service – worldwide

Transcription

service – worldwide

EXTRACTS
FROM VARIOUS NEWSLETTERS 2013
SERVICE – WORLDWIDE
SMS group reprint newsletter 2013
CONTENTS
46 Special coatings for longer service lives
Contents
4
From a single
source: Service of
the SMS group
24 Inspections,
Repairs,
Modernization
34 Spare parts and
value added parts
36
Hightech – Made by SMS
13
Interview:
Customer Partnership
26
Pooled repair knowledge
at SMS Siemag
42
Fresh power from the
substitutes’ bench
14
Service – worldwide
28
Save time and money
43
16
All-round
carefree package
30
Challenging
converter repair
Warehouse in DuisburgRuhrort, Germany
44
More reliability
for repairs
32
Customer-oriented with
eService
45
New for old
46
Special coatings for
longer service lives
48
Safe and durable connections
49
Reliable rolling oil quality
50
New spindle convinces by
higher capacity
52
Premium technology for
premium tubes and pipes
18
19
In brief
20
Service Sales Seminar
22
Service for everything to do
with the blast furnace
MASTHEAD
In brief
Publisher SMS group
Corporate Communications
Eduard-Schloemann-Straße 4
40237 Düsseldorf, Germany
www.sms-group.com
Cover photo SMS Siemag experts in the
new special repair center.
2
CONTENTS
43 Warehouse in Duisburg-Ruhrort, Germany, opened
Editorial
54 Technological
consulting and
maintenance
management
56
Overcoming the salamander
57
Genius CM: Stabilized system
58
In brief
60 Training
62
Knowledge for the daily routine
64
TECademy program 2014
66
MEERcoach® training
on mill moduli
68
MEERcoach® program 2014
Experience, knowledge, closeness to the customer : That is
what characterizes the Service of the SMS group companies. Also in 2013, we provided support with large-scale
services. The year was full of challenging projects. SMS
group provided solutions via a global network, ensuring for
the customers the safe and cost-effective operation of their
plants over the entire life cycle.
The Service network has been expanded further. By now,
more than 60 locations enable fast supplies and service deployments all over the world. Uniform standards at all locations ensure high quality. Rapid operations are guaranteed,
whether they involve an electric arc furnace, a rolling mill
or a tube welding line.
We regard the relationship with our customers as a partnership. We not only support you with our know-how and
our experience but also with product developments and innovations. We assist you over the entire life cycle of your
plants. Together with you, we increase the efficiency of your
plants and upgrade them to the latest state of the art, so
that the quality of your products is continuously being enhanced while the running costs are decreasing. Also in the
past year, our Service solutions increased the competitiveness of our customers in many cases. Our employees know
the details of the plants and can thus implement systematic improvements. Some of these projects are illustrated in
this Special Service magazine.
Also in 2014, we will make use of our more than 100 years
of experience to increase the quality of your plants. We
thank you for trusting us in 2013 and look forward to continued and fruitful cooperation.
Your Service Team from SMS Siemag and SMS Meer
3
SERVICE
FROM A SINGLE SOURCE:
SERVICE OF THE
SMS group
4
5
SERVICE
»WE ASSIST OUR CUSTOMERS THROUGHOUT THE
USEFUL LIFE OF THEIR PLANTS.«
Pino Tesè, Member of the Management Technical Service Division of SMS Siemag
W
hen thinking of service
activities many people
picture a technician who
drives up to a customer
with his toolbox, repairs a defective
part or system, and after he has finished his work will not be seen by the
clients for a while. This image is outdated and does not at all apply to the
customer service of the SMS group.
“Our service solutions comprise distinctly more. We accompany our customers throughout the whole life cycle
of their plants. Even in times the plant
is operating smoothly, we consult our
customers on how they can make
their facilities run more efficiently,”
says Pino Tesè, Member of the Management Technical Service Division at
SMS Siemag. Based on the knowledge
of an Original Equipment Manufacturer (OEM), SMS makes sure its customers will remain competitive in the
long run.
Whether submerged arc furnaces
in Indian steelworks, aluminum rolling mills in China or PQF® tube plants
in Brazil are concerned, the service
6
solutions of the SMS group are tailored to the specific customer needs.
