Automated Predicitive Analytics For Steel/Metals Industry

SORBA IoT

Automated Predicitive Analytics For Steel/Metals Industry

SORBA IoT SORBA IoT
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OVERVIEW

Asset to be monitored: Wire Compactor that produces Steel Rebar

Customer Faced The Following Challenges:

  • Dependent upon machine uptime.
  • Pressure cylinders within the compactor fail to control compression and speed causing problems in binding the coil.
  • Equipment failure occurs in the final stage of production causing the entire line to stop, can you say bottleneck?
  • Critical asset unequipped with sensors to produce data.

A Steel Manufacturing Plant Produces Ponstruction Grade Rebar. 24 Hours a Day, 7 Days a Week, Scrap Metal is Converted into Steel. Each Year the Plant Produces 1.1 Billion Pounds of Steel Rebar Used in Concrete. That’s Enough Rebar to Circle the Globe.



The Results:

  • SORBA-SDC (Smart Data Collector) connected to a Siemens PLC, collecting months of time series data to analyze behavior of equipment.
  • Eliminated unplanned downtime for critical plant assets.
  • Improved asset utilization rates, thus optimizing or reducing CapEx/OpEx costs.
  • Minimized cost but not engaging IT personnel to connect into the enterprise network.
  • SORBA does not require any firewall ports to open.
  • Detected anomalies with lead times up to 20 days. Correlated all potential issues with work order events.
  • Achieved an operational savings, in one application, of over $100,000 annually at just one site.

 

IOT
Mature (technology has been on the market for > 5 years)
OPERATIONAL IMPACT
Minimized cost but not engaging IT personnel to connect into the enterprise network.
SORBA-SDC (Smart Data Collector) connected to a Siemens PLC, collecting months of time series data to analyze behavior of equipment.
QUANTITATIVE BENEFIT

Achieved an operational savings, in one application, of over $100,000 annually at just one site.

Detected anomalies with lead times up to 20 days. Correlated all potential issues with work order events.

Eliminated unplanned downtime for critical plant assets thus Improving asset utilization rates while also optimizing/reducing CapEx/OpEx costs.

TECHNOLOGY

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