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Steel Mills - Production Control - Factories .. Computers work

Steel Mills

Steel mills produce a huge amount of diverse products, which greatly complicates the organization of production in these factories and their effective management. This has led to the use of electronic computers in the various stages of steel production, starting with preparing the metal and even making steel plates and strips.

Production Control

The figure on page 114 shows the sequence of production stages in a typical steel factory in which an electronic computer plans, controls and coordinates the production stages. The main data processing center computer receives purchase orders for steel in its various forms, from bars, beams and sheets, and in its various types, such as mild steel, manganese steel, etc. The computer sorts the purchase orders according to the required shapes and types, collecting, for example, all orders for mild steel bars with a circular section and a specific diameter. Obviously, this facilitates production operations. A single mix of mild steel is used to manufacture all the required bars without the need to change the requirements from one section to another. The computer also prepares a future production plan that aims to use the various production capacities in the factory to the fullest extent. This plan is changed successively as required by production conditions, and is used to inform management about the progress of production operations and to inform customers about expected delivery dates.

The central computer's mission in some factories is limited to preparing detailed instructions for the various production operations. As for the more advanced factories, they rely on the connected computer system, as the central computer translates the main production plan into specific instructions for a number of production control computers that in turn control the main production machines directly without human intervention.

The steel production process begins by preparing the metal and pouring it into large ingots of the required weight. The ingots are darkened into tiles and their shells are removed. Scissors cut the tiles and make them into bars of the required size and weight according to the computer's instructions. The bars are then darkened into surface bars of the required section using suitable mills that were prepared in advance according to the computer's instructions, then the bars are cut into the required lengths and left to cool.
Analysis sequence The computer provides the delivery department with the instructions needed to prepare the bars for shipment to customers.

(General view of a steel mill)

(Production sequence in a typical steel mill (right)) Automatic analysis of steel samples by computer (top).