Tata Steel Slide Kees de Haan LIMS in a digital company Requirements and selection
Tata Steel Slide 2 Agenda 1 Intro Tata Group and Tata Steel 2 Tata Steel Digital Strategy and LIMS 3 Tata Steel IJmuiden laboratories 4 LIMS requirements 5 The Selection Process 6 Expected benefits and status
Introducing Tata Steel Tata Steel Slide 3 Introduction to the Tata Group One of the world s fastest-growing and most reputable corporations Tata Group Founded in 1868 Operations in more than 100 countries and 600,000 employees Total revenues of more than $109 billion (68% from outside India) Ranked world s 11th most reputable and 17th most innovative company Tata Steel Group 11 th largest global steel producer Annual steel capacity of more than 28 million tonnes Around 75,000 employees Manufacturing operations in 26 countries across five continents
Introducing Tata Steel Tata Steel Slide 4 Our key markets Serving the most demanding markets worldwide Aerospace Consumer products Automotive Construction Learnings and Intro Team Lifting & excavating Defence & security Energy & power Packaging
Tata Steel in IJmuiden Tata Steel Slide 5 Tata Steel in IJmuiden
Tata Steel in IJmuiden Tata Steel in IJmuiden Our strength Top steel producer in Europe Approx. 9.000 employees, including 250 researchers Capacity: 7.5 million tonnes of steel Fully integrated production process Tata Steel Slide 6 Strength through knowledge Own RD&T in IJmuiden for process products and application research. Close co-operation with (international) knowledge institutes Own training centre in Velsen-Noord Co-operation with (regional training centres) and universities of applied sciences (InHolland and HU University of Applied Sciences Utrecht)
Tata Steel in IJmuiden Tata Steel Slide 7 Example of product innovation Advanced high-strength types of steel (stronger and lighter) for: Automotive Construction industries iron ore kolen Sinter Pellets coke blast furnace HISARNA Liquid iron HISARNA Process innovation direct use of powdered raw material Iron ore is melted in the cyclone reactor Fine coal is injected directly into the smelter 20% less CO2 emission
Tata Steel in IJmuiden Tata Steel Slide 8 Tata Steel in IJmuiden: high-quality processes.. TS IJmuiden produces high-quality hot-rolled, cold-rolled and coated steel Raw materials - Pig iron - Steelmaking benefits - Casting - Rolling - Coating
Tata Steel Slide 9 Agenda 1 Intro Tata Group and Tata Steel 2 Tata Steel Digital Strategy and LIMS 3 Tata Steel IJmuiden laboratories 4 LIMS requirements 5 The Selection Proces 6 Expected benefits and status
Tata Steel Digital Strategy and LIMS Tata Steel Slide 10 Tata Steel in Europe wants to become a Digital Master Digital enabled Support functions
Tata Steel Digital Strategy and LIMS Tata Steel Slide 11 Big Data roadmap AP 17/18 (Focus on Operations and R&D only), DRAFT LIMS for PA LIMS for R&D Product Data OSF2 Product data Analitycs tooling SPH, Proces data IoT Installation data Connectivity eg Lora IoT Platform IoT as a service Data Business Rules Assignments Data lake Process, Product, Installation data Other data sources Smart Steel Factory Replace current R&D UK Hadoop cluster
Tata Steel Slide 12 Agenda 1 Intro Tata Group and Tata Steel 2 Tata Steel Digital Strategy and LIMS 3 Tata Steel IJmuiden laboratories 4 LIMS requirements 5 The Selection Proces 6 Expected benefits and status
Tata Steel IJmuiden laboratories Tata Steel Slide 13 Product Analyses Laboratories Characteristics Sampling and chemical and physical analysis of: raw materials, semi- and end-products, water, waste and by-products on behalf of process control, product quality and environmental control 100.000 lab tests/yr 250.000 automated tests steelmaking Current systems: Labvantage (not substantially updated since 1999) for lab tests Sparcs (up to date) for automated tests (out of scope of this project)
Tata Steel IJmuiden laboratories Tata Steel Slide 14 Mechanical testing (TST) Characteristics Mechanical tests of end-products for product release and product development: tensile, charpy impact (kerfslagproef), bending, hardness, enamelling 180.000 tests/yr 120.000 certificates Current system: Klabbes, own development (not substantially updated since 2001)
Tata Steel IJmuiden laboratories Tata Steel Slide 15 Testinglab
Tata Steel IJmuiden laboratories Tata Steel Slide Innovation R&D RD&T main office in IJmuiden Approx. 250 employees Co-operating with Centres of Expertise Process research - Test installations for making iron - Pilot rolling mills - Mathematical and water models Product research - Alloy development Application research - Strain and deformation measurements - Accelerated corrosion tests - Tin can production - Car parts 16
