Digital Transformation


Schedule

25–28 March 2019Omni William Penn Hotel • Pittsburgh, PA, USA

►Download Schedule (PDF)

Monday, 25 March 2019

4 p.m.

Registration

5–6 p.m.

Welcome Reception

Tuesday, 26 March 2019

7 a.m.

Registration and Breakfast

8 a.m.

Opening Remarks
Ron Ashburn, Association for Iron & Steel Technology, and Michael Dudzic, ArcelorMittal Dofasco G.P.

8:10 a.m.

Keynote Presentation: Digitalization and the Steel Industry
Dr. Pinakin Chaubal, ArcelorMittal Global R&D
Today, the steel industry is faced with many challenges — the rising use of alternate materials in traditional steel application and the increasing focus on being a responsible keeper of our environment, just to name a few. The industry has always been at the forefront of applying new technology — whether it has been reinventing via continuous casting or advanced process control.  This new age of technologies, which we refer to with myriad names — Industry 4.0, Digitalization, etc. — holds tremendous promise, and the question in front of us is whether we look at these as transformational technologies. The answer seems to be yes — and our challenge is to convert this into reality. How do we ensure that we are able to take full advantage of these technologies while also setting up our base for sustainable growth and adoption of this new generation of technologies? The presentation will look at how the steel industry has been transforming its systems to move into this new age and look at key developments that are important to the steel industry.

9 a.m.

Overview of the Digital Transformation of Industry
Gary Fedder, Carnegie Mellon University
This presentation will define the buzzwords relevant for the digital transformation of industry (a.k.a. Industry 4.0) (e.g., data lake, big data, system integration, AI, smart sensor, machine learning, digital twin) and will include a brief overview of how all these terms tie together, as well as a brief overview of current technologies.

9:40 a.m.

Break

9:55 a.m.

Creating and Leveraging Digital Ecosystems to Deliver Real ROI
Steve Carlson, ThermoFisher Scientific
Digital journeys seem to be the hot topic of the day, but much of the conversation is centered on the technology. Technology that does not enable real return on investment (ROI) and competitive advantage is akin to that fancy elliptical trainer gathering dust in your basement: cool idea, but didn’t actually deliver any real value. To generate real returns, you’ll need a better plan and a network of partners, an ecosystem, aligned and enabled to help you achieve your goals. We’ll take a quick tour of where there is ROI to be had, how to unlock it, how to sustain by putting digital to good use, and how to create an ecosystem aligned to deliver better outcomes for your customers.

10:35 a.m.

Digital Transformation: The Edge Analytics Approach to Industry 4.0
David Kober, iba America LLC, and Andreas Quick, iba AG
It is vital to the success of any business to be aware of the technological disruptions that directly impact the industry in which they serve. In the ever-changing landscape of manufacturing, the current point of emphasis revolves around converging information technology (IT) and operational technology (OT) using the Industrial Internet of Things (IIoT) in order to achieve Industry 4.0. The purpose of this discussion is to characterize a common-sense approach using edge devices and analytics to satisfy the dynamically changing IIoT requirements

11:15 a.m.

Synchronized Real-Time Analysis of Video Data and Measurement Data for Holistic View of Steel Production
Andreas Quick, IBA AG​
Synchronized acquisition of measurement data and video is necessary to digitalize your process as part of your Industry 4.0 strategy. Building a digital twin based on process data together with video data helps to understand and to optimize your process. By integrating machine vision algorithms to the system, video data can be processed on-line in real time. Thus, your process is continuously monitored and data can be gained, for which often no sensors are available. In this presentation, several examples are given, including how data can be archived and reviewed in efforts to tune process parameters to optimize the steel manufacturing process

11:55 a.m.

Lunch

1 p.m.

Autonomous Material Handling System (AGVs and Cranes) in the Steel Industry
Edgardo LaBruna, Janus Automation LLC
In a highly competitive environment, it becomes critical to optimize material flow, minimize movement of the products and increase the available time for material handling equipment. With the implementation of automatic movement using automatic cranes and AGVs, substantial increases in productivity and equipment reliability, reduction of product damage, and improvement of safety can be obtained. This paper discusses the key aspects to take into account for successful implementation, including the selection of the best and most reliable technology, safety considerations, logistics optimization and implementation strategies, including Industry 4.0 and artificial intelligence aspects. Several real-life application cases are discussed, including phase implementations.

1:40 p.m.

Steel Drones
Jeffery Yeager, AM/NS Calvert LLC
Over the last four years, the drone program at AM/NS Calvert LLC has been developed to provide a sophisticated yet simple and cost-effective solution for performing various inspections, mapping, inventory, and security functions throughout the plant environment. Various site-wide inspection programs have been commissioned, such as hot-dip galvanizing furnace inspection, hot strip mill crop shear inspection, and crane girder and bolt inspections. Additionally, mapping of the site has been integrated into the as-built. Using drones provides a safer working environment, greatly reduces the amount of time required for doing inspections, and allows for inspections to be performed during production without affecting production.

