Steel demand is benefitting from the broad and favourable global economic momentum affecting both the developed and developing world at the same time.

Figures published by the World Steel Association suggests a growth of 1.8% in 2018 and 0.7% in 2019.  The global metal manufacturing market is expected to reach around $4000 billion in 2020.  Factors driving the global market include a growing global population, an increase in infrastructure and rapid industrialisation.

Latest figures published for world crude steel production for the 64 countries reporting to the World Steel Association (worldsteel) was 154.6 million tonnes (Mt) in July 2018, a 5.8% increase compared to July 2017.  The crude steel capacity utilisation ratio of the 64 countries in July 2018 was 77.5%. This is 3.8 percentage points higher than July 2017. Compared to June 2018, it is 1.4 percentage points lower.

The market is expected to stabilise due to recovery in developed economies and accelerating growth in emerging and developing markets such as Russia, China, Brazil and India.  Companies are focussing on improving competitiveness by optimising existing and developing new processes to reduce cost and environmental impact, and improve quality.

What Greycon can do for you

The challenging dimensional requirements of the metal industry fits exceptionally well within the solutions that Greycon has established as the world-leader for roll and flat sheet industries.

Greycon provides optimisation at multiple stages of the production and planning process, allowing significant savings, quick return on investments, and better decision making.


Greycon Metals Case Studies


Greycon's Solution

opt-Studio

opt-Studio can help you to increase throughput, reduce stock levels, improve manpower utilisation and minimise overrun. In addition, you will be able to reduce delivery lead times, strengthen customer relationships, prioritise orders and respect promised delivery dates.

  • Create production cycles for mills and let the system automatically adjust the schedule upstream (slitting) and downstream (cutting, folding, painting, etc.).
  • Automatically allocate orders to cycles as they arrive, using Available-to-Promise / Capable-to-Promise (ATP/CTP).
  • Dynamically distribute tasks among similar machines to reduce setups and balance the load.
  • Build simple yet powerful models with partially-defined products and order level attributes.

X-Trim

X-Trim’s world class optimisation capability is now (December 2012) in use in 16 metals plants around the world.

Applications include many different end-uses, such as:

  • Rings for bearing production
  • Panels for the automotive industry
  • Plates for civil engineering
  • Pipes
  • Coils (for several purposes)

Functionality

Specific functionality for metal cutting includes:

Width tolerance

Specially for square section tube production, the same item (tube) can be made from a strip of metal within a given range in width, without altering its specification or product definition. X-Trim understands this and can take advantage of it to maximize the use of the stock roll.

Raw Material Optimal Width

Even though is not the primary function of X-Trim, it will allow the company to calculate which are the best widths to purchase (or have in stock), based on the average order. In many metals companies, this is done rarely, even though the average width of the orders change over time. With X-Trim this can be done in a matter of minutes.

Scrolling Graphical Display

A scrollable and zoomable, coil-by-coil graphical display can show length and width losses:

Coil Stock Inventory

X-Trim considers many different aspects in evaluating the possible consumption of input coils, such as:

  • Age
  • Quality
  • Width & length waste

The system also evaluates return-to-stock as a possible solution option.

xtrim_metal_stock_penalty

Production Routes

As with all versions of X-Trim, orders can be fulfilled from coil stock, semi-finished stock and finished stock (and any mixture thereof). A sheet order for example could be produced like this:

The user can either allow the optimisation to select the route mix (with appropriate cost factors for each option) or also pre-allocate some stock manually.


Some of Greycon's Metals Industry Clients

Axis Pipe and Tube

GGB Bearings

PROLAMSA

Regiopytsa

Usiminas

Vallourec