The range extends from the supply of
spare parts over maintenance measures and staff training to complex
modernizations. The experts of the
SMS group have always one goal in
mind: achieving high plant availability
at low maintenance costs.
TRUSTING PARTNERSHIP
A target that has convinced a large
number of customers, some for many
years now. At annual intervals since
1997, the engineers of SMS Siemag
have inspected the mill-pinion gear
units of a six-stand hot wide-strip mill
and replaced defective drive parts at
NLMK in La Louvière, Belgium. “We
appreciate the know-how of SMS Siemag’s engineers and technicians. And
in the course of the years, we have developed a trusting partnership,” comments Jacques Sulmon, Maintenance
Engineer at NLMK. On this mill, NLMK
produces wide strip which is used in
the automotive industry and in the field
of building construction. The strip is
mainly delivered to NLMK’s subsidiaries in the north of France. The regular
services rendered by SMS Siemag help
ensure the high availability of the
plant.
In the stainless steel sector, too, the
experts of SMS Siemag provide the
customers with advice and support, as
for example in the case of a stainless
steel Steckel mill at Outokumpu Stainless Oy in Tornio, Finland, which had
been expanded by a finishing mill in
2004. SMS Siemag has been responsible for the annual hydraulic inspection
of the plant since 2007. “If the hydraulic system fails, the complete plant will
come to a standstill”, says Teemu Lomu, General Manager Maintenance at
Outokumpu. “We rely on the expertise
of SMS Siemag as its specialists know
the system best.” Every year now, a
service expert travels to the customer’s site and checks the hydraulic system together with Outokumpu to find
potential weak points as early as possible.
EARLY is the keyword for an optimum service. And this is exactly
Top: Plant-specific
maintenance schedules
include checks at regular
intervals, here at a horizontal leveler.
Bottom: Imparting
knowledge is one of the
measures by which SMS
employees like Recai
Erdem, SMS Siemag, help
increase the productivity
of their customers’ plants.
7
SERVICE
Good advice: The
experts of the SMS
group provide their
customers with
knowledge on how to
operate their plants
even more efficiently.
i
SERVICE
in the business area SMS Meer
MEERcare®
Spare parts service, maintenance,
modernization, field service
MEERcoach®
Training & Support
Assessment, standardized and
individual training, e-learning
MEERconsult®
Consulting & Implementation,
Fact-finding audits, feasibility
studies or maintenance management systems
where the equipment check of
SMS Meer steps in. “We examine the
performance and the condition of a
plant in detail,” says Friedhelm Bitter,
Commercial Head of Business Unit
Service at SMS Meer. “Repeated analyses rapidly reveal alterations so that
we can submit our customer-specific
suggestions for improvement.” For instance, the service experts of SMS
Meer analyzed the condition of an eccentric press, type VERK 1600, at Sona
BLW Präzisionsschmiede GmbH in
Remscheid, Germany. They overhauled
the slide, pressure rod and slide guide
and modernized the slide adjustment
system. “We are very satisfied with the
result. Despite the fact that further
damaged parts were detected after
assembly work had started, the team
of SMS Meer managed to adhere to
Fast delivery and installation:
spare parts such as roll shafts.
8
the stringent schedule,” says Stefan
Schäfer-Kuhl, Maintenance Manager
Mechanical Equipment at Sona.
CONSULTING AND TRAINING
At SMS Meer the service products are
divided into the categories MEERcare®,
MEERcoach® and MEERconsult®. “The
decisive factor is the right mix,” says
service expert Bitter. The specialists of
SMS Meer prepare maintenance concepts, among others, consult the customers in terms of plant optimization
(MEERconsult®), take over warehousing as well as repairs in the case of an
emergency (MEERcare®). “The right
service concept is essential, but the
most important success factors are
certainly the staff members and their
know-how. Investing therein always
pays off. The more knowledge the operating team of a plant has gained and
the more details they understand of the
processes and machine sequences,
the more efficient will the customer
produce”, Bitter points out. “Our experts from MEERcoach® provide many
valuable tips gained in practical
The know-how of its staff distinguishes the customer service of SMS.
9
SERVICE
»WE DO NOT ONLY SUPPORT OUR CUSTOMERS WITH OUR
KNOW-HOW AND OUR EXPERIENCE, BUT ALSO WITH PRODUCT
ADVANCEMENTS AND INNOVATIONS.«
Friedhelm Bitter, Commercial Head of Business Unit Service at SMS Meer
experience for practical application.
