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Yard Management System: Automation Division Tata Steel Ltd. CII Steel Summit, Delhi On 4 November, 2009

A Yard Management System (YMS) was implemented to improve efficiency in yard operations at various Tata Steel plants. Previously, yards used manual processes which led to inconsistencies, poor planning and visibility. The YMS integrated multiple functions including stock management, yard layout optimization, equipment tracking and process interfacing. It provided real-time visibility of material locations and movements. This reduced search time, improved dispatch compliance and allowed better utilization of yard space. The case study at CRM showed benefits like increased dispatch rates and reduced demurrage charges after implementing the Coil Transport and Tracking System, a key component of the YMS.

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Vinay Kumar
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267 views31 pages

Yard Management System: Automation Division Tata Steel Ltd. CII Steel Summit, Delhi On 4 November, 2009

A Yard Management System (YMS) was implemented to improve efficiency in yard operations at various Tata Steel plants. Previously, yards used manual processes which led to inconsistencies, poor planning and visibility. The YMS integrated multiple functions including stock management, yard layout optimization, equipment tracking and process interfacing. It provided real-time visibility of material locations and movements. This reduced search time, improved dispatch compliance and allowed better utilization of yard space. The case study at CRM showed benefits like increased dispatch rates and reduced demurrage charges after implementing the Coil Transport and Tracking System, a key component of the YMS.

Uploaded by

Vinay Kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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YardManagementSystem

By
AutomationDivision
TataSteelLtd.
At
CIISteelsummit,Delhi
On4th November,2009

CONTENTS
YMS Function
(Sachin Gupta)

Why ?
Functions
Benefits
Highlights

YMS Case Study


(Joshi Jacob)

Coil Tracking &


Transport System
at CRM

BEFORE YMS: Yard Scenario

A Trailer Arrives
With Some Material
PLZ..PLZPLZ do
this

Manual Reporting of
Material Arrivals or At Berth

Manual Job Orders To The


Transporter & Operator

BEFORE YMS: Yard Scenario

YARD
YARD

Crane Operation By
Hand/Manual Signaling

YARD
YARD
YARD

BEFORE YMS: Yard Scenario

YARD
YARD

YARD
YARD

YARD
YARD
YARD
YARD

Continuing instructions for the material


movement
Maintenance of spread sheets, clip
board or tables to update the stock
information

End Results

YARD
YARD

YARD
YARD

YARD
YARD
YARD
YARD

Manual Search Of
Materials In Yard

Poor house keeping


Labor intensive jobs
Inconsistency of information
Poor planning at all stages
Poor compliances to the
order fulfillment

Problems Encountered

Everyone keeps different information.


Information never remains current.
Researching trailer status takes hours.
Locating materials is tedious.
Visualizing yard is even more complex.
Staff spent time on trailer shuffling on yard.
Phone, fax times takes up to hours a day.

Effects on Plant Operation?


High labor cost due to manpower involvement at
all stages.
High operating & maintenance cost due to lack of
process optimization and damages resulting from
operator errors.
Poor product tracking due to verbal data transfer,
loss of time/material.
Generic Yard Management System (Yard Scope)
Addresses Each of These Problems.

YMS: Functional Modules


STOCK IN MANAGEMENT
Material receipt management in yards.
Material feeding to various process lines.
YARD MANAGEMENT
Optimized material storage in yards
(location management)
Material movement across different yards
& process lines.
Material re-arrangement as pre-dispatch
arrangement.
STOCK OUT MANAGEMENT
Evacuation of materials from different process lines.
Dispatch planning.

YMS: Functional Modules


EQUIPMENTS MANAGEMENT
Crane management.
Coil conveyor management.
Transfer car management.
PROCESS LINE TRACKING
Material tracking and history in its complete lifecycle across
process lines.
System interfaces with Line L#1, Line L#2, SAP & MES for
capturing relevant information and process interlocking.
DESPATCH MANAGEMENT.
Execution of dispatch plan in accordance for best fit.
Wagon/trailer tracking (Thru Vehicle Tracking System).
Reporting and documentation.

YMS: Highlights
Single window Logistics solution
Inbound
In Process
Outbound
Inter/Intra yard material flow scheduling
Yard optimization
Contingency handling
Equipment Control, Tracking & Interlocking
Crane control
Transfer car tracking
Coil conveyor tracking

YMS: Highlights
Smart information management
Transparent information flow and consistency
Seamless connectivity with lower (process) and
higher (SAP/MES) level systems
User defined reporting and visualization
Scalable and Expandable
Bay extensions/additions
Yard re-configurations

Principal Components
Remote
Clients

RF Networking &
Mobile Hand Held
Terminals
Loading/Unloading
Yard Map Updating

Process Interlocking
Conveyors
Transfer Cars
Cranes

Crane Automation
Guidance System
Auto-Positioning

Yard Mgt. Server


Stock In
Stock Out
Dispatch
Tracking
Equipment Mgt.
Reporting

Process
Interfaces
Line L-1/2
S.A.P.
M.E.S.

Man Machine
Interfaces
Yard Management
Crane Automation

YMS: Hardware & Software Platforms


Operatingsystem
Server Win2008Server.
Crane WinXPEmbedded.

