How can data transparency in a rolling mill be sustainably improved?

Sustainable data transparency requires continuous acquisition and centralized availability of process data across all relevant plant areas. With ibaPDA, data from different process stages are acquired synchronously and provided in a consistent structure. Based on this, ibaDaVIS enables simple, role-based access for different user groups. This creates a unified data foundation that supports informed evaluation and fast decision-making.

How can production data be used to reduce scrap rates and improve the CO₂ footprint?

Targeted scrap reduction requires clear assignment of quality deviations to specific process steps. With ibaAnalyzer, continuously acquired data can be evaluated in detail and relevant KPIs calculated. This allows precise identification of root causes for scrap and enables targeted optimization measures. As a result, material losses are reduced and the overall CO₂ footprint is improved.

How can production plants be made comparable using standardized KPIs?

Comparability across plants requires the definition of standardized signals and KPIs. By defining uniform process signals, ibaPDA enables consistent data acquisition across different plants. These data are processed into KPIs in ibaAnalyzer, allowing objective performance comparison. This makes it possible to identify best practices and transfer them to other plants.

How can access to production data be simplified for different user groups?

Simplified data access requires an intuitive and centralized visualization solution. With ibaDaVIS, data can be provided via a browser-based interface without requiring additional software installation. Different user groups such as production, maintenance, and quality assurance access the same data foundation. This reduces coordination effort and accelerates problem analysis.

How can data-driven analysis support the commissioning of new plants and products?

During commissioning, rapid evaluation of process conditions is critical. With continuous data acquisition via ibaPDA and analysis using ibaAnalyzer, process deviations can be detected at an early stage. ibaDaVIS provides a clear visualization of this information and enables fast derivation of corrective actions. This accelerates commissioning and improves the stability of new processes.

Data Acquisition and Visualization in a Rolling Mill With ibaPDA and ibaDaVIS

Democratization of Data With ibaDaVIS

A strip steel producer based in Germany uses ibaDaVIS to overview and evaluate data over the long term. This allows problems that arise to be solved more quickly and thus to start completely new evaluation approaches proactively.

Business Benefits The Technology Used Functions More Success Stories

Initially used in one rolling mill, the iba system has been rolled out more and more, and currently about half of the plants in the mill are equipped with measurement technology from iba. The continuous data acquisition enables the steel producer to analyze the individual process steps of the manufactured products with ibaAnalyzer and thus to calculate meaningful quality parameters (Key Performance Indicators, KPIs), which are used to compare the plants and to analyze the production – a big step towards Industry 4.0. In this way, optimization potentials can be quickly identified and implemented. In particular, scrap quantities can be sustainably reduced through precise allocation. This improves the CO₂ balance of production and helps save money. It also facilitates the work of commissioning engineers and application technicians when ramping up new plants and introducing new products. In addition, thanks to ibaDaVIS, all users can access the data quickly and easily. The right way to the democratization of data.

Precise analysis

of individual process steps

Uncomplicated access

to data for different users

Energy savings

and improvement of the CO2 balance through allocation of scrap quantities

The Technology

The central component of the data acquisition in the plant is the versatile measuring software ibaPDA (Process Data Acquisition). To be able to compare the respective process steps of the different plants better, 10 to 15 standard signals were defined in advance, which were recorded and calculated in the iba system. For a more precise evaluation of the recorded measurement data, the strip steel producer uses ibaAnalyzer, for the automated management of the same ibaDatCoordinatior. Messages on the plant conditions are automatically transmitted to the operator or maintenance staff. Thanks to the precise recording and the clear visualization with ibaDaVIS, improvement measures can be derived directly from the collected data and thus rapid optimizations can be achieved. The relevant data is easily and quickly accessible for application engineers, foremen, supervisors and employees from the laboratory. More than 100 users are currently working with the system. In addition, the strip steel producer uses ibaDaVIS to access digitally stored protocols, for example to provide reports for the calibration verification of measuring instruments during audit appointments. Thanks to the results achieved, it is planned to implement the iba system even further in the plant in the future.

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The insights with ibaDaVIS on the process values and signals for trend and outlier analysis is only the first step. Quickly, completely new insights and thus potentials to processes are recognized on the same data.

Thomas George
Product Manager, iba AG

Used Functions

The following functions of the iba system are used in this success story.

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Frequently Asked Questions (FAQ)

How can data transparency in a rolling mill be sustainably improved?: Sustainable data transparency requires continuous acquisition and centralized availability of process data across all relevant plant areas. With ibaPDA, data from different process stages are acquired synchronously and provided in a consistent structure. Based on this, ibaDaVIS enables simple, role-based access for different user groups. This creates a unified data foundation that supports informed evaluation and fast decision-making.
How can production data be used to reduce scrap rates and improve the CO₂ footprint?: Targeted scrap reduction requires clear assignment of quality deviations to specific process steps. With ibaAnalyzer, continuously acquired data can be evaluated in detail and relevant KPIs calculated. This allows precise identification of root causes for scrap and enables targeted optimization measures. As a result, material losses are reduced and the overall CO₂ footprint is improved.
How can production plants be made comparable using standardized KPIs?: Comparability across plants requires the definition of standardized signals and KPIs. By defining uniform process signals, ibaPDA enables consistent data acquisition across different plants. These data are processed into KPIs in ibaAnalyzer, allowing objective performance comparison. This makes it possible to identify best practices and transfer them to other plants.
How can access to production data be simplified for different user groups?: Simplified data access requires an intuitive and centralized visualization solution. With ibaDaVIS, data can be provided via a browser-based interface without requiring additional software installation. Different user groups such as production, maintenance, and quality assurance access the same data foundation. This reduces coordination effort and accelerates problem analysis.
How can data-driven analysis support the commissioning of new plants and products?: During commissioning, rapid evaluation of process conditions is critical. With continuous data acquisition via ibaPDA and analysis using ibaAnalyzer, process deviations can be detected at an early stage. ibaDaVIS provides a clear visualization of this information and enables fast derivation of corrective actions. This accelerates commissioning and improves the stability of new processes.