Integrated automation of foundry production with 1C:ERP and integration with a custom-built MES
Client company
Abinsk Electric Steel Works (AEMZ)| https://www.abinmetall.ru
Industry
metallurgy
About the company
A ferrous metallurgy company and producer of metal products in Russia. It is located in Abinsk, Krasnodar Territory, and is part of the Novostal-M metallurgical holding. The plant’s products: steel billets, construction rebar, round bars, wire rod, and welding and galvanized wire
Base solution
1C:ERP Enterprise Management
Automated areas
- Operation-level planning
- Shipment management
- Equipment downtime management
- Sales planning
- Warehouse and inventory
Results
- An integrated operation-level management system based on primary data from industrial equipment controls
- Shipment management in specific formats and packaging types
- Improved efficiency of full loading and repair downtime of casting and rolling equipment
- Improved target efficiency of the company’s inventory
AEMZ. Integrated automation with 1C:ERP and integration with a custom-built 1C-based MES
Industry: metallurgy
Headcount: more than 2,000
Software: 1C:ERP + custom-built MES
Number of workstations (user seats): 70
Project duration: 1 year
Current project status: fully implemented, under ongoing development
AEMZ’s core business areas are:
- steelmaking
- section rolling
- metal hardware
- oxygen plant
The company had historically developed its own MES that covered its production needs. The custom-built MES worked with the process equipment: Danieli (Italy) rolling mills. However, it completely lacked an economic calculations module. As a result, standard and actual costs were very difficult to calculate.
Goal:
Achieve integrated automation of the company by implementing 1C:ERP
Initially, there was an attempt to implement an MES module in 1C:ERP, but it failed because the standard 1C:MES did not handle their tasks the way the custom MES, developed specifically for them, did. Therefore, it was decided to integrate the legacy system with 1C:ERP
Objectives:
- transmitting all information on equipment status and on the start and completion of operations via the MES to 1C:ERP
- using data from the controllers of Danieli (Italy) casting and rolling equipment for operation-level management in 1C:MES;
- preparing formats for cut-to-length shipments of finished products, taking into account “tolerance,” shipping deviations, and delivery types;
- optimizing casting equipment loading depending on raw material types and on the results of semi-finished sample analysis at the central plant laboratory;
Results:
- An integrated operation-level management system based on primary data from industrial equipment controls
- Shipment management in specific formats and packaging types
- Improved efficiency of full loading and repair downtime of casting and rolling equipment
- Improved target efficiency of the company’s inventory