Quad Infotech Completes QMOS MES System Implementation at Nucor Steel Texas
QMOS is the system of record in all facets of production process ranging from order download, roll shop, stand building, guide shop, scheduling, melt shop, ladle management area, billet yard, rolling mills quality control, chem lab, tagging, saw cut and rework stations. QMOS has facilitated seamless integration of steel making process and data collection from the scrap yard all the way to bundling and shipping operations.
Through the integrated quality control functions of QMOS, Nucor Steel Texas utilizes dynamic spec ranges based on intended size and grade of the finished good material to resolve melt specs. This allows for grouping of products of the same grade that behave similarly from a physical testing stand point when rolled in the mill. Furthermore, by designing a chemistry range for these size groupings, alloys and additions are doctored to minimize cost to the melt shop. Safeguards have also been placed to prevent orders without appropriate specs from being put on the schedule and appropriate visual indications are provided to the users. This new feature is an addition to static chemistry ranges required for sale billets.
Through its advanced shop management modules such as the roll shop, guide shop, and stand building Jewett's setup shops have taken advantage of many functions such as inventory and location management, product setup, shop planning, account summary and more.
The melt shop is enjoying advanced melt shop production tracking and reporting tools along with mold management, ladle management and custom reports.
Material management in the billet yard has been improved to allow charging the reheat furnaces of both mills with ease using a user friendly touch screen. Billet movements and count corrections have also been made easier for the operators.
Billet detection and tracking rolling durations in the rolling mills have been enhanced using automation OPCs. Rolling mill enhancements include custom KPI reports, billet weight recording for more accurate measurement of metallic loss at various points of the production process, additional billet scanning features, multi-cutting quick selection for the saw operations and live tracking and forecasting of rolling production start and end dates.
Furthermore, QMOS is communicating with their level 1 ERP (ROSS) for a streamlined data communication, production reporting, production adjustments, inventory tracking, order downloads, part and recipe creation. Significant developments were made to automate the synchronicity of duplicate data existing between ROSS and QMOS which improve user experience and prevent manual entry by the schedulers.
Nucor Corporation is the largest manufacturer of steel products in North America. In 2009 more that 14 million tons of steel were produced at Nucor's approximately 200 operating facilities. Nucor has operating facilities in 22 states. Products produced are: carbon and alloy steel in bars, beams, sheet, and plate; steel joists and joist girders; steel deck; cold finished steel; steel fasteners; metal building systems; and light gauge steel framing.
Quad Infotech is a software engineering and design company that specializes in the development of manufacturing execution systems (MES) as well as energy management systems. Quad's unique knowledge of industrial process, combined with computer software design expertise, renders its Level-2 and Level-3 software products unique in the global metals market. Quad's flagship MES product, QMOS has been operating in numerous steel plants throughout North America and Europe since 1994.