The recently conducted training course
on rolling modules for the staff of ArcelorMittal Hamburg is a good example.”
Training courses are also included
in the scope of services offered by SMS
Siemag. “In 2010, we established our
own customer academy, called TECademy,” says service manager Tesè.
“Here we conduct trainings on all issues concerning plant operation, including maintenance and technology.”
Upon request, courses may be individually arranged with the customer.
The last two years, for instance, SMS
Siemag trained constantly personnel
from the Saudi Arabian steelmaker
Hadeed in its Hilchenbach location.
LOCAL PRESENCE DUE TO WORLDWIDE
NETWORK
“Our experts will also conduct training
courses directly at the customer’s site,”
continues Tesè. This is ensured by the
worldwide SMS network. The locations
are distributed over the entire globe –
39 run by SMS Siemag and 25 by SMS
Meer. “This network stands for fast de10
livery of components. In the case of an
emergency our service experts will be
on the spot shortly,” says Tesè. All locations have uniform standards to
guarantee high quality. In 2014 further
service workshops were established
in Cilegon, Indonesia, and Maripol,
Ukraine. There is a continuous exchange between the development, design and service departments, as this is
the only way for SMS to achieve the target of low-maintenance plants – to the
benefit of the customers.
“This means that every innovation is
checked for its contribution to cutting
maintenance costs, for instance,” explains Tesè. “It is important that our
staff continuously search for further
improvements of our products.” To be
mentioned here are the new procedures in coating technology which,
among others, increase the life cycle
of mold copper plates. “Our customers
have to face ever-growing competition
worldwide and therefore strive to lower costs and save resources,” adds
Friedhelm Bitter, the Commercial
Head of Business Unit Service at
i
SERVICE
X-Cellize® product groups at
SMS Siemag
Spare parts service
Inspection and repairs
High-performance components
Maintenance service
Modernizations
Condition monitoring and
maintenance management
Erection and commissioning
Training and consulting
Maintenance of complex parts belongs to the typical maintenance measures performed by the customer service of the SMS group.
11
Experienced specialists advise customers worldwide.
39 25
The service network extends across the
whole globe. 39 locations run by SMS Siemag
and 25 by SMS Meer permit fast deliveries
and service activities all over the world.
12
In seminars conducted by the TECademy, employees like
Dr. Hartmut Pawelski impart their expert knowledge.
SMS Meer. “And this is exactly
what our innovations are aiming at.”
The most recent example by SMS
Meer is the variable-speed pump control, VSP for short, which is used in
gap closing presses. Its special feature: The oil pressure is generated exclusively upon system demand, i.e.
when it is actually required. Hydraulic
systems with VSP do not need a cooling system or a central hydraulic station with large tank. Expenses for
housings or casings and hydraulic cellar plus long pipelines are omitted. All
hydraulic components are installed
directly at or on the machine in a
maintenance-friendly way.
At SMS Siemag as well, innovations
are not exclusively aimed at better
quality, but also at reduced costs for
the customers. The new Sieflex® HT
spindle for hot strip mills, for example,
is able to reliably transmit more than
50 percent higher drive torques and
hence needs less maintenance (also
refer to page 50).
CUSTOMER PARTNERSHIP
The companies of the SMS group
closely cooperate in all service activities. Hence, the customer will be presented the optimum solution from one
source. “We understand the relation to
our customers as a partnership. This
includes on the one hand the provision
of high-quality services and products,
at short notice and favorable prices. On
the other hand, we do not only stand by
our customers with our know-how and
our experience, but also with product
advancements and innovations,” Bitter
sums up the service solutions of SMS.
Knowledge, experience, local presence
– throughout the useful life of a plant.
More than just a toolbox.
www.sms-siemag.com/service
www.sms-meer.com/service
SERVICE
Interview
Customer
Partnership
Pino Tesè, Service SMS Siemag, and
Friedhelm Bitter, Service SMS Meer, on
individually tailored service solutions.
What does service-oriented mean to you?
Bitter Service-oriented means that all solutions must be
tailored to the needs of our customers. Particular flexibility
is required. Nowadays, service does not only mean to be
there for the customer, but to jointly develop individual
solutions.
