INTERNET OF THINGS IN STEEL MANUFACTURING

Computer Applications Technology Committee Meeting,

9th Oct 2014
Presented by HCL Technologies
Copyright 2014 HCL Technologies Limited | www.hcltech.com

Agenda

Definition

Significance of IoT

Making a Steel Plant Smart

Modeling How IoT can help

Big Data Analytics How IoT can help

Cloud & SaaS

IoT & MES

IoT Framework

Challenges in Implementing IoT

Copyright 2014 HCL Technologies Limited | www.hcltech.com

Definition

IoT is enabler for digitizing Manufacturing to be highly efficient and productive. It includes
Using intelligent devices, equipment to produce assets;
a cloud-based infrastructure for data processing
big data storage capable of addressing a complex value chain;
a combination of descriptive, predictive and prescriptive analytics and
software to support asset and system optimization;

Timelines

Copyright 2014 HCL Technologies Limited | www.hcltech.com

Significance of IoT

Smart
Manufacturing is
the targeted
New Normal
USs SMLC &
Germanys
Industry 4.0

Every Major
Vendor offers
Remote
monitoring
services

Automation to
substitute ageing
skilled work force

Copyright 2014 HCL Technologies Limited | www.hcltech.com

Making a Steel Plant Smart

Implement Condition monitoring/Predictive Analytics

Each Machine is like an Individual

The process automation data is not enough for diagnosing

such complex machinery as a plate rolling mill.
Example System & Causes of Hydraulic system
in Hot Rolling Plant

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Making a Steel Plant Smart

Interoperability among systems & equipment

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Making a Steel Plant Smart

Plant Operations Management from Mobile Devices

Accessories on mobile phones Intelligent Data acquisition devices

Mobile Workflow Management

In near Future Google Glass

Copyright 2014 HCL Technologies Limited | www.hcltech.com

Making a Steel Plant Smart

Wireless
Interoperability Control System, Mobile Devices
Ease of Remote Management

Track & Trace logistics solutions

RFID

Overall, the Ability to log all activities in a plant either by humans or machines for analysis

Copyright 2014 HCL Technologies Limited | www.hcltech.com

Modeling How IoT helps

Many models used in Steel Operations - e.g.

Sinter plant - Ore bed distribution in Sinter Plant
Blast Furnace Burden Distribution Model
Basic Oxygen Furnace Steel Bath &
Slag models

Models

provide accurate predictive

information leading to energy savings

IoT Engines
Packages for Genetic Algorithm
Abundant past data for model creation
R can be used for Modeling-solving differential equations deSolve, ReacTran
CARET package in R ideal for modeling
Fitment of existing models becomes very easy.

Copyright 2014 HCL Technologies Limited | www.hcltech.com

Big Data Analytics How IoT helps

Dynamic Rescheduling using IoT

Hot Charging
MES do not have vision of upstream units

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Copyright 2014 HCL Technologies Limited | www.hcltech.com

Big Data Analytics How IoT helps

Pattern Recognition
Constant Risk monitoring based on past data

Video Analytics on Cloud

Thermal Imaging of refectories,
High-speed video captures roughing mill operation for analysis

Complex Event Processing (CEP)

Data Stream Analysis e.g. Alert when sinter size exceed 5% deviation in 10
minute timeframe
Microsoft StreamInsight,
SQLStream open source

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Copyright 2014 HCL Technologies Limited | www.hcltech.com

Cloud & SaaS

Performance and Availability Guaranteed

Unlimited, almost inexpensive data storage
Multi Tenanted Architecture
Pay only for what is used
Subscription Model Gold, Silver, Bronze
Services offered
Analytics as a Service
Storage as a Service
Applications as a Service

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Copyright 2014 HCL Technologies Limited | www.hcltech.com

Cloud & SaaS

Select List of Providers of Machine Learning as Service

13

Name

Services

Microsoft Azure Machine

Learning

Based on Azure platform, MS offers standard R and their research

division developed Algorithms

Yottamine Analytics

provides machine learning (SVM) based predictive models in the cloud.

Pricing is based on usage.

Zementis, Inc

offers predictive models as a fully hosted service through Amazon

Elastic Compute Cloud (EC2).

Sight Machine

merges machine vision and big data to control quality.

Ayasdi

provides a mathematical framework for analysis of complex, multivariate datasets

SkyTree

Successfully deployed algorithms for preventive Maintenance

Copyright 2014 HCL Technologies Limited | www.hcltech.com

ML Studio in MS Azure

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Copyright 2014 HCL Technologies Limited | www.hcltech.com

IoT & MES

MES is specific to 1 plant, IoT is plant wide

Power of IoT is on the Cloud,
Analysis Services, Pay as you Use
Periodic Application change
Remote Monitoring of equipment
Large Historian Data Analysis

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Copyright 2014 HCL Technologies Limited | www.hcltech.com

IoT Framework

16

Copyright 2014 HCL Technologies Limited | www.hcltech.com

Challenges in IoT Deployment

Cyber security
Can affect any equipment
Apprehensions of Cloud Security
Making old equipment smart
Reliable Internet connection
scalability, security, availability and inexpensive
Changing Managers/Operation Mindset
Training
See Tangible Benefits

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Q&A

Copyright 2014 HCL Technologies Limited | www.hcltech.com