MSW Roll Shop Management System (RMS) Features

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1 METROLOGY SYSTEMS WALES PAGE 1 OF Bessant Clse Cwbridge Suth Wales United Kingdm CF71 7HP Tel and Fax: +44(0) MSW Rll Shp Management System (RMS) Features Issue N: 1.2 This dcument accmpanies the brchure Metrlgy Systems Wales Rll Management System and prvides a detailed descriptin f the features f the Rll Management System. Overview The Rll Management System (RMS) gathers data at key pints in the rll preparatin/usage cycles as shwn in the system verview belw: Dr D Alun Armstrng B.Sc. (Wales), Ph.D. (Liverpl). G M Armstrng. VAT Reg. N G:\MSW Dcuments\Marketing\White Papers\RMS\MSW RMS White Paper.dc

2 Page 2 f 24 Technical Architecture The MSW RMS emplys Client-Server architecture, using Micrsft SQL Server 7/2000 RDBMS with all client screens prduced with Brland Delphi. The Client-Server architecture ensures that the applicatin will scale t fit the requirements f even the largest rll shps and rlling mills and allws fr rapid data retrieval. The system and its database may be integrated with mdern mill cmputers as shwn in the typical schematic belw: Mill Cntrl Cmputer Mill Database cmputer Rll Shp Database cmputer d i gi t a l Ethernet User cmputers n Cmpany Netwrk Ethernet Cmpany Netwrk Rll Shp Grinders' Cmputers Rll Shp Supervisr's Cmputer

3 Page 3 f 24 Key Features The key features f the MSW RMS include: Easy Capture f Rll Grinding Data Finished grund rlls Partial grund rlls Salvage f damaged rlls Flexible Capture f Rll Measurement Data frm standalne r integrated CNC devices Grund and Wrn Prfiles Diameter Hardness Surface Rughness Rundness Ovality Eccentricity TIR Crack/Bruise map Capture f Rll Building Data Wrk rll assembly Backup rll assembly Recrd details f all assembly cmpnents Rlls Chcks/Bearings Sledges Cupling Bxes Maintenance f Chcks and Bearings Inspectins Dimensinal checks Bearing re-zne Chck Failure recrding Bearing Failure recrding Inventry Management Add, scrap and track all cmpnents: Rlls Chcks Rller Bearings Bushes/Sleeves Thrust Bearings Sledges Cupling Bxes Brush Rigs/Brush Rlls/Brush Chcks Advanced Data Retrieval Facilities RllShp Explrer allws Windws Explrer like retrieval f all histrical data Pwerful Reprting Facilities Many pre-defined reprts fr rllshp supervisrs, managers and accunting staff Pwerful Reprt Generatr allws users t define their wn reprts

4 Page 4 f 24 Capture f Rll Grinding Data The system is designed t capture rll grinding jb data (fr example, diameter) at the pint f grinding. This is a majr advantage ver many ther rll management packages, which tend t capture the grind jb data at the end f shift. Capture Finished Grind details via an easy t use Grinding Wizard : The Grinding Wizard allws peratrs t view the finish grund prfile frm either the MSW Cadn Rll Measurement System r frm a cmpatible CNC grinding machine and t recrd the finished grind details by cmpleting five easy steps: Step 1: Read Finish Grund Prfile (frm MSW Cadn r CNC Grinder) Step 2: Select aim Camber Targets (symmetrical, chamfered, CVC) Step 3: View Rll Prfile Chart (see screensht 1) Step 4: Enter Grinding Jb Data (see screensht 2) Step 5: Optinally print a hardcpy Capture f unfinished Grinding Jbs : Grind details when rll prfile measurement is nt pssible Partially cmpleted Grind Jbs e.g. backup rlls grunds in stages Grinds made in the prcess f salvaging damaged rlls Capture f Wrn Out f Mill Prfiles fr cmparisn with Finish Grund Prfiles. Screen Sht 1: Viewing the Rll Prfile

5 Page 5 f 24 Screen Sht 2: Entering the Grinding Jb Data Screen Sht 3: Wrn and Grund Prfiles

6 Page 6 f 24 Capture Rll Measurement Data The system allws all key rll measurement data t be recrded. Rll Hardness measurements (see screensht 4) Recrd wrk rll and backup rll hardness Analyse rll hardening ver time Rundness Measurements Ovality Eccentricity TIR Screen sht 4: Entering Hardness Measurement Data

