Manufacturing Metals

Asset: Wire Compactor

A Steel Manufacturing Plant Produces Construction Grade Rebar. 24 Hours a Day, 7 Days a Week, Scrap Metal is Converted into Steel. Each Year the Plant Produces 1.1 Billion Pounds of Steel Rebar Used in Concrete. That’s Enough Rebar to Circle the Globe.

Challenge:

• Dependent upon machine uptime
• Pressure cylinders within the compactor fail to control compression and speed causing problems in binding the coil
• Equipment failure occurs in the final stage of production causing the entire line to stop, can you say bottleneck?
• Critical asset unequipped with sensors to produce data

Results:

• SORBA-SDC (Smart Data Collector) connected to a Siemens PLC, collecting months of time series data to analyze the behavior of the equipment
• Minimized cost by not engaging IT personnel to connect to the enterprise network. SORBA does not require any firewall ports to open
• Detected anomalies with lead times up to 19 days. Correlated all potential issues with work order events

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