Case Study and Examination of Production Methods in a Steel Manufacturing Facility

This research represents a practical case study focusing on the technical and energy evaluation of proposed production lines within a steel manufacturing facility. It incorporates IoT-enhanced SCADA (Supervisory Control And Data Acquisition) technology into its modern control systems framework. The analysis also includes an examination of the mechanical and electrical maintenance sectors in the factory, as they significantly influence both production costs and energy usage. The investigation was carried out in two primary stages: initially, data collection and process assessment were performed through traditional direct observation methods along with activity classification; subsequently, a proposed control methodology emphasizing architectural design was introduced. Furthermore, this study recommends implementing a maintenance planning program aimed at reducing downtime during maintenance activities to lower associated costs. The analyzed steel plant produces various products including concrete reinforcing bars (ReBars), flat bars, square section bars such as standard flat bars and round plane bars, alongside wire mesh of different dimensions as well as steel pellets. Within the realm of steel manufacturing automation can generally be categorized into two distinct levels:  First Level: This pertains to device actuation at an electromechanical level within the production facility; it is prevalent across all plants.  Second Level: This refers to supervisory control over the entire production process which is less frequently implemented and often only partially so. In practice, producing steel involves numerous complex physical processes governed by sophisticated mathematical models that rarely offer real-time guidance for effective supervision or control over these processes. Most operators rely on simpler microprocessor-based systems for support during steel manufacturing tasks. As part of enhancements based on operational findings from this study, the factory has acquired a new melting furnace with a capacity of 60 tons to replace an older 30-ton model previously utilized prior to this research initiative. Additionally, plans are underway for budgeting towards acquiring scrap pressing equipment intended to enhance scrap quality before melting—this will aid in decreasing electrode consumption rates within furnaces. To streamline operations further, there will be consolidation between electrical and mechanical maintenance divisions under one department managed by an assistant manager appointed specifically for overseeing these functions.