7 Page 7 f 24 Rll Building Recrding f wrk and backup rll building and cnditin checks. Wrk Rll Building (see screensht 5) Recrd all items in final assembly Tp/Bttm rlls Operatr/Drive side chcks Pst Texturing/Chrming surface rughness data Sledges Cupling bxes All lists are filtered t shw nly rlls/chcks etc which are legal fr the selected stand Many user definable alarms Abslute rll diameter fr stand Diameter matching limit fr rll pair Chcks past maintenance targets (tnnage, meterage) Bearings past maintenance targets (tnnage, meterage) Backup Rll Building Recrd all items in backup rll assembly Autmatically calculate packer size (ptinal) fr the mill Recrd final checks and inspectins Screen sht 5: Wrk Rll Building

8 Page 8 f 24 Chck/Bearing Maintenance Recrding f wrk and backup Chck / Bearing Maintenance Chck/Bearing Maintenance (Screensht 6) Chck Inspectins Bearing Inspectins Chck Dimensinal Checks Bearing Dimensinal Checks Bearing ReZning Screen sht 6: Chck Visual Inspectins

9 Screen sht 7: Bearing Visual Inspectin Page 9 f 24

10 Screen sht 8: Chck Dimensinal Checks Page 10 f 24

11 Screen sht 9: Chck Assembly Page 11 f 24

12 Page 12 f 24 Failed Chcks and Bearings may be remved frm service fr repair, refurbishment r scrap Screen sht 10: Remve Failed Chck frm Service

13 Page 13 f 24 Inventry Management The Inventry Manager allws fr management f all key items f Rll Shp inventry, including: Rlls Chcks Rller Bearings Bushes Sleeves Thrust Bearings Sledges Cupling Bxes Brush Rigs Cmpnents can be managed thrughut their life-cycle: Added t stck Issued frm stck int service Tracked thrugh their usage cycle Remved frm service fr damage Scheduled fr maintenance n the basis f tnnage, meterage r elapsed time Returned t service after maintenance r repair Scrapped Rll Fleet Management The Rll Fleet Manager, fr example, allws fr easy inspectin f the entire rll fleet, tracking f damaged rlls and cntrlling the re-mating and de-mating f rlls. View Rll Fleet (Screensht 11) Rlls in stck In-Service Single Rlls In-Service Paired Rlls Damaged Rlls Scrapped Rll histries Filter Rll Fleet By Stand By Rll Type By Supplier By Tracking Status e.g. Grund, Built, In Mill, Out f Mill. By Diameter Distributin t assist scheduling f rll purchasing Damaged Rll Handling (Screensht 12) Recrd Damaged Rll Adjust target salvage diameter after nn-destructive testing r plunge grinding Maintain a histry f rll damage fr analysis f trends Rll Mating (Screensht 13) Frm Rll Pair (Re-mate) Split Rll Pair (De-mate) Optimised mating based n clsest diameter matches

14 Page 14 f 24 Screen sht 11: Viewing the Rll Fleet Screen Sht 12: Recrding damaged Rlls

15 Page 15 f 24 Screen sht 13: Re-Mating Rlls Chck/Bearing Fleet Management The Chck Fleet Manager, allws fr easy and cst-effective schedule f chck/bearing maintenance. Schedule Chcks/Bearings Maintenance (Screensht 14) User definable maintenance basis Tnnage rlled since last maintenance Meterage rlled since last maintenance Hurs in Mill since last maintenance Elapsed (calendar) time since last maintenance Maintenance schedule may be based upn usage rather than elapsed time Mre cst effective Helps t reduce chck/bearing failure in mill Filter Chck Fleet By Stand By Chck Type By Tracking Status e.g. Available, Built n Rll, In Mill, Out f Mill. Flagged fr maintenance Remved frm service fr maintenance Remved frm service fr repair r refurbishment Damaged Chck Handling (Screensht 15) Recrd Failed Chcks and Bearings Enables supervisrs t track failures and rder repairs and refurbishments Full recrding f repair and refurbishment details when chck/bearing returned t service