2:20 p.m.

VR and AR Visualization for Digital Transformation
Chenn Zhou, Purdue University Northwest
Virtual reality (VR) and augmented reality (AR) visualization technologies are increasingly playing a key role for digital transformation of steel manufacturing. These technologies, combined with simulation and real-time sensor data, can provide intuitive understandings, enable faster and better decision making for optimized operating conditions and predictive maintenance, as well as deliver better and safer training for current and future employees. The Center for Innovation Through Visualization and Simulation (CIVS) and the Steel Manufacturing Simulation and Visualization Consortium (SMSVC) have been using VR and AR for a variety of projects to improve quality, increase productivity, reduce downtime, and provide safer and more in-depth training. An overview of these technologies and practical examples of implementation will be presented.

3 p.m.

Break

3:15 p.m.

The Role of Real-Time Operational Data in the Digital Transformation of Steel Companies
Osvaldo Bascur, OSIsoft, and Alexandre Cote, ArcelorMittal Long Products Canada
A critical aspect of digital transformation will be the availability and management of real-time operational data. This data will be required for a variety of decision-making systems including those using advanced analytics, artificial intelligence and machine learning techniques. As an example, integrating data silos and transforming sensor data into operational insights is a basic step to develop predictive models. A framework for collecting, managing and using operational data will be presented. Also, ArcelorMittal Long Products Canada will discuss several projects that they have been working on that leverage real-time operational data and the results from these projects.

3:55 p.m.

Using AI Modeling for Predictive Quality and Routing​
Heiko Wolf, PSI Metals GmbH
In this presentation, we will show the case study in which we attempt to predict “hidden defects” after a Hot Rolling Mill using AI modelling. To predict this defect, a model is built from many process parameters of all parts of the HRM including process data, order data, quality measurements and other data points. This model is trained with nine months of production data, using different algorithms such as Gradient Boosting, Random Forest and Logistic regression. This model is then used in multiple stages of prediction. Based on the prediction, different actions can be chosen, such as rework, change of order, or change of routing.

4:35 p.m.

Cybersecurity Systems and Its Implementation/Practical Application of Cybersecurity Systems​
Johannes Bauer, UL International Germany GmbH
Greater connectivity has added significant benefits to production such as data analytics, predictive and preventive maintenance, remote management, and interoperability of systems. With these benefits also comes the added challenge of security of the control infrastructure from cyber threats. Today, in manufacturing there is greater pressure to demonstrate strong security practices. Capital equipment owners from job shops to production plants are now demanding suppliers of industrial automation systems provide evidence of their security road map in their practices and supply chain management to help ensure the security of their assets, facilities, systems and data. There are cybersecurity best practices that can easily be implemented by job shops or production plants to assess and build security into their operations. Some of those best practices include the cybersecurity requirements for industrial automation control systems in IEC 62443 and factory risk assessments to understand security risks and gaps and the steps to take to start to build a cyber road map.

5:15 p.m.

Reception

Wednesday, 27 March 2019

7 a.m.

Breakfast

8 a.m.

Keynote Presentation:  Digital Transformation: Beginning with the End in Mind
R. Joseph Stratman,
Nucor Corp. 
There are many roads a company can take and call it digital transformation. Some deal within the plant: robotics, machine learning, augmented reality, etc. Some deal with human resources: safety awareness, technical training. Some deal with the customer interface, while others deal with business intelligence. The presentation will lay out the various opportunities for steel manufacturers to harness the digital transformation of our industry.

8:50 a.m.

Steel Industry and Plant Engineering — The Way From Digitization Toward a Digital Ecosystem!
Katja Windt and Markus Reifferscheid, SMS group GmbH
The challenges and potentials of digitalization have been discussed in the steel industry for several years. Digitalization affects company strategies, processes, structures, and products equally and will transform traditional companies sustainably. The main enablers are big data analytics, embedded systems, digital service platforms, the ability to deliver mobile connectivity in the plants, the power of embedded and cloud computing, as well as the increasing automation and autonomy within the plant operation. People, machines and goods will communicate with each other in real time in the future. The potential of generating value out of existing and new data is wide. Machine learning algorithms integrated in process models and service applications are already changing the value-added process chains toward dynamic value-added networks. Current transformation trends are outlined on the basis of product and service examples from innovation, plant engineering and steel production.

9:30 a.m.

