Gen AI to optimize scheduling at Continuous Annealing Lines

My big gratitude to all of them who have been continuously supporting me in this initiative. Highly indebted to all. Lots of networking and lots of learning is indeed making me push the limits set. :)

This time the focus is on Continuous Annealing schedule Optimization

Continuous Annealing is one of the important and core process in a steel industry. It is used to set desired material properties by passing coils of flat steel through a high-temperature furnace in a precisely controlled manner. High efficiency is achieved by feeding the steel through the furnace in the form of a continuous strand.?Since this is a continuous line each coil is welded with the next one in line. Not always can similar type of material be scheduled one after the other. In such cases a backup material is scheduled in between them. This make the scheduling in a continuous annealing line extremely complex. Since this operation is at the fag end of the lifecycle any unused inventory is extreme burden for the firm. In this month’s exercise I tried to use Gen AI to schedule a continuous Annealing line with the aim of increasing the due date adherence (line level) and reducing the number of back up coils used. Not all organizations required this. Stable demand might reduce the need of using backup coils. But Volatile demand and high range of product mix makes it necessary.

Advantages of continuous Annealing lines.

-?????? Enhanced Strength and Ductility

-?????? Consistent Quality

-?????? Higher Efficiency

-?????? Customizable properties - CALs can be configured to anneal steel to specific mechanical properties depending on the product requirements (e.g., high-strength steel for automotive, ultra-low carbon steel for electrical uses).

- Shorter processing times

CAL product Applications

-?????? Automotive Industry

-?????? Appliances-Household and white goods

-?????? Construction

-?????? Electrical Steel applications

-?????? Aerospace and Railways.

Set Up:

As in my previous exploration the Gen AI set up remains the same.

Used limited set of attributes. The results may/will vary depending on how deep the constraints are taken into. But since the focus was mostly to eliminate the need of the backup material and adhere to the due date the limited set of characteristics was good enough.

I simulated the data needed for scheduling based on my previous experience with it. Fed the model with multiple data set.

This is the result for the due date adherence. 14 out of 15 times Gen AI resulted in better adherence. The comparison was done based on the PLSQL procedures I had previously made in my previous experiences.

The number of back up coils used for the same schedule were reduced using Gen AI.

Increased due date adherence coupled with reduced backup coils usage, double delight for anyone.

The aim was to study how Gen AI can really help in this area. I had tried for the Batch Annealing Furnaces in my last new letter and thought it would be good to take the step at continuous annealing lines and found similar results.

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Happy to discuss and learn!

And,

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To all my friends back home, on start of auspicious occasion of,

Navratri, may you be forged in the furnace of devotion

On day 1 – Shailaputri- Start fresh with Annealing, softening your heart for transformation.

On day 2- Brahmacharini- Gain strength through Hardening, becoming tough against challenges

On day 3- Chandraghanta- Like Quenching, cool down negativity, solidifying your inner resolve

On day 4- Kushmanda – Let life’s experiences Temper you, balancing toughness and flexibility

On day 5- Skandamata- Smooth out your journey with Grinding, refining your character.

On day 6- Katyayani- Weld relationships through the art of Fusion, creating unbreakable bonds.

On day 7- Kalaratri- Be Rolled under pressure, emerging stronger and more resilient.

On day 8 – Mahagauri – Pickle away impurities, revealing your purest form

On day 9- Siddhidatri – Finally, achieve the perfect finish with Polishing, shining with divine energy!".

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Happy Festive Season!