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| Industry Solutions - Metals |
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CASE STUDIES
INCO – Case Study
Visual8 designed a Converter Aisle Simulation-based planning system for INCO, which was used to investigate output & process improvements.
This simulation included dynamic links to a metallurgical model to ensure proper levels within the furnaces to feed the converters. In addition, crane movements were optimized to minimize converter delays and maximize production output. The system has the capability of scheduling and monitoring converter aisle activities for equipment on a real-time basis, and was used for capacity planning, power consumption, and feed rate analysis.
Falconbridge – Case Study
Visual8 created a detailed production model for Falconbridge to accurately capture the flow of material through two mines, and the utilization of materials handling equipment. Routing information, equipment parameters, processing times, and shift patterns were incorporated into the model. From the production plan and waste production forecasts, the model generated a stope schedule that governed which areas of the mine came on-line at any given time.
This simulation could be used to quickly evaluate the mine’s output when different operating parameters and rules were implemented.
This simulation has transformed the company’s ability to predict future mine output, and thus the feasibility of mine expansion to a risk-free, flexible, and intuitive process. It helped to not only prove that the target ore throughput could be reached; it also helped planners to determine the levels of equipment and staffing that would be needed to reach these goals.
Novelis – Case Study
The Fairmont plant, a part of Novelis’s Light Gauge division, produces slit aluminum coils for the automotive, cookware and lighting consumer market. The Plant produces finished product for a range of customers by passing product through its cold rolling and slitting operations.
The planning and scheduling process here was manual, time-consuming and disjointed, so Novelis requested that Visual8 create a scheduling tool which would plan order flow through the plant.
The new system automated the planning system, increased schedule flexibility, provided a plant-wide visibility of the current and future production schedule, lowered the amount of work-in-progress, and reduced order delays. It also gave planners the ability to quickly locate and retrieve orders currently in the system.
Metal Treatment Plant – Case Study
A plant which furnace treats metal bars and tubes (our client would like to remain anonymous) required schedulers to balance several potentially conflicting priorities. This included meeting client due dates, optimizing furnace efficiency, and minimizing piece delays and overall cost.
For this plant, the tension of maintaining equilibrium between due dates and efficiency was always a problem. Obtaining acceptable sequences was a manually intensive process, which could not be easily changed because the plant lacked the manpower.
Visual8 constructed a detailed production model to accurately capture the flow of material through the furnaces and surrounding equipment.
Using complex scheduling rules for the furnace system, customized reporting options, complete system integration, and rapid schedule generation, the SIMUL8-Planner Adaptive Planning and Scheduling System has provided this metal manufacturer with responsive scheduling capability. This allows the scheduler to successfully balance a range of performance criteria, satisfying both customer expectations and plant’s operating constraints.
This plant is now experiencing higher throughputs through its facility than ever before.
METAL & MINING SIMULATION BENEFITS
Typical Metal Models:
- Mining operation
- Smelter processing
- Supply and demand forecasting
- Aluminium and steel product processing
Types of Problems We Resolve:
- Energy Consumption Planning
- Capacity Planning & Plant Layout
- Production Planning & Scenario Analysis
- Operations Scheduling and Monitoring
We Can Ensure Your Goals Are Met:
- Proving product delivery capability
- Maximizing your throughput and ROI
- Generating accurate forecasts
To determine how a metal or mining simulation can specifically benefit your company, contact us.
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"Visual8's coaching and training teams are excellent to work with. Their resources are always available to discuss simulation applications and software features. Their combination of simulation and software knowledge makes them a great resource."
Greg Warkentin,
JMP Engineering Inc. |
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