01 — 5-STEP SEQUENTIAL SHOP-FLOOR WORKFLOW
Sequential Screens from Raw Material to 3D Warehouse
In this sector, shop-floor operations progress across 5 sequential stages. At each stage, responsibilities are structured across operator cockpits, shift supervision, quality engineering and 3D spatial monitoring.
STEP 01
Billet Selection, Overhead Crane Feeding and Furnace Entry Verification
Manages selection of billets from the stockyard or continuous caster according to the active rolling order, overhead crane loading onto the charging table, and camera/scale verification of length, weight and heat number prior to furnace charging.
Operator Screens (POD)
- Billet Allocation List and Crane Feeding Operator Screen
- Furnace Entry Camera / Barcode Verification and Charging Screen
- Raw Material Return and Unmatched Billet Management Screen
Shift Supervisor & Control
- Rolling Mill Order Management and Active Campaign Selection Screen
- Component Allocation and Billet Consumption Reconciliation Report
Quality & Laboratory
- Incoming Billet Quality, Heat Analysis and Spectrometer Verification Screen
3D Digital Twin & Warehouse
- 3D Billet Stockyard and Furnace Entry Twin (Overhead bridge crane, billet stacks, entry camera checkpoint and live charging flow)
STEP 02
Reheating Furnace Walking-Beam Tracking, 3-Zone Thermal Process and Billet Map
Tracks step-by-step billet progression through preheating, heating and soaking zones via walking-beam strokes, visualizing each slot by order and heat color while verifying discharge temperature and descaling pressure.
Operator Screens (POD)
- Reheating Furnace Order and Process Operator Screen
- In-Furnace Billet Slot Position, Heat Color and Dwell Time Map
- Furnace Discharge Temperature and Descaler Pressure Monitor
Shift Supervisor & Control
- Reheating Furnace Dashboard and Furnace Readiness Report
- Natural Gas Shift and Dimension-Specific Energy Consumption Report
Quality & Laboratory
- Furnace Zone Temperatures, Soaking Time and Thermal Quality Monitor
3D Digital Twin & Warehouse
- 3D Reheating Furnace SCADA and Digital Twin (FIFO billet array, color-coded heat transitions, 3-zone thermal map and SCADA-MES piece reconciliation)
STEP 03
Hot Rolling Mill Line, Main Pulpit Tower and Specific Energy Monitoring
Controls rolling of discharged billets through roughing, intermediate and finishing stands into target diameter/section, tracking line speed, micro-stops, roll groove/pass life (PRT), cobbles and water/electricity consumption from the Main Tower.
Operator Screens (POD)
- Hot Rolling Line and Main Tower Operator Screen
- Micro-Stop and Breakdown / Downtime Reason Entry Screen
- Roll Pass / Groove Calibration (PRT) and Shift Crew Screen
Shift Supervisor & Control
- Control Tower Live Production Monitoring Display
- Rolling Mill OEE, Lost Time and Downtime Analysis Report
- Hourly Output, Water and Electrical Energy Monitoring Panels
Quality & Laboratory
- Rolling Dimensional Gauge and Hot Sample Tracking Screen
- Production Scrap and Mill Cobble Report
3D Digital Twin & Warehouse
- 3D Hot Rolling Mill Line Twin (Furnace discharge, roughing/intermediate/finishing stands, in-mill bar flow, stop alerts and live OEE cards)
STEP 04
Cooling Bed, Cold Shear, Abrasive Saw Cutting and Surface/Crack NDT
Coordinates bar cooling across the walking-beam cooling bed, cutting to customer lengths on cold shear or abrasive saw lines, mechanical tensile testing, and surface/subsurface crack verification at the automated NDT station.
Operator Screens (POD)
- Cooling Bed Monitoring Screen
- Cold Shear and Abrasive Saw Cutting Operator Screen
- Surface and Crack Inspection (NDT) Operator Screen
Shift Supervisor & Control
- Cooling Bed and Saw Cutting Performance Reports
- Digital Shift Book and Shift Handover Panel
Quality & Laboratory
- Non-Destructive Crack Testing (NDT) Defect Report
- Mechanical Tensile/Yield Test and Lab Sample Entry Screen
3D Digital Twin & Warehouse
- 3D Finishing and Quality Line Twin (Live simulation of cooling bed, cold shear, saws, NDT inspection station and sorting tables)
STEP 05
Bundling, Strapping, End Painting, Labeling and 3D Finished Goods Warehouse
Completes automated stacking and strapping of bars or coils, bundle weighing, steel-grade end-painting color indication, barcode tag printing and putaway into 3D finished warehouse bays.
Operator Screens (POD)
- Bundling and Strapping Operator Screen
- Production Confirmation, Heat-Based Confirmation and End-Paint Color Screen
- Rejected Confirmation / Reversal Screen
Shift Supervisor & Control
- Bundle Tracking and Finished Goods Production Panel
- Warehouse-Level Production Confirmation and Dispatch Readiness Report
Quality & Laboratory
- Finished Bundle Quality Release and Mill Test Certificate (EN 10204) Screen
3D Digital Twin & Warehouse
- 3D Finished Goods Warehouse and Dispatch Digital Twin (Multi-row/tier 3D bay matrix, occupancy rates, bundle/heat lookup and dispatch simulation)