Tesè The customer comes first. We do not only offer standard solutions from our product range, but respond directly
to the customer’s requests. If he wants a service that we
have not rendered so far, we will try to find approaches in a
common effort.
Service at SMS – what does it stand for?
Tesè Service at SMS implies continuity. We accompany our
customers throughout the useful life of their plants. This
ensures high product quality and productivity in the long
run.
Bitter We understand the relation to our customers as a
partnership. This includes on the one hand the provision of
high-quality services and products, at short notice and favorable prices. On the other hand, we do not only stand by
our customers with our know-how and our experience, but
also with product advancements and innovations.
What are the advantages for customers purchasing a
service from the SMS group?
Bitter We supply everything from one source. The service is
the hub where all threads converge – from the machine
via the technology to the service activities. On the basis of
such information we strive to find the best solution for our
customers.
What are the demands customers
have nowadays in terms of service?
Tesè They expect high quality, fast response times and all that close to their
site. Service must be available around
the clock. This is a demand of growing
importance, and our teleservice is one
of our answers. Via hotline we can be
contacted around the clock.
We assist our customers “throughout the useful life of their plants”
– what does it mean?
Bitter This means that we design a
machine, commission it in cooperation
with the customer, train his staff, provide him with spare parts, carry out
repairs and modernizations when the
machine is showing its age and give
advice for process optimization. A crucial factor is the advancement of core
equipment, our value-added components. The best example is the PQSC®
mandrels (also see page 52).
Tesè The keyword is process optimization. An essential factor in this connection is our advanced high-performance components which are also
suited to increase the efficiency of existing plants.
Pino Tesè
Member of the Management Technical
Service Division at
SMS Siemag.
What objectives do you have for the
future?
Tesè We will expand our global network to be even closer to our customers. Jointly we will develop new individual solutions and products to
strengthen their competitiveness with
the aid of our services.
Friedhelm Bitter
Commercial Head of
Business Unit Service at SMS Meer.
13
SERVICE
SERVICE WORLDWIDE
SMS Siemag and SMS Meer with their experts offer service in
OEM quality. Customers benefit from manifold advantages – worldwide.
Some examples from different countries reflect the range of
services and the competent service support.
China
Exchange of blocks
Where heavy plates are processed, systems
like the profile, contour, and flatness control
(PCFC) operate with extreme accuracy. Even
for more than five-meter-wide hot-rolled
plates, the purchasers demand tolerances in
the micrometer range. Here, the CVC® shifting system plays a key role. Reason enough
for Anshan Steel to decide in favor of original spare parts from SMS Siemag. In its
new heavy-plate rolling mill in Bayquan, the
customer replaced the existing blocks which
will be overhauled in the service workshop in
Zhangjiagang.
China
For Dongbei Special Steel, China, SMS Meer
Service has given three peeling machines built
in 1988 a general overhaul, dismantled them
in the Dalian plant in the Lianoning Province,
and reinstalled them in the new plant outside
the city center. The machines now achieve an
improved surface quality and closer diameter
tolerances. Falk Rößler, Project Manager at
SMS Meer, stated: “Thanks to the modernization of the peeling machines Dongbei Special
Steel will be able to meet the increased requirements of its customers in the future.”
14
Photo Frauke Schumann / plainpicture
Dismantled and generally overhauled
SERVICE
Brazil
South Africa
Repair quartet
Modern-age service
In the first half of 2013 alone, SMS Siemag
carried through four major repair projects.
During the past months, the service experts
repaired three payoff reels, two in hot-dip galvanizing lines at CSN Para and one in a pickling line at ArcelorMittal Vega. In the Ipatinga works of Usiminas they coated the mold
copper plates of a slab caster and relied on
UniGuard® (also see USA).
The experts of the SMS Meer modernization
service improve plants and equipment to enhance productivity and product quality – also
at the site of ArcelorMittal South Africa where
they installed, adjusted and connected an
SMS Meer speed increaser. Allan Collard, Senior Planner at ArcelorMittal South Africa,
was very satisfied: “All persons involved in the
cooperation with the SMS specialists have immensely benefited from this exchange.”
