Challenge
- High quality requirements for rolled steel tubes (constant tube thickness over entire length) in various dimensions and qualities
- Experienced operators with many years of know-how will soon retire (knowledge drain)
- Training new operators is lengthy and generates a lot of scrap at the beginning
- Per order, 15 to 20 pipes are scrap until quality is satisfactory
Solution
- Acquisition of all important production data
- AI-based scrap analysis and optimization of all steel tubes produced
- Simulation of all possible pipes and their best possible configuration using AI
- Pre-configuration of all steel pipes produced in the future as support for operators
Benefit
- Higher quality of all seamless steel tubes even for tubes never produced before
- Reduction of scrap by more than 80%
- Faster training of new operators
- Reduction of maintenance costs through predictive maintenance
- Integration of all production data into an overall concept for optimizing facility control
- Simultaneous process control of several facilities with consistently high quality
