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Case Studies: #ARC-001

ArcelorMittal Case

Steel manufacturing giant utilized data from i-5O’s vision system to track and predict lance usage and change requirements

ArcelorMittal

Overview


ArcelorMittal

ArcelorMittal is a world-leading steel manufacturer, headquartered in Luxembourg City. With steel manufacturing operations in 15 countries, 14 research centres, and customers in over 140 countries, ArcelorMittal is an industry leader in using innovative processes that are more efficient, use less energy, and emit significantly less carbon. The company continues to push boundaries, whether developing technologies to reduce the carbon footprint of steel, 3D printing automotive parts using steel powders or, through the adoption of artificial intelligence and advanced automation across their operations. i-5O Computer Vision System is deployed in their manufacturing facility in Hamilton, Canada. The video data generated by i-5O has helped the team with process validation in lance operations eliminating downtime due to Lance breakage.

Problem


Inability to accurately track lance operations resulting in production delays

In steel manufacturing a long, tube-like tool called a lance is used to blow oxygen or other gases into molten metal. This process helps refine the steel by burning off impurities and controlling the temperature, ensuring the steel has the right composition and quality. Lance operations are a backup to other standard procedure methods, therefore lances need to be changed at an optimal time in order to avoid production delays caused by the changing process. The time to change a lance isn’t standardised and there are numerous factors involved that need to be closely monitored. Although the team at ArcelorMittal would document when a lance would be used, the operations involved various complexities that could not be tracked manually. Inability to accurately identify the optimal time a lance had to be changed led to significant production delays resulting in lost output and huge costs for the manufacturer. When a lance broke during production, broken shards would contaminate the mixes, leading to additional clean up costs as well.

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Solution


Implementation of i-5O computer vision system to provide automated and continuous tracking of lance operations and predictive analysis to avoid potential breakage

i-5O computer vision was deployed to effectively monitor ArcelorMittal's lance operations on the production floor, through identification of lance IDs and uninterrupted tracking of individual lance cycles when in use. i-5O’s vision capabilities allowed each cycle procedure to be tracked from start to finish, per minute. Data was collected to include start and end dates and cycle time, including time zones. This data was made accessible and displayed for production managers. Realtime alerts were sent out when the lance needed to be replaced, avoiding production delays. Additionally, predictive analysis capabilities were also incorporated to identify and alert for potential lance breakage and accurately predict lance change times before a breakage were to potentially occur. This ensured smooth workflow and significant reductions in downtime due to production delays.

Our Results

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7 figure savings per year from production delays prevented

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downtime from lance breakage eliminated

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lance change process standardized for operators

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