Turkey
Netherlands
Germany
Classic total repair
Maintenance for higher productivity
Prepared for an emergency
The personnel of the service workshop SMS
Siemag Turkiye repaired the copper plates
and water jackets of Hadeed’s slab caster.
These activities included removal of water
jackets from the copper molds, checking
them for cracks and damage, machining badly eroded spots with the aid of CNC machines
and coating the plate surfaces with nickel.
This treatment will significantly increase the
service life and prevent failure due to wear.
“SMS Meer is a reliable service partner.
Thanks to the good cooperation we managed
to measurably improve the efficiency of our
three extrusion presses,” says Rob van der
Meij, Technical Director at Nedal Aluminium,
Netherlands. The company counts on the
customized maintenance solutions by SMS
Meer which are individually tailored to the
needs of the respective customer no matter
whether it is a one-off maintenance activity or
a permanent cooperation.
Every hour is decisive in a case of emergency,
but for SMS Meer speed must not necessarily
be detrimental to quality. In the plant of GSA
Schneider in Aalen, Germany, the damage at
the countershaft of a forging machine type
SM 1600 was remedied. Thanks to preventive maintenance consulting, the customer
had many of the required parts in stock. SMS
Meer could finish disassembly, supply of further parts and assembly of new components
within a period of a mere six weeks.
India
U.S.A
Russia
From chromium to nickel
Less wear
Continuous equipment checks
Nickel ensures gradual cooling, also for the
beam blank mold of Jindal Steel and Power
in Raigarh. A team of experts from the Bhubaneswar workshop protected the copper plates
against high wear by subsequently coating the
initial chromium faces of the copper plates with
nickel. The layer thickness need not exceed 0.5
to 1.0 mm. Other service specialists were engaged in activities at a more than 20-year-old
coil box at Tata Steel Ltd. in Jamshedpur. The
lasting heavy loads had detached the anchoring
which was replaced by a team of SMS and Tata
staff within one week only.
For the purpose of improving product quality,
ArcelorMittal Dofasco, U.S.A, entrusted SMS
Millcraft with the modernization of two continuous casters manufactured by other suppliers in the years 1987 and 1996. The copper
plates were provided with the ceramic-metallic mold coating UniGuard®. “Since that time,
we did not only observe less mold wear, but
also noticed an essentially reduced number of
inadequately filled corners,” says Dan Riddle,
responsible for the facilities in ArcelorMittal
Dofasco’s Works No. 1.
High availability and efficiency of plants are
the basic requirements for competitiveness.
To discover potential defects as early as possible, SMS Meer developed machine-specific
equipment checks. One of the companies relying on this procedure is Uralskaja Kuznitza
OAO in Tchebarkul, Russia. At regular intervals, the machine technology is individually
analyzed with regard to its condition and critical points. SMS Meer describes improvement
potentials, prepares detailed service reports
and, in the case of need, recommends spare
parts or modernization measures.
15
SERVICE
24/7
The service team of SMS Meer is available for
SULB 24 hours a day, seven days a week.
Top: Quick
reaction of the
service team
ensures minimal outages.
Bottom:
Availability
of spare and
wear parts is
ensured by
three-shift
operation.
16
SERVICE
ALL-ROUND
CAREFREE PACKAGE
The new service company of SMS Meer in Bahrain takes over spare
parts management for the new plant of United Steel Company.
T
he newly established service company of SMS
Meer in Bahrain has started operations. The personnel headed by Siegfried Gruber look after the
complete spare parts management of the new
section mill of United Steel Company (SULB) in the Kingdom of Bahrain. From the outset, SULB has opted for this
type of warehousing.
Advantage for the customer: no own warehouse, no administrative costs, no payroll costs – and yet everything you
need right on hand. SMS Meer is responsible for spare
parts availability of all companies involved. This means:
warehouse and inventory management of initial reserve of
SMS Meer and SMS Concast for all parts supplied as well
as warehouse and inventory management for spare parts of
partner companies. This ensures high quality of spare parts
supply and minimizes the costs for storage.
operation of the warehouse. Gruber
and his team are available on a 24/7
basis.
The entire warehouse concept was
originated in close coordination with
SULB. The customer has access to the
whole storage system at any time
and thus has complete cost transparency. The stock is retrievable online
around the clock. SULB is just one
of several examples in which the
SMS group has assumed warehouse
management.
i
Project SULB
For United Steel
(SULB), Kingdom of
Bahrain, SMS Concast and SMS Meer
have supplied a turnkey minimill plant for
beams and sections.
