AUTOMATION OF MATERIAL HANDLING IN VIZAG STEEL PLANT

PROJECT STATUS REPORT SUBMITTED BY P.Ashok Chakravarthy Registered No: 1221312101 M.Tech, IE&M.

Under the guidance of Smt.V.V.K.Lakshmi Assistant Professor, Department of Industrial Engineering, GIT, GITAM University. Visakhapatnam-530045.

Abstract With Modernization of Steel Plants the demand for Automation of Supply Chain Management has been increased which involves the computerization of material flow records. Computerization of record can be accomplished with many techniques which includes RFID and Barcodes. RFID (Radio Frequency Identification) technology uses radio frequency signals to realize contactless information transmission by space coupling (alternating magnetic field or electromagnetic field) and attain the identification by transferred information. RFID technology cuts a brilliant figure by the chance. Tags with lower and lower costs could be glued on the packages of commodity conveniently and replace bar codes as an important method of supply chain management. It is suggested to increase the strength of supply chain management by automation of certain parameters of supply chain . This project work will suggest the implementation of RFID technology at Vizag Steel Plant to improve the existing logistic in transportation system and identification of items. Implementation of automated Supply chain management can be suggested to increase profit and more customers oriented. It is suggested to increase the strength of supply chain management by automation of certain parameters of supply chain. RFID technology in transportation and identification of products can be implemented. The implementation of this technology will minimize errors in transportation and identification.

Literature Review
[1]

Rajat.Kumar Panigrahy, S Pattnaik, N.G.P.C. Mahallick, A. K. Panda, 2011. Implementation of automated Supply chain management can be suggested to steel plant to increase profit and more customers oriented. After modernization of steel plant material tracking. A large number of steel plants from the other private entrepreneurs are leading in the nation. RFID technology is suggested to increase the strength of supply chain management by automation of certain parameters of supply chain management. RFID technology in transportation and identification of products can be implemented. The implementation of this technology will minimize errors in transportation and identification.
[2]

Muhammad Muazzem Hossain, Victor R. Prybutok, 2008. Radio frequency identification (RFID) technology is used in numerous applications and offers a plethora of interesting potential new applications. However, this potential raises issues that require addressing to achieve its widespread acceptance by consumers. This paper investigates the factors that affect consumer acceptance of RFID technology. The purpose of this effort is to develop and test a theoretical model that contextualizes the technology acceptance model (TAM) within the context of RFID technology. The research model proposes that convenience, culture, privacy, regulation, and security are the principal factors influencing the consumerspsila acceptance of RFID. However, the results show that convenience, culture, and security are significant predictors. This study is the first in the RFID literature to use the TAM for explaining consumer acceptance of RFID technology.
[3]

Ming-Ling Chuang, M.-L:Western Connecticut State Univ., Dandury ; Shaw, W.H. 2007 RFID: Integration Stages in Supply Chain Management. Radio frequency identification (RFID) is an enabling technology that promises to create value through greater visibility in supply chain networks, higher product velocity, more efficient inventory management, reduced labour cost, and reduced human error. However, it is still not clear if these objectives can be fully achieved due to high tag costs and uncertain return-ofinvestment (ROI). We introduce the key components and concepts of RFID applications and identify key issues when implementing RFID in supply chain networks. We suggest an RFID integration model that allows for degrees of integration breadth
[4]

K. Michael, L. McCathie,2005.The pros and cons of using Radio-Frequency Identification (RFID) in Supply Chain Management (SCM). While RFID has a greater number of benefits than its redecessor, the bar code, it currently comes at a price that many businesses still consider prohibitive. On the one hand, RFID is advantageous because it does not require lineof-sight scanning, it acts to reduce labor levels, enhances visibility, and improves inventory management. On the other hand, RFID is presently a costly solution, lacking standardization, it has a small number of suppliers developing end-to-end solutions, suffers from some adverse deployment issues, and is clouded by privacy concerns. Irrespective of these factors, the ultimate aim of RFID in SCM is to see the establishment of item-level tracking which should act to revolutionize SCM practices, introducing another level of efficiencies never before seen.

[5]

Jinhe Wang ; Sch. of Comput. Eng., Qingdao Technol. Univ., Qingdao, China ; Nan Zhang ; Qinggang He 2009 Automated logistics is very important for the growth of a manufactory, with which the efficiency of the operation is much obvious than doing the work manually. Therefore, the application of automated logistics is more and more important in modern manufactory. This paper discusses the application of logistics automation, and analyzes the techniques for manual and automated solutions. Finally, the automated storage & retrieval system is described, and the flexibility and efficiency of the AS/RS can be rapidly deployed and integrated to provide customers with improved inventory visibility and maximum throughput.
[6]

Bin Hou ; Bus. Sch., Hunan Univ. of Technol., Zhuzhou, China,2011. Optimization of logistics warehousing distribution is of a significant practical meaning for improving the efficiency of logistics. RFID techniques can identify goods exactly, track the process of warehousing distribution and improve its efficiency. This paper establishes an optimized model of the logistics warehousing distribution based on RFID technology. By using this model, the efficiency of warehousing and resources utilization can be improved while the cost of logistics decreased, and thus improve the customer service.
[7]