Tata Steel Slide 17 Agenda 1 Intro Tata Group and Tata Steel 2 Tata Steel Digital Strategy and LIMS 3 Tata Steel IJmuiden laboratories 4 LIMS requirements 5 The Selection Process 6 Expected benefits and status
Tata Steel Slide 18
Tata Steel Slide 19 International standard Customer requirements ERP Test certificates Inspection plan FQD Additional requirements External orders (e.g. PT opdrachten) Local Inspection plan MES Sample instruction to PC Test plan (What) Sample taken Test results Test plan (How) LIMS Test equipment E.g. tensile tester BIN info from PC
LIMS requirements Tata Steel Slide 20 Main Requirements Functional fit for Ana lab and Testing Lab Experience in steel industry and testing labs in particular Reporting Facilities User configurable desktop Fit so hardly any bespoke development is necessary Control Chart (SQC module) with real time actions in LIMS. LES functionality (Laboratory Execution System) Compliant with ISO 17025 geaccrediteerd lab Connectivity Lab Equipment (modern and old technology) Fit in Tata Steel Architecture Integration layer Fit in TS IT standards Standard DB and OS
Tata Steel Slide 21 Agenda 1 Intro Tata Group and Tata Steel 2 Tata Steel Digital Strategy and LIMS 3 Tata Steel IJmuiden laboratories 4 LIMS requirements 5 The Selection Process 6 Expected benefits and status
The Selection Process Tata Steel Slide 22 The standard software selection process Long List: Desk study, Gartner quadrants etc Requirements: functionality, performance, technical and architecture, commercial, supplier maturity, future support etc Implementation process Request for Information (RFI) Short List: Selection based on the provided information. Might invite selected suppliers, run Q&A sessions etc Request for Quotation (RFP) RFP process: Invite supplier, presentations, demo s, customer visits etc. Score Lists: score on requirements, weight factors etc Deal with personal preferences etc
Tata Steel Slide The actual selection process Three suppliers were selected from different backgrounds for a pitch presentation on new technologies and innovations in laboratory processing. From this pitch 2 suppliers remained. No additional suppliers were selected since it was expected that these would provide only more of the same. A Request for Proposal was issued on October 1, 2015 followed by Q&A session and a proposal clarification session including a condensed training on both systems. Proposals were received mid November 2015. Evaluation conducted guided by a evaluation document focussing on the Tata Steel instructions. One suppler was selected More experience with their product and as LIMS supplier 23
The Selection Process Tata Steel Slide 24 Example assesment sheet Assessment of compliance with Functional Requirements L IMS for P roduct Analys is R fp AS S E S S ME NT Instruction # Thermo Instruction 8. Instruction 10. Importance 1-4 Score 0-4 Total The S uppliers are required to explicitly state their compliance with the F unctional R equirements for the TS T or, in case their solution is 4 4 not in full compliance, clearly indicate their exceptions and 16 S ample R egistration 4 3 12 S ample Ds itribution and T racking 4 4 16 Assigning work 4 3 12 C alculations and numerical repres entation 4 4 16 Data edit / C orrections 4 4 16 Q uality C ontrol Monitoring 4 4 16 Specification Checking 4 4 16 C hecking, R eviewing and approving res ults 4 4 16 R eporting res ults 4 4 16 Managing L ab O perations 4 4 16 Mis cellaneous 4 4 16 F or detailed analysis and reporting, Tata S teel uses a R eporting 4 4 F actory. The supplier has to specify what standard reporting functionality their s olution provides. 16 15
Tata Steel Slide 25 Agenda 1 Intro Tata Group and Tata Steel 2 Tata Steel Digital Strategy and LIMS 3 Tata Steel IJmuiden laboratories 4 LIMS requirements 5 The Selection Process 6 Expected benefits and status
Tata Steel Slide 26 Business benefits Quickness of response to changes in customer requirements and product development will improve The number of manually made corrections in daily operations will reduce resulting in improved efficiency and processing time The connection with MES will be easier More Laboratory instruments will be coupled to LIMS. Less manual input is needed resulting in higher data integrity and improved efficiency Internal customers will get insight in progress of their samples Overall benefits Continuous improvement due to availability of data Productivity improvement Better tracking and tracing of samples Compliance with ISO supported Audit trail and data integrity 26
Tata Steel Slide Thank You