Summary
Key results
Full visibility into product status, parameters and flow across all stages of production
A consistent, modular technology foundation for a system comprising more than 200 applications and around 6 000 users
The need for full production visibility and data-driven decision-making
At the Dąbrowa Górnicza plant, the system supports processes from the blast furnace through to the finished product. At this scale, the client needed access to data on production status, quality, key technological parameters, production equipment performance indicators, transportation and warehousing. The goal was to increase business awareness across all levels of the organization and enable decisions based on actual process data.
Greater visibility was also expected to improve workplace safety by helping detect failures, unplanned downtime and their causes. The client also aimed to reduce energy consumption and production losses through precise furnace control algorithms, minimized downtime and fewer losses resulting from the inadequate quality of manufactured components.
Further system development was hindered by a lack of common standards, technical debt, an insufficient pace of change delivery and limited access to specialists combining .NET expertise with knowledge of industrial automation and manufacturing processes. The organization needed a partner that could provide the right expertise, support the maintenance of the extensive environment and enable its consistent further development. To address these needs, the client partnered with Sii Poland.
Developing a modular foundation and common standards
Sii Poland assembled a team of experienced engineers responsible for developing and maintaining the application layer of the Manufacturing Execution System. The team worked on existing solutions and created new modules addressing the needs of different areas of the plant.
A key part of the work was the development of a core module responsible primarily for system configuration and user access rights. It provided a common technology standard and shared libraries for the remaining applications.
The scope of work included:
- Developing the core module responsible for configuration and user access rights
- Creating and developing multiple modules for different purposes, covering both user interfaces and the server-side layer
- Maintaining and developing an internal set of libraries, templates and tools supporting developers in their day-to-day work
- Introducing common technology standards and software development best practices
- Organizing the work of the internal IT team around a consistent approach to application development
- Partially streamlining the software delivery process
Greater production control & scalable system development
The system developed by Sii Poland provided access to data on production processes, quality, and key technological parameters at every stage – from the blast furnace through to the finished product. It is used by operators, shift supervisors, maintenance staff, and engineers. The solution enables users to track products throughout the entire process, monitor their status and parameters, and detect failures, unplanned downtime and their causes. Reporting available at different levels of the organization supports decision-making based on actual data.
Up-to-date information on process status & detected irregularities supports workplace safety and gives the client greater control over production. Across the production environment, precise algorithms controlling furnace operation support energy savings, while reducing downtime and losses caused by inadequate product quality helps minimize overall production losses.
A common technology foundation, standards, and libraries standardized the way applications are developed. The modular architecture allows individual components to be added or removed without rebuilding the entire system, making it easier to further develop an environment comprising more than 200 applications.
Organizing the work of the internal IT team and providing access to specialists who combine software development expertise with knowledge of manufacturing accelerated project delivery and the release of required software. Over 8 years of cooperation, Sii Poland provided the client with continuous support in developing and maintaining its system.
Key results
- Visibility into product status, parameters, and flow from the blast furnace through to the finished product
- Production data and reporting available to around 6 000 users across different levels of the organization
- Detection of failures, unplanned downtime, and the causes of anomalies
- Support for energy savings through precise furnace control, reduced downtime, and fewer quality-related losses
- A modular technology foundation supporting the development of a system comprising more than 200 applications
- Faster delivery of development work and release of required software