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DRIVING INNOVATION IN STEEL MANUFACTURING
Modern steel making uses large, plant-wide, automation systems that require continuous upgrades to stay competitive. Integrating new technologies such as, for instance, artificial intelligence, within a cybersafe environment, requires a comprehensive understanding of the information exchange process. Letico’s expertise in automation makes it a trusted partner in steel transformation. Our involvement with ArcelorMittal is an example of where Letico’s expertise in large, plant-wide, automation systems played a pivotal role in helping to implement ArcelorMittal’s vision.
Steel plants are highly integrated environments where even minor system upgrades can significantly impact overall operations. Letico excels in managing these complexities. Our collaboration with ArcelorMittal included meticulous planning, multi-stakeholder engagement, and detailed system testing, ensuring a robust and reliable process for integration into their existing infrastructure.
ArcelorMittal tasked Letico with integrating an autonomous robotic marking system, to achieve improved efficiencies at three of its sites, each with unique requirements.
Marking systems permit tracking of steel product from one stage to the next and between facilities. ArcelorMittal planned to integrate data from the automated marking system into its multi-level control architecture (levels 1, 2 and 3) to ensure traceability of steel products across production stages and facilities.
After integrating tracking into the control architecture, ArcelorMittal aimed to leverage the data across three applications in three different facilities:
1. Contrecoeur East (CCE) Slabs: Letico worked on improving the efficiency of yard operations.
Photo: Slab, Source
2. Contrecoeur West (CCW) Rebar: Letico automated the Simac strapping machine to streamline the rebar bundling process.
Photo: Rebar, Source
3. Longueuil (LGL) Wire Rod: The team upgraded the weighing station at the factory exit to optimize the flow of data from the shop floor to the central management systems.
Photo: Wire Rod, Source
(Photo: ArcelorMittal)
Letico aimed to integrate a new robotic marking system across multiple facilities. The process included assessing technical feasibility, negotiating with stakeholders to receive buy-in, careful planning for a successful integration with plant-wide automation systems and planning for continuity of legacy equipment. Letico updated PLC programming, managed engineers at ArcelorMittal and reported key insights.
Diagnostics
Letico conducted a comprehensive assessment of the marking process, identified process and spatial limitations which impacted system performance, operator access and the safety of personnel.
Further assessment showed that the marking process needed to be redesigned. To ensure the redesign would be compatible with new equipment, Letico wrote core PLC programming to interface with legacy equipment. The resulting program permitted the implementation of a robust tracking system and integration of data at Levels 1, 2 and 3. Letico supported this initiative through planning, coordination and close collaboration across departments and levels.
Implementation: Reengineer for Robustness
Implementation of the tracking system at each site, Contrecoeur East, Contrecoeur West and Longueuil, then required custom integration. To effect this change, Letico worked with ArcelorMittal’s leadership team, engineering, maintenance personnel and IT group to understand the context of each production site. Letico planned and engineered the integration to address both mechanical and operational aspects of the autonomous marking system and to fit the OT/IT context of each site.
For the sake of brevity, we provide an overview of CCW only. But we would be pleased to discuss CCE and LGL. Please contact us to learn more.
Contrecoeur West (CCW): Evaluation
The control sequence redesign at CCW started with an assessment of the entire production process. Letico identified mechanical complexities and system design challenges that impacted process flow & timing. Next, Letico suggested modification to the marking process including the label, the hook, the stud, the welder used to attach the stud and the industrial robot used to insert the label on the hook. Letico identified several issues that limited the function, integration, or compliance of markers with performance targets.
CCW: Resolution
Letico then committed to rework the entire control sequence and provided strategic planning to organize both internal and OEM resources to minimize production line disturbances. Once the control sequence was corrected, it was tested offline. After verifying the offline test, Letico proceeded with online testing.
CCW: Implementation
For online testing, Letico stayed to supervise and manage the site preparation, the installation of the robot module, the commissioning and production ramp-up phases while reporting progress to management at ArcelorMittal.
Through the redesign of the automated marker systems at Contrecoeur West, and similar work at Contrecoeur East and Longueuil, Letico played a key role in helping ArcelorMittal enhance traceability across its operations. This collaboration uncovered valuable insights and laid the foundation for continual improvement to the steel production process, all while managing operational complexity. Building on this success, Letico looks forward to the next opportunity to support ArcelorMittal and advance both existing and new automation initiatives.