Introduction to Big Data: The Fuel to Digital Transformation
Kevin Modreski, IBM North America
This presentation will cover the concepts of big data and an overview of big data analytics. Beginning with an explanation of the big data concept, its technologies and data architectures involved, it will give attendees the technical basics of what this new phenomena really is. It will then continue into a discussion about artificial intelligence, mobile and Internet of Things, and how they are driving data complexity, and new forms and sources of data. Finally, it will cover big data analytics, including the use of advanced analytic techniques against very large, diverse data sets and the benefits of analyzing big data using advanced analytics techniques.

10:10 a.m.  

Break

10:30 a.m.

Cloud computing examples in the Metals Industry​
Patrick Gallagher, Management Science Associates Inc.
Cloud computing is a commonly used term that encompasses a wide variety of IT services and capabilities. Almost everyone interacts daily with aspects of cloud computing whether they are aware of it or not. This presentation introduces the types of cloud computing available for organizations (i.e., public private, hybrid), identifies standard services (i.e., IaaS, SaaS, PaaS), and discusses the benefits and challenges associated with their use. Specific case studies of cloud computing examples in the metals industry will be provided.

11:10 a.m.

What Is AI and How to Get Started With It in Steel Operations
Mukesh Ranjan, Noodle.ai
The presentation starts with a quick overview of AI technologies. Not knowing where to start is one of the biggest barriers to the adoption of AI technologies in industrial settings. This presentation provides several best practices for getting started in the right manner. Next a framework will be discussed that helps verify if AI can be a viable solution to a specific operational problem. The presentation is concluded by providing an overview of key areas to incorporate AI across the steel industry value chain.

11:50 a.m.  

Lunch

1 p.m.

Applications of AI in Steel Manufacturing: Selected Client Cases
Jose R. Favilla, IBM Worldwide Industry Solutions
This presentation provides a brief overview of the recent advances in artificial intelligence and will cover practical examples and cases of its application in the steel industry — in product development (new alloys), operations, maintenance and safety.   Concepts of hybrid cloud and security will also be discussed, as they are very important considerations for a successful deployment.

1:40 p.m.

How AI Can Fast-Track Your Industrial Automation
Dudon Wai​, Canvass Analytics
It’s been estimated that artificial intelligence (AI) can improve the manufacturing sector’s productivity by 45% by 2035. Learn how AI enables industrial operators and engineers to dive deeper into their operations floor and identify opportunities to not only optimize individual machines but automate the entire manufacturing line. This presentation will include real-world case studies, including how a major North American steel manufacturer optimized and automated its production processes and improved quality of production.

2:20 p.m.

From Buying Scrap to Delivering Coils — How AI Can Enable a Better Steel Industry
Ying Tat Leung and Hyungil Ahn, Noodle Analytics Inc.
Modern steel mills are equipped with large numbers of computer-controlled sensors and actuators generating data captured in central databases. This environment is very well suited for AI-enabled applications, which require plenty of data to train their underlying models. A range of such applications will be illustrated, covering managing scrap and energy costs, controlling coil width, and planning coil delivery. Models utilized in these applications include regression, tree-based methods and the more recently developed deep probabilistic models. The last approach, which is called a "deep probabilistic AI" framework, will be discussed. It combines sensory, prediction and simulation-based recommendation engines to recommend optimal process control input to produce finished coils more precisely within the width tolerance. The presentation concludes with a vision of a "learning mill," which employs a broad set of AI-based applications to help improve mill performance continually.

3 p.m.

Break

3:15 p.m.

Case Study for a Data Lake Implementation in a Sheet Mill
Robert Oldroyd, Nucor Steel – Decatur LLC
This presentation shows a case study for a data lake implementation in a typical sheet mill. The presentation examines the project progression from the initial motivators for pursuing the project, through the applications and architectures investigated for the project, to the current status of the project.  Finally, the vision for what the project should be able to achieve is discussed.

3:55 p.m. 

Manufacturing 4.0 for Metals
Manish Lunge, TATA Consultancy Services
The presentation will cover TATA Consultancy Services’ (TCS) experiences with Manufacturing 4.0. TCS has undertaken various aspects of Manufacturing 4.0 involving advanced technical areas such as standardization, automation, digitization and analytical solutions for key shop-floor operations like production execution, planning and scheduling, quality operations, warehouse and transport management, energy and utilities, research and development, and process control. These applications of advanced technologies will be discussed through a few steel industry case studies.

​4:25 p.m.

Data Analytics Based on Projected Quality Data Enabling Product Optimization and Development of New Steel Grades
Wolfgang Oberaigner, Primetals Technologies Austria GmbH
This presentation shows the implementation of a newly developed Industry 4.0 quality management system where process parameters are collected and production data is measured. The centralized storage of high resolution process data across the entire production route allows intelligent data analytics for product optimization and development of new steel grades within a short time. Performance is optimized by applying know-how based rules for quality decisions, monitoring performance by KPIs and stabilizing production through advanced Statistical Process Control. An example is presented of how this has been implemented at a producer’s site including design considerations, and project pros and cons. The system increases plant efficiency, supports quality management and can dramatically accelerate producers' time to market with cutting-edge, high-value products.

