Driving Circularity with a Multi-phase Approach

It is time to accelerate circularity for critical materials for global transformation of Energy, Transportation, and other sectors.

The Big Idea

“Launch into Industry 4.0 with an AI-infused platform to drive Cast House performance & competitive advantage.”

RoadMap

Staged delivery of requirements:
CASTHOUSE PROCESS OPTIMIZATION SYSTEM

Phase 1 Blending Calculations & Batch Management

  • Integrate inventory, elemental composition & cycle time
  • Level 1 Optimization across 5 NCH melters
  • Level 2 Optimization across 4 NCH holders
  • Allow for user level control of charge blend
  • Optimize for chemistry, cost & alloy  spec
  • AI Model development for scrap types
  • Web based UI

Phase 2 Cast House Process Optimization

  • Operational orchestration for optimization of melter to holder blending
  • Forecast material need at the plant level
  • Forecast material need at each melter based on order demand
  • Monthly / Weekly / Daily batch planning with metal procurement estimations and “actuals” reporting
  • Integrated Scenario Planning
  • Inventory Management Module Development

Phase 3 Cast House Quality Management

  • CPOS rollout for SCH – 8 Melters and 7 holders
  • Integrate Pricing, scrap availability and quality alerts
  • Blending Forecast (Future Planning) – scheduling and production planning integration
  • Automate BOM creation
  • Integrate Plant QMS to match ingot quality against material performance
  • Enhanced UI delivery

Phase 4 Industry 4.0 Enablement

  • Chemical Error Optimizations based on Actual vs. Predicted
  • Predictive Maintenance
  • Integrate to PLC for autonomous control
  • Governance structure with an enterprise level focus
1
Batch
Management
2
Process
Management
3
Predictive Quality
Enablement
4
Manufacturing 4.0
5
Business
Value

Customer Value is First Priority

  • Your value increases with volume
  • We cap Circularity AI Platform costs
  • We align goals for each Phase

Enabler to Increasing Circularity

Industry-wide Stochastic AI Models of:

  • Composition & price variability for each scrap type & source
  • Scrap-to-Product conversion performance, quality & risk

GOAL: Reduce cost & quality risks

Contact Us to Learn more

Learn more about how our Circularity AI Platform works, why it is both valuable and essential, and how we succeed in Accelerating the Circular Economy with Data, Technology, & Artificial Intelligence

Talk to A Specialist