Hui Tan,Department of Business Management,Nanjing Institute of Industry Technology The influence and function of RFID in supply chain logistics management, analyzes the technological advantages of applying RFID and establishes a RFID application framework in logistics & supply chain management according to the characteristics of RFID itself and logistics industrial; In order to solve the problem of information sharing and collaboration among many enterprises in different fields, this paper proposes RFID internet of things application system based on Web Service-based distribution and states in detail as to the realization of the system.
[8]

Sun Lu, Management School, Harbin University of Commerce, Harbin, China. In recent years, Radio Frequency Identification (RFID) gradually becomes essential to improve the logistics supply chain management. This paper describes the characteristics of RFID technology, also analyzes problems of RFID applied in logistics supply chain management, such as the high cost of raw materials, real-time tracking problems, the limited service, low level of logistics management. The application of RFID technology can achieve cost savings, real-time tracking of goods, improve the recognition rate, and improve operating efficiency. On this basis, further study on RFDI development prospects in the logistics field has a certain reality and reference.

Report
RFID IN VIZAG STEEL PLANT At present all the handling activities are performed by visually identifying a product. Writing down its identifier and entering the information into the appropriate IT system. This process consumes time, there is also a risk of human error. The hot rolled still coils are tracked in the yard and with the help of a chalk it is marked. This job is highly tedious. Transporting slab, sheet, coils between different locations inside the plant and outside the plant is very important task of the supply chain management. In business case RFID in slab and coil logistics makes most sense when there is a significant amount of transportation is required between production sites or a significant amount of coil locations. Inter site transportation requires secure Identification. Wrong identification of slabs and coils increases the cost, reduces efficiency, risk of human error and safety issues. Optimal vehicle management is a crucial step. Due to manual use the number of fleets of trucks, trailers, heavy lifting vehicles are very high. By use of RFID technology optimal use of lifts and vehicles will be possible. By RFID the identification of each coil both with overhead cranes and forklifts is easier. Both the overhead crane and forklift operator should have a RFID reader. When this comes in close contact with the coil it can be identified. The system will keep track where coils are which have been moved to the target. When the crane moves into the coil storage yard, the coil ID number and the storage location are identified and co-ordinate in a database. So the plant worker can locate where coil is present. A. Slab yard inventory & issue of rolling schedules At present for each coil a number is generated by PPC system and accordingly invoice is prepared. The invoice is sent the customer. By this process there is possibility of human error at every stage a model of the tag to be attached is enclosed. This contains the Coil No., cast No, Grade Size, Weight, Destination, and Date of loading. This is passed with the coil. Even though bar code is mentioned but it is not implemented. Computers are used to process, analyze and display information about many processes involving moving things. Entering the information about the status of moving things requires repeated data entry which is cumbersome, expensive and error-prone. Consequently, many automated systems have been developed to perform this data entry task. Together these systems are referred to as automatic identification (Auto ID) system.

B. Role of RFID Tag in slab yard/coil yard The slab yard stores a large no of slabs ready for the Hot Strip Mill where each slab will be reheated and rolled into the steel coil. A proper slab is to be fed as per the rolling program. If a required slab is not at the top of the stack, the above slabs must be put aside first. This is called slab stack. By RFID proper slab can be identified. The improper slab selection causes more shuffling operation and even delay in slab delivery. Further charging with improper slab will create disturbance in the supply chain. At present the supervisor present in the field locates the slabs and as per his instruction the slabs are being selected and charged by the crane operator. During delivery to the customer proper coil is selected in yard and loaded in the locomotives.

Conclusion: In the given project so far the literature review is being completed, related data for the purpose of the project is being collected and the required calculations are being calculated by using effective methodology which result in improvement in problem solution of the project Finally, the documentation work needed to be completed

Signature of the Guide, (Smt.V.V.K.Lakshmi)

Submitted by P.Ashok Chakravarthy (Regd NO: 1221312101)

Bibliography: [1]. Rajat.Kumar Panigrahy, S Pattnaik, N.G.P.C. Mahallick, A. K. Panda, Automation of Supply Chain Management in Rourkela Steel Plant, 978-1-4577-1894-6/11/2011 IEEE. [2]. Muhammad Muazzem Hossain and Victor R. Prybutok, Consumer Acceptance of RFID Technology: An Exploratory Study, IEEE TRANSACTIONS ON ENGINEERING MANAGEMENT, VOL. 55, NO. 2, MAY 2008, 0018-9391/ 2008 IEEE. [3]. MING-LING CHUANG ,WADE H. SHAW, RFID: Integration Stages in Supply Chain Management, IEEE DOI 10.1109/EMR.2007.899757, IEEE ENGINEERING MANAGEMENT REVIEW, VOL. 35, NO. 2, SECOND QUARTER 2007. [4]. Katina Michael, Luke McCathie, The Pros and Cons of RFID in Supply Chain Management, 0-7695-2367-6/05 , 2005 IEEE.

[5]. Jinhe Wang, Nan Zhang, Qinggang He, Application of Automated Warehouse Logistics in Manufacturing Industry, 978-1-4244-4246-1/09, 2009 IEEE.

[6]. BinHou, The Optimizing Model of the Logistics Warehousing Distribution Based on RFID Technology, 978-1-4577-1587-7/111,2011 IEEE. [7]. Hui Tan, Application Research of RFID in Supply Chain Logistics Management, 9781-4244-2013-1/08, 2008 IEEE.

[8]. Sun Lu, Research on Supply Chain Management Based on RFID Technology, 978 -14244-8385-3/11/ 2011 IEEE.