The integrated steel
www.sms-meer.com/service
plant includes among
other things an electric arc furnace and
UNWANTED DOWNTIMES ARE HISTORY
a heavy-section mill.
This forward-looking development and implementation of
an advanced spare parts supply concept reduces the servicing times and prevents unwanted downtimes. All previously specified articles and parts are available in tested
OEM quality (Original Equipment Manufacturer). The availability of spare and wear parts is ensured by three-shift
The project concluded
at the end of 2012
was carried out together with Samsung
Engineering.
17
SMS workshop and service experts working hand in hand.
MORE RELIABILITY
FOR REPAIRS
To improve all relevant processes involved in service repairs,
SMS Siemag established a separate assembly area in Germany.
I
n its German workshop, SMS Siemag
had carried out repair work parallel
to the assembly of new equipment
until quite recently. The opening of
a special repair center in 2013 paves
the way for a best possible repair service. Frank Benfer, Head Spare Parts
Department Technical Service, says:
“We are in a much better position now
to tackle the challenging repair work
immediately and to its full extent.”
FIXED CONTACT PERSONS
A team of skilled and experienced service experts and technicians represents the core competence of the
18
workshop. Fixed contact persons support the customers. Repair coordinators continuously check the state of
projects and orders which are readily
available. Since these specialists have
exact knowledge of the customer
wishes they are able to flexibly respond
to special requirements or processes.
The project manager prepares a repair
history for the core components giving
quick information on the reconditioning work already performed. SMS Siemag repairs the complete range of
core components.
The experts are in close contact with
the development and design depart-
ments. SMS considers new approaches in their planning phase and offers
its customers innovative solutions. Viola Frenyo, Member of the Management
Technical Service Division, comments:
“With us the customers will be able to
maintain their plants on a sophisticated technical level. Our repair team can
draw on the high degree of expertise
available throughout the whole group.
Technical innovations will be integrated if so requested by the customer.”
These items are not considered by other companies. SMS offers more than
just a one-to-one repair, which is particularly important nowadays since
New at SMS Siemag in Gurgaon, India:
a Service Entry Point for automation.
i
SERVICE
Kick-off in
India
Quality in
China
Further Service Entry
Point in New Delhi.
SMS Siemag workshop
in Tianjin receives the
ISO 9001 certificate.
Core components
Coiler mandrels
Trimmers
Hydraulic adjustment cylinders
Pinch rolls
CVC® bending and shifting blocks
Roll chocks
Gear units
Morgoil® bearings
many companies are continuously
reducing their maintenance staff.
Very often, this is combined with a
loss in professional competence.
Tailor-made frame contracts offer
the customers further advantages:
Stock-keeping of critical spare parts
prevents long times of delivery and
allows precise deadlines to be set.
These special parts are readily available in the repair center. Thus, SMS
can quickly carry out even unplanned
repair work.
Frank Benfer
frank.benfer@sms-siemag.com
Excellence rewarded: The Tianjin workshop
in China.
After one year of intensive construction activities at the New Delhi site
in Gurgaon, SMS Siemag has opened
2013 a further Service Entry Point
for automation systems. Here, local
service engineers are available to
respond to queries from customers
based in India. They will place special emphasis on aspects of safety,
maintenance and development of
electrical equipment.
Via a remote access communication interface provided for in the
network, all SMS service experts
have instant and secure access to
the respective automation systems.
Thus, support can be provided on a
24/7 basis. This saves the operator
time, especially in an emergency
situation. The experts solve problems by combining worldwide teleservice and individual on-site support to best suit the requirements of
the customer.
automation-hotline@in.sms-siemag.com
TÜV NORD (German Technical Inspectorate) has now awarded the
ISO 9001 certificate to the SMS Siemag location Tianjin in China. Prior
to this, the Service team had defined and documented the processes locally and introduced a quality
management system (QM). Already
by then, the processes had been improving continuously. With the QM
encompassing all employees, errors are avoided and corrective
measures can be taken rapidly. The
certificate represents intensive
quality management (QM) and
transparent processes. This provides a crucial advantage and enhances the sales opportunities for
the products.
