Development and deployment of a data capture and reporting system for Onesteel Wire Products*

摘要

Newcastle and Geelong Wiremills processes approximately 200,000 t/a of steel rod and bar into wire, wire products and fence posts. The processes in the plant involve over 100 individual machines, three continuous galvanising lines, cleaning lines and effluent plants. The complexity of these plants and significant reliance on manual labour led to a number of data gathering systems being developed by individual departments. These systems generally did not share a common platform, calculated critical measures differently, and data was not shared or compared. In 2010 a project brief to implement a machine data capture (MDC) system in Newcastle and Geelong Wiremills was developed. The gathering system was to be plant-based for direct operator input, with the reporting system being web-based, for ease of access. In 2011 the capital approval for stage one of the project was approved with installation of this stage being completed later that year. Currently there are 28 MDC stations installed and over 22 months of data gathered, which is being reviewed in different forms on a daily basis. This paper is a review of the whole process from development of the specification, installation of the system, development of the reporting system, and then some practical examples as to how the data gathered is being used to improve overall equipment efficiency.