16 Page 16 f 24 Screen sht 14: Schedule Chck/Bearing Maintenance based n usage Screen sht 15: Supervisrs rder repair/refurbishment/service fr damaged chck

17 Page 17 f 24 Data Retrieval Facilities The Rll Shp Explrer screen allws easy retrieval f all data captured frm the preparatin f rlls, chcks and bearings in the rllshp and their usage in the mill. (Screensht 16) Filter Rlls By Entire Fleet Mill/Stand Operatr Grinding Machine Further Filter by Grind Histry Mill Trip Histry (screen sht 17) Damage Histry Hardness Measurement Histry Rundness Measurement Histry Display Preparatin Cycle details: Grinding Hardness Eccentricity/Ovality Building Mill Trip Wrn Prfile Screensht 16: Rll Shp Explrer Finish Grund Prfile

18 Page 18 f 24 Screensht 17: Rll Shp Explrer Cmpleted Mill Trip Screensht 18: Rll Shp Explrer Rll Gap Chart

19 Page 19 f 24 Reprting Facilities The system includes a range f pre-built reprts and als a very flexible reprt generatr. Canned Reprts (see screensht 19) Rll Shp Reprts Rll Fleet Reprts Damaged Rlls Reprts Grinding Reprts Rll Hardness Reprts Chck Fleet Reprts Rll Building Reprts Mill Trip Reprts Management Reprts Rll Perfrmance Reprts Chck/Bearing Perfrmance Reprts Grinding Machine Perfrmance Reprts Operatr Perfrmance Reprts Accunting Reprts Current Rll Fleet Value Reprt Histrical Rll Fleet Value Reprt Csted Stck Lss Reprts Scrapped Rlls Reprts Screen Sht 19: Reprting Sample Rll Fleet Reprt

20 Page 20 f 24 Query/Reprt Generatr The Reprt Generatr allws a manager t custmize existing reprts r t generate cmpletely new reprts t suit their needs. The Query Wizard allws users t select the data fr their reprt frm the RMS database. Screen sht 20: Query Wizard select table/view step Screen sht 21: Query wizard select data fields step

21 Page 21 f 24 Screen sht 22: Query wizard autmatically generates SQL t retrieve data frm RMS database The Reprt Wizard allws the users t easily design the layut f their reprt Screen sht 23: Reprt Wizard allws users t define data grups fr their reprts

22 Page 22 f 24 Screen sht 24: Reprt Wizard allws users t pick pre-defined styles fr their reprt The Reprt Designer tl allws users t make changes t the reprts created by the reprt wizard. Screen sht 25: Reprt Designer allws users t tailr reprts

23 Screen sht 26: Reprt Previewer allw users t preview reprt befre printing Page 23 f 24

24 Page 24 f 24 Benefits The RMS brings the fllwing majr benefits t Rll Shp Operatins: Optimisatin f spending n rlls by prviding accurate Rll Perfrmance Figures Reprts Tnnes/Metres rlled per mm f stck reductin Enables cmparisn between cmpeting rll suppliers Enables cmparisn between rlls cmprised f different materials 1 Analysis f stck lss due t rll damage fr different rll types and suppliers Minimise rll stck usage Optimal re-mating f rlls reduces stck usage allwing fewer replacement rlls t be rdered Internal Analysis by ne Custmer has estimated substantial savings per annum Reduced chck/bearing maintenance csts Allws chck/bearings maintenance t be scheduled accrding t usage rather than elapsed time: Tnnes rlled Metres rlled Time spent in mill Failure analysis indicates best bearing types and suppliers Reduce mill dwn-time By using better perfrming (in damage terms) rlls By preventative maintenance f cmpnents based upn actual usage e.g. chcks, bearings 1 hur saving = xxk Accurate perfrmance reprting f Rll Shp peratins Grinding perfrmance By Machine By Operatr Average Stck lss reprts 1 Prgressin t 100% HSS Wrk Rll Use in the Early Finishing Train Stands at Crus Llanwern HSM. I. Beverly, A. Witts, G.A. Williams & S. Emery. Presented at Rlls 2003 Cnference.

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