Zhou Tianling
zhou.tianling@sms-siemag.com
19
More than a dozen employees of SMS Siemag participated in the first Service Sales Seminar.
QUALITY UNITES
SERVICE SALES SEMINAR
QUALITY UNITES – WORLDWIDE
Management Technical Division Service of SMS Siemag (from left):
Doug Dunworth, Pino Tesè and Viola Frenyo.
20
This is the maxim of the SMS Siemag Technical Service
Division which is continuously extending its presence in
important markets such as China and India. The customers benefit, for example, from new manufacturing
and service workshops that will ensure the accustomed
SMS quality. The high quality level is furthermore reflected by the skilled personnel undergoing regular professional training by SMS Siemag. Each year international Service Sales Seminar are held in Hilchenbach,
Germany.
“Our goal is to familiarize the staff with the products
of SMS Siemag, especially in the field of service, and
with the Hilchenbach location. Furthermore, we want
the colleagues to exchange their ideas and experience
across national borders and to enhance their network,”
says Pino Tesè, Member of the Management Service.
During the one-week seminar, the participants had
enough time and opportunities for sharing their knowledge as the seminar was attended by experts from Italy,
India, China, Brazil, Russia, and South Africa, in addition
to the Hilchenbach service specialists. “It is a good thing
“I will communicate this quality-oriented
awareness experienced during the seminar
to our Indian customers,” states Ganesh
Bayari, Deputy General Manager Technical
Service in India.
“It is a good thing to become acquainted with the colleagues from other SMS locations and
to learn about the challenges in their countries,” says Ni Jianren (left), Department Manager
Service Sales, SMS Siemag location in Zhangjiagang, China.
to become acquainted with the colleagues from other SMS locations
and to learn about the challenges in
their countries,” says Ni Jianren,
Department Manager Service Sales,
SMS Siemag location Zhangjiagang,
China, during the seminar.
In the course of the event, a number of internal and external instructors provided knowledge on such
topics as “Coating/Plating” or “Condition Monitoring Systems”. The
German colleagues provided information on current service products
and new technical developments.
“We pass on the knowledge to our
employees,” supplements Tesè.
“This is the only way to gain the customers’ trust in reliability and quality
worldwide.” For that reason, advanced seminars will be held at regular intervals in the future to
strengthen the connection between
the German and the international
service locations. “This will be to the
benefit of our customers who will
not only be supplied with high-tech
products, but get competent advice
at their location, as to how they can
make their plants more efficient,”
says Tesè. Ganesh Bayari, Deputy
General Manager Technical Service
in India, underlines this statement:
“I will communicate this quality-oriented awareness experienced during
the seminar to our Indian customers.”
in the operation of a plant. The company offers a comprehensive product
portfolio and a vast process knowhow ensuring the customers’ longterm success. In addition, a worldwide service network convinces with
local experts and a high quality level
thanks to more than 100 years of experience.
The range of services includes the
supply of spare parts, maintenance
services, on-site erection, training
courses, and modernizations, in addition to the Genius CM (Condition Monitoring) and IMMS® (Integrated Maintenance Management System).
THE MISSION STATEMENT OF THE
SERVICE EXPERTS IS:
“We are X-Cellize – the original service by SMS Siemag.” The SMS Siemag Service is the competent partner to meet all challenges involved
21
SERVICE
i
Service range
Paul Wurth offers
services for a wide
spectrum of areas,
which includes raw
material handling,
cokemaking plants,
sinter plants,
charging systems,
hot blast stoves, pulverized coal injection
(PCI) plants, blast
furnace plants, blast
furnace charging
systems, slag granulation as well as all
ancillary facilities,
for example for water treatment or gas
cleaning.
Top: At Paul
Wurth, customers are
partners.
Bottom:
Experienced
experts inspect the plant
components,
here a sealing
flap.
22
SERVICE
Service for
everything to
do with the
blast furnace
Plant building company
Paul Wurth assists customers throughout the
life of their plants.
U
p to 80 meters high, more
than 2.5 million tons of hot
metal per year and a hazardous CO-containing atmosphere – in the more than 220
plants supplied by Paul Wurth worldwide, working conditions are definitely
not easy.
