The customer is a global steel and steel-related mining company, producing a wide range of
steel products for mining, automotive, construction, mechanical engineering, fuel and energy industry sectors. The
customer’s automated steel qualification system interacts with the industrial control systems of several
steel shops and the enterprise resource planning system (ERP).
Manufacturing Execution System (MES) is a vital system used in manufacturing to facilitate
the control over multiple elements of the production process. The proper functioning of MES depends on the inputs
from a variety of business management systems. The customer commissioned MERA engineers to develop a middleware
that would allow for the integration of a recently introduced automated steel qualification system into a
large-scale steel plant.
To perform the integration, the MERA team developed several quality assessment algorithms
and implemented them on the qualification system side. The middleware solution enabled the data transfer from the
systems in the shop to the automated steel qualification system.
It is important to note that the automated steel qualification system interacts with the
industrial control systems at the shop floor and MES in parallel. That said, the qualification system collects
data from both levels separately. The system analyzes the obtained data in real time by certification groups such
as chemical composition, geometry, etc. Intermediate, final or corrected certification results are recorded and
stored in MES.
The middleware solution developed by MERA closes the gap between the shop floor and MES
subsystems and provides the seamless data procession between operations and production levels. In-depth analysis
of the product quality before shipment allows reducing the reject rate and increasing customer satisfaction.