Broner Metals Solutions selected for Manufacturing Execution System for new Steckel Mill and Plate Mill complex at Gerdau Aominas

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Broner Metals Solutions, provider of integrated MES, supply chain and scheduling solutions for metals, has been selected by Gerdau Aominas to implement a new MES Solution to manage their new Plate and Steckel Mill complex in Ouro Branco, Brazil.

The objective of the new project is to provide Aominas with modern Production, Quality Management and Inventory Management functions to  manage production in real-time and to integrate the new Process automation systems with SAP. The new systems will place Gerdau Aominas amongst the most efficient producers of Plates and Hot Coils.
The new MES system will also be integrated with Gerdau's in-house LIMS and Roll Shop Management systems. The New system also shares the same platform as the existing Broner supplied Planning and Scheduling systems which have avoided the need to build interfaces to third party solutions.
Broner's MES solutions for the metals industry are built from a set of packaged MES Modules developed specifically for the metals industry and designed in accordance with the ISA-95 Specifications for Manufacturing Execution Systems. 
Production Management
The Production Management process supervises the plant operations by exchanging key production and status information with internal business systems and plant processes.

Production Management provides the ability to edit and dispatch production schedules to plant equipment, to track a product from raw material to finished product, to control the flow of a product in a multi-step process, send recipes to the control system, and track production against a schedule.
The Production Management module also keeps a record of all production, rework, quality and logistics activities at a heat, slabs, coil, and plate level to provide a full genealogy for each finished plate or coil.
Quality Management
Broner Quality Management manages all the quality inspection, sampling and testing processes in the shop floor to ensure that the finished goods meet customer requirements.  It automates many, previously manual, processes leading to faster and more efficient management of 'failed' material, resulting in improved customer satisfaction and higher yields.
Broner Quality Management is a complete environment for managing the quality process within a metals plant and provides the following functions:

  • Sample cutting and tracking and Test instructions and results
  • Non-Conformance Reporting
  • Quality Recovery
  • Claims & Returns

Inventory Management (WMS)
The Broner Inventory Management module manages the many complexities of inventory and material movements, tracking, and storage within a metals plant. 
Broner's configurable solution has a in-built understanding of the metals production process, leading to more efficient production activities by ensuring that the required material is readily available and accessible, and in the correct locations.  This reduces the cycle-time of inter-process material movements, resulting in increased on-time deliveries, reduced delivery times and improved productivity.
Some of the benefits which will be provided by Broner's MES solutions include:

  • Integration of production across plant
  • Reduction of Inventory levels
  • Improved Delivery Performances and utilisation of the shops
  • Reduction in Production Costs
  • Improved Management control

David Mushin, Broner Chief Executive said, "I am pleased that Gerdau is relying on Broner's modern MES system for their Steckel and Plate Mills to provide valuable business benefits".

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