Applicationsoftware
Server SunJava

RFNetwork
OnGround 2.4GHzDSSS
OnCrane 2.4GHzDSSS

Others

Crane C#2.0

PLC/Drives(Cranes)
LaserDistanceMeters

DataBase
Server Oracle10G

ComputerHardware
Server HPProliant

Crane None

Clients PanelPC.

CASESTUDY
CTTS/SYMS
At
TataSteelLtd.

CONTENTS
Details of CRM
Layout of CRM
Operations in the yard
CTTS system configuration
Interfaces of CTTS
Various process times of coil handling
Benefits

DETAILS OF CRM PLANT


No of process lines 11
(PLTCM -1, ECL -1, BAF-1, SPM-1,CGL -2, RCL -3,
PL -1, CPL -1)
No of cranes under CTTS control- 18
No of coil cars & conveyors 10
No of storage bays 7
Storage space 3800 coils
Average coil movements per day 1000 coils
Dispatch Rated - 3500 T/day,

LAYOUT OF CRM AT TATA STEEL

COMPLEXITY IN THE
DIFFERENT YARD OPERATIONS

CTTS SYSTEM CONFIGURATION


YARD MANAGEMENT SERVER
DEVELOPMENT PCS
NETWORK
PRINTER

SYSTEM ARCHITECTURE

LAYER 3 SWITCH
SWITCH AT YARD2

SWITCH AT YARD3

SWITCH AT YARD4

SWITCH AT YARD1

RADIO
ACCESS
POINT

RADIO
ACCESS
POINT

RADIO
ACCESS
POINT
RF
CRANE

RADIO
ACCESS
POINT
RF

RF
CRANE

CRANE

RF
CRANE

CTTS SYSTEM INTERFACE STRUCTURE


CRM-IS Server

CYMS Server

Production Scheduling & Recording

HR Coil Transport

PDI
Coil Supply Request
Weighing Result
Tracking Information

Coil Supply Completion


Location Result
HR Coil
Transportation

Returning
Result
Picking List

(Conveyor/Coil Car)
Movement Control

Order Management
Picking
Result

Lock/Unlock
request

Saddle Status
Lock Result

Level-I

SAP

CTTS Server
Lock/Unlock
request

Crane Work Order

Lock/Unlock
result
Work
Information
Crane Work result
Crane Position

Line Computer
(PLTCM, SPM, RCL, CPL)

Production, Mill Setup

Trailer Arrival
Work Result

Crane Computer

HHT

Guidance, Data Communication

Yard Verification, Trailer Arrival Events

VARIOUS PROCESS TIME


Rolling Time
0%
Trailor
Waiting Time
15%

Waiting for
despatch
18%

Loading Time
4%

Stocking Time
1%

Time of Coil
on Saddle
62%

FACTORS INFLUENCING
YARD OPERATION

Manual Data and


Doc. Handling
20%

Delay in Stocking
due to Manual
Coordination
5%
Coil Tracing time
for Loading
31%

Wrong Trailor
Loading
17%
Delay in Trailor
arrival Inf.
27%

AREAS WHERE WE CAN IMPROVE BY CTTS


COMPUTERIZED YARD
MANAGEMENT SYSTEM
PROVIDES EFFECTIVE
DOCUMENT HANDLING

Manual Data and


Doc. Handling
20%

Delay in Stocking
time, Information
to Crane
5%

Coil Tracing time


for Loading
31%

Wrong Trailor
Loading
17%

TRAILOR TRACKING SYSTEM


ENABLES IDENTIFICATION OF
RIGHT TRAILOR FOR RIGHT
COIL IN RIGHT TIME

WIRELESS DATA
CONNECTIVITY TO
CRANE ENABLES
INSTANT MESSAGING.

Delay in Trailor
arrival
Information
27%

LOCATION BASED
TRACKING SYSTEM
WITH AUTOPOSITIONING

BENEFITS OF YARD MANAGEMENT AT CRM


CRM dispatch increased from 1.2 MT to 1.5 MT
(increase of 25%, CTTS had a part to play).
Maximization of yard space utilization.
Reduction of demurrage charges
due to wagon turn around time
(documentation Wagon builder software)
due to reduction in trucks/trailer waiting time
& visibility (VTS)
Reduction in inventory held- due to visibility of material,
reduction in various process cycle times.

SLAB CASTER YARD LAYOUT

SYMS SYSTEM CONFIGURATION

BENEFITS OF SYMS AT TATA STEEL


Optimum utilisation of space handling of 2 MT from 1MT
in the same yard (investments in equipment handling also)
Increase in use of direct hot slabs in rolling from nil to 54%
(investments in equipments like CTRT also)
Scheduling effectiveness from 60% to 67% ( compliance to
schedule generated from FP planning system)
Reduction of lost slabs due to traceability down from 20%
to zero. (in conjunction with FP planning system)

YMS- DRIVER FOR OPERATIONAL EXCELLENCE


Achieving 100% visibility of vehicles/wagons (VTS) and inventory, in
the yard.
Leveraging a single point of yard command and control
Achieving dispatch compliance to customers
Maximizing yard space utilisation ( 2high coils, traceability etc )
Facilitating transport appointment scheduling (VTS)

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