AI is transforming Steel Manufacturing

Achieve real impact with pre-emptive actions because real-time is often too late.

DataProphet’s PRESCRIBE is at the forefront of AI for the manufacturing sector. We offer a manufacturing optimization solution designed to prescribe changes to multiple processes in order to eliminate defects, reduce scrap and improve yield in the production process.

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Suite of AI solutions

DataProphet PRESCRIBE works in tandem with our other products, DataProphet CONNECT and DETECT, in order to create a holistic system to provide data and guidance from all available data.

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Expandable across multiple plants

DataProphet’s solutions are able to scale across multiple processes, production lines and plants. This allows businesses to start small and expand effortlessly further down the line.

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Increase productivity and reduced costs

DataProphet PRESCRIBE, through prescriptive changes to process parameters and smart identification of potential issues, is able to mitigate most of the costly events on the production line, including; defect occurrence, line interruption for troubleshooting, slow production rate due to control plan fine tuning.

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Integration with existing systems

Our AI solution integrates with current systems in the plant both for data integration as well as delivering prescriptions leveraging existing “level 2” controllers.

Steel plays an important role in the global economy and pioneers in the steel industry must find efficiencies through new technologies to remain competitive amidst increasing pressure on margins. An integral aspect of the steel manufacturing process are rolling mills, which consist of equipment for reheating, rolling, and cooling. Each of these three stages contain several parameters that play key roles in the outcome of the final product.

During the rolling stage, temperature, reduction in area, inter-pass time, and strain rate are important parameters to control. The combination of which, along with others, may affect the quality outcome of a given product including surface defects or out of specification mechanical properties.

Those defects in the steel manufacturing process include chatter, scabs, seams, and silvers as well as rolling defects. In fact, the defect rate within rolling mill production can vary from 3% to 20% depending on the product which results in lower yield, extensive troubleshooting, downtimes, as well as the scrapping of valuable products.

Expert Execution Systems (EES), such as DataProphet PRESCRIBE, are able to learn from existing process and quality data sources in order to understand the complex interactions within manufacturing processes. In doing so, DataProphet PRESCRIBE is able to prescribe changes to key parameters, preemptively, in order to avoid non-quality and keep product metrics such as dimensions and surface quality within specification.

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Some of the clients benefiting from DataProphet’s PRESCRIBE

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The Data Requirements for AI in Manufacturing

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How machine learning can optimize the steel milling process

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Maturity Self-Assessment for Industry 4.0

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