support new business models based on
collaboration and services.
November 2017Tenova in the Industry 4.0
INDUSTRY 4.0
Microsoft - Tenova partnership
November 2017Tenova in the Industry 4.0 5
GOALS
• The goal of our partnership with the IT world leader is to develop an
integrated industrial system where the analysis of data gathered on the field
through multiple sensors and actuators allows to monitor plant machines,
detect anomalies autonomously and optimize overall plant performances. This
complex architecture is enabled through Microsoft Azure cloud platform and
provisional algorithms based on machine learning technologies.
• The centralized digital platform developed with Microsoft will provide more
informative support, so to offer a broad service portfolio, including
predictive maintenance, spare parts management, personalized settings,
and more effective remote assistance. The added value for the customer is
not just in the final product, but in the optimization of the entire process, gaining
advantages in terms of productivity and, consequently, competitiveness.
Tenova IoT Facts & Figures
13 December 2017
EXCEPTIONAL PRODUCTS WITH CUSTOMER IN MIND
Submerged Arc Furnace (SAF)
40Electric Furnace
(EAF, LMF)
Vacuum Degassers (VD/VOD/RH)
1000Heat treatment
Furnaces
11,000DRI Plants
20Burners on
Reheating Furnaces
20,000
300Strip
Processing &
Cold rolling mills600
Roll
Grinders
500,000 +
IoT devices
200,000+
IoT devices
80,000+
IoT devices
1,500,000+
IoT devices
800,000+ IoT devices 100,000+ IoT devices
50,000 +
IoT devices
6Tenova S.p.A. | Confidential & Proprietary
One Service
November 2017Tenova in the Industry 4.0 7
A SERVICE MODEL CENTERED IN THE RESULTS
Provide customers with the technology, information and insight needed to improve the productivity of their plants
Predict downtime and increase plant Availability/reliabilityGather data from the field Customers Deliverables &
Revenue Drivers
• Predictable maintenance and reduction of non-
planned assistance.
• Maintaining a high level of productivity and
production capacity for plants
• Remote spare parts and stocks Management
• Efficient assignment of labour resources
• Increasing the overall equipment efficiency
• Improving reliability and up-time of assets
• Energy saving & Environment sustainability
Customer Benefits
• Collecting product usage information and configuration
from customers to offer new value added services
• Collecting running data and root causes of downtown and
diagnostics to improve our product design
• Analysing data and insights coming from all production
plants in the world to ensure high level of productivity
• Digitalization of technical manuals and Bill of Material
(BoM) with focus on spare parts management
• Add value to our existing products by adopting cloud
technologies and Software
Win-Win opportunities
• Remote support by Tenova specialists who constantly monitor key
plant data: Telemetry, Performance, Maintenance and giving
suggesting actions, and advice for troubleshooting;
• Service assistance and spare part digitization and purchasing portal
fully integrate with maintenance (MTBF, MTTF) and remote support;
• Plant dashboard to provide more effective problem solving and
supervision both from client resources or our customer service
specialist with support of advanced technologies;
• Automatic Anomaly detection and Predictive Maintenance service, to
identify when equipment is likely to fail or need service in the future.