For more than 60 years, Paul Wurth
has been building complete blast furnace plants all over the world, playing
a decisive role in the development and
implementation of both newly built
plants and modernization projects.
Within the framework of a wide range
of services, Paul Wurth has accompanied its customers as a life cycle partner during the entire blast furnace
campaign.
For Paul Wurth, service means assisting the customer in tackling technical challenges as a partner by providing solutions and support. The task
is to understand and cope with unforeseeable situations, unexpected challenges and customer-specific requirements in cooperation with the
customer. This can be done by timely
delivery of spare parts, repair of critical equipment on site or in Paul
Wurth’s workshops, by refurbishing
and modernizing plant and equipment
or providing services such as staff
training, support during standstills,
feasibility studies, process advice or
maintenance services.
Within the area of spare parts services, Paul Wurth offers warehouse
management concepts, spare part
supplies as well as spare part optimization strategies. With its assistance,
Paul Wurth helps plant operators to
reduce warehousing costs and optimize the spare part management system. In addition to assisting in reconditioning complete gearboxes, the
service team can also assist the customer during on-site rebuilds and repairs, for example when exchanging
the chute at the blast furnace top,
which often may turn out to be rather
complicated as the chute must be
mounted and dismounted through the
gear. The modernization of existing
equipment may range from retrofitting
a greasing system to the planetary
gearbox through to replacing a gearbox with latest-generation equipment.
TAILOR-MADE SERVICE
Condition monitoring systems developed by blast furnace specialist Paul
Wurth help the operator to have a
clear view of the condition of the plant
and equipment and develop preventive
maintenance concepts, which have the
purpose not only of keeping the equipment running but also of analyzing and
deriving knowledge from the collected
data. “Our focus is always on the customer. We appreciate our customers’
views and expertise and closely cooperate with them in implementing their
ideas and suggestions for improvement,” comments Jochen Burg,
Vice-President Corporate Service Paul
Wurth.
Paul Wurth is not merely a supplier
of equipment and components but
contributes solid process understanding and plant operation know-how.
This wealth of expertise has been accumulated since the beginnings of the
steel industry and as a result of longstanding customer dialogs. The permanent dialog with and experience
from a broad customer base form the
solid foundations for new challenges.
Being an OEM, Paul Wurth is in a position to deliver perfectly fitting parts
and solutions on time and to the satisfaction of its customers. All core components and plants are supplied from
a single source.
All Paul Wurth’s worldwide staff go
through many years of instruction and
training. The quality of the plants and
machines is checked by functional
tests on test rigs.
CUSTOMER INTIMACY
More than 120 employees in 22 countries provide local and direct support
to customers. The service teams can
rely on a group-wide expert and knowledge network. With development, engineering, manufacture and commissioning competence all under one
roof, the Paul Wurth experts can respond quickly and individually to customer requests. Thanks to this global
set-up, Paul Wurth is ready to help
customers in emergency situations.
For example, if a replacement gearbox
is urgently needed, Paul Wurth can
check the availability of appropriate alternatives and propose solutions.
Paul Wurth operates service workshops in Europe, the U.S.A., Brazil,
China and, in future, also in India, ensuring the quality of products, repairs
and refurbishments.
www.paulwurth.com
23
SERVICE
INSPECTIONS
REPAIRS
MODERNIZATION
24
25
Finish-machining of a bearing bush 74”-76 KLX for use in a heavyplate mill stand.
SMS Siemag experts support customers on-site and off-site.
POOLED REPAIR KNOWLEDGE AT SMS SIEMAG
Professional maintenance support from A to Z.
No two are ever alike. Repairs are more
than the Wikipedia definition: Restoration of the original condition of a defective object. Depending on the state
of wear, a component may be nearly
intact in the one case, but can no longer be saved in the other. The mandrel
body of coiler A may still be in good order whereas that of coiler B must be
considered no longer operational.
REPAIR OF CORE COMPONENTS
The Service Division of SMS Siemag
has attended to this complex issue and
just recently bundled its activities and
provided sufficient space for performing repairs. On a surface of approx.
3,000 square meters, a dedicated repair area was established. The core
26
competence is represented by a team
of skilled and experienced staff members from the assembly and the repair
departments.
“This new repair center enables us
to do repairs in a more customer-oriented and flexible way in a faster time