Thursday, 28 March 2019

7 a.m.

Breakfast

8 a.m.

Keynote Presentation: Artificial Intelligence: Enabling a Leap to Radical Efficiency
Stephen Pratt, Noodle.ai
Artificial intelligence (AI) is transforming our companies and careers, from the factory floor to the boardroom. By arming our operators with AI-enabled tools, capable of listening to every signal in our business, we can significantly improve decision-making at each level of our organizations. This is a unique opportunity today to retool business, and the steel industry itself, for radical levels of efficiency, but this will force us to reconsider many of the assumptions that we've held to be true

8:50 a.m.

Driving Operational and Economic Impact With Real Machine Learning Applications
Aldo Ferrante, ITG Technologies
This presentation will equip an OT/IT audience with real AI/IoT problem solving frameworks to tackle their predictive maintenance/process optimization problems common throughout the industry. There is a tremendous gap between data science academia and real life industrial applications pertaining to the bottom line. AJ will share an AI/IoT analytics operating system encompassing applications of real-time BIG DATA edge data collection all the way to creating ML models within 4 clicks not having any prior data science or development experience…did I mention NO CODE? This hybrid edge/cloud intelligent decision making model is disrupting the industry and coupled with the deep domain knowledge of steel SME’s offers the 1st end-to-end digital transformation solution in our new age of Industry 4.0.

9:30 a.m.

Plan wide DT actual implementation example: smart factory​
Chris Sousa, ANDRITZ
The steel industry is transforming; it is continuously embracing digitalization. Building on technologies like big data, artificial intelligence and IoT platforms, what benefits can be expected? This presentation will look at the extent to which process optimization can contribute to greater plant efficiency and increased profitability, as well as outcomes achievable.

10:10 a.m.

Break

10:30 a.m.

Digital Transformation in the Steel Industry:  Big Data & IoT Impact – Your Digitization Journey
Leonard Kosatka, Rockwell AutomationIt’s a simple objective – improve productivity.  But where do you start?  Which assets do you monitor to get the biggest payback?  Can you connect those assets in an industry where shutdowns are very expensive?  That is what digital transformation is about – converting the physical assets into a digital footprint so that you can extend the value and visibility from “old” assets and new assets alike.  In the steel industry, identifying potential issues before they become failures can produce profound outcomes.  Learn how the right approach can help you decide where to start translating data insights into meaningful action.

11:10 a.m.

Digital Transformation: The Importance of a Strategy and Road Map
Craig Thornton, Hatch Ltd.
The rapid advancement of digital technologies and methods promises to have significant impact on the steel industry. However, the market is flooding with many ideas for improvement with digital buzzwords like “IIoT,” “big data” and “machine learning” adding to the confusion. The key to a successful implementation of digital technologies begins with a clear, “top down” vision of what your operations will look like in the future. The vision could be focused on achieving higher throughput while reducing product or process variability and optimizing resource utilization. It could be focused on improving equipment performance through a more effective asset management approach. It could be about investing in people and culture to improve workforce engagement, retention and safety. More likely, it will be a combination of all of these factors. Once the vision is set, it takes effort to create a detailed “road map” that will outline your digital journey and identify the key value drivers that will be unlocked at each step. It will address not just the technologies but also the people and process transformation that must occur to make the journey a complete success. Lessons learned will be shared based on ongoing and past implementations to reduce the implementation risk and ensure that the intended value is achieved throughout the journey.

11:50 a.m.

Lunch

1–3 p.m.

Digital Transformation Roundtable Discussion
To maximize the value from this roundtable session, the organizing core committee is pleased to announce an enhanced session composed of 2 panels as follows:

1 p.m.  The first panel will be composed of Digital Transformation representatives from North American Steel producers who are going to answer the following 3 questions:

  • Can you tell us about your company’s Digital Transformation journey and how are things going? 

  • What are your company’s expectations from Digital Transformation? 

  • What do you see as some of your upcoming, key challenges for Digital Transformation and how are you preparing for them?

Panelists:
Nucor Steel - Decatur LLC
ArcelorMittal Dofasco GP
Big River Steel
AK Steel Corporation
SSAB
SDI
US Steel
Commercial Metals Company (pending)

2 p.m. The second panel will be composed of a variety of Vendor companies involved in Digital Transformation. They will provide answers to the many questions that we have received from the attendees via the Forum pre-survey and questions we will hear from the first panel. If time permits, we will also take additional questions from the audience. Companies represented in the second panel are:

Panelists:
IBM
SMS
Primetals
Hatch Engineering
PSI
Rockwell Automation

3 p.m.

Adjourn Conference