Value proposition
Sensors
Telemetry
Data from Equipment
Uptime/Downtime
Equipment
Digitalization
Plant Performance
Personalized
SettingsRemote
Assistance
Spare parts
Management
Predictive
Maintenance
Handheld
dashboardEquipment & Spare
Parts Digitalization
Analyze data coming
from plants
Digital Diagnostic
Center Customer Service
Advanced Analytics /
Machine Learning
Anomaly Detection
Assistance
One Service
November 2017Tenova in the Industry 4.0 8
A SERVICE MODEL CENTERED IN THE RESULTS
Practical example of system platform
November 2017Tenova in the Industry 4.0 9
A SERVICE MODEL CENTERED IN THE RESULTS
On Site
Off Site
• Agumented Reality
• Simulation
Training
Commissioning
• Monitoring key
equipment KPIs
• Anomaly Detection &
problem solving
Remote Plant
Monitoring
• Predictive Maintenance
• Entire process
optimization
• Equipment parameters
tuning
Cloud based
services
• Web Portal
• Digital Catalogue (Spare
parts Management)
• CRM (Service)
Online
Marketplace
Secure & Open
Standard
Hybrid Cloud
SAF EAF Furnaces
LOI
Furnaces
HTC
Grinders SP
I2S
Furnaces
ITA
DRI
Plant
OPC Gateway
Plant Control:• Sequence/PID
• Alarms
• Emergencies
Digital
Diagnostic
Center
Mobile tools
ERP
CRM
MES
Local
Partners
Scrap
YardEAF LF CCM
Reheat
FurnaceRolling
Mill
Billet
Yard
Heat
Treatment
Steel_4.0 Lighthouse: ORI Martin Cyber Physical FactoryIntelligent steelmaking as a collaborative platform
Tenova
DEPSRemote service
PLC / OPC Server
Plant Telemetry
Real-Time
Calculations
Big Data analysis
Level 3 production information
Tenova Electronics and
software
Anomaly Detection
Advanced Correlation
Process deviation
Model offline tuning
Plant Equipment feedback
Self auditing
Process measurements
Water leak detection
Equipment inspection
Process control
Safety
Environment
Predictive Maintenance
> 80 plants data
available
MADE4LO
A new model of productive chain based on 3D manufacturing. Starting from the optimization of the metal powders
process, the selection of the components to be made with 3D printing, with a focus on burners components for heat
treatment, reheating and electrical arc furnaces, and the realization of a furnace for their heat treatment that will be
assembled in the Pomini workshop, within Tenova’s Campus in Castellanza, Italy
November 2017Tenova In the Industry 4.0
OUR BUSINESS AREAS
Metal Additive for Lombardy
November 2017Tenova in the Industry 4.0 12
MADE4LO
• Additive Manufacturing (AM), also known as 3D printing, is one of the enabling
technologies of Industry 4.0.
• Despite rapid growth, the use of AM in industry is still marginal so far respect to
the traditional subtractive technology, but at AM is disruptive technology. The
use of AM with metal powders (Metal Additive Manufacturing) is a growing
industry and already suitable to produce complex metal parts. The current
applications span from aerospace and defense to automotive, industrial
products, medical devices and consumer products.
• MADE4LO, partially funded by the European Regional Development Fund in the
framework of Lombardy Region’s Research and Development Agreements,
consists in an investment of 6.6 million euros and involves in the partnership
two universities, among which Politecnico di Milano, three Big Industries and six
SMEs led by Tenova.
Metal Additive for Lombardy
November 2017Tenova in the Industry 4.0 13
MADE4LO PROJECT PARTNERS UNDER THE LEADERSHIP OF TENOVA
LINEA “ACCORDI PER LA
RICERCA E
L’INNOVAZIONE”
@#
Project definition
safety
Health and Safety
3d printing
laserPost
processing
Post treatment Final users
steel
Cu
powder
plant
Metal powder
process/technologies
!?!
Metal powder
production
Metal Additive for Lombardy
November 2017Tenova in the Industry 4.0 14
MADE4LO
Customised
product
Customised
powder
New
generation
3D printer
Technological
Knowhow
On-job
Training
13/12/2017
Case
study
Casing
valve
Gearmakers
Silencer
Laser head
for DEM
EAF oxygen
injector
3D printed parts for EAFs
November 2017Tenova in the Industry 4.0 15
FIRST EXAMPLE OF A 3D PRINTED PART FOR THE EAF STEELMAKING
EAF KT Supersonic Oxygen Lance Nozzles
• Formerly machined with conventional methods
• New material has been studied with CFD tools
• New optimized geometry has been designed
• New additive manufacturing process has been defined
• The right printer has been selected for the purpose
• Nozzles are now 3D printed and are working in EAFs
Benefits for Steelmakers
• Customized geometry
• Lighter weight
• Enhanced performance
• Extremely short lead time
• Reduced cost
• Streamlined supply chain
Tenova S.p.A.
Via Gerenzano 58
21053 Castellanza, VA – Italy
tenova@tenova.com
www.tenova.com
Tenova Inc.
100 Corporate Center Drive
Coraopolis, PA 15108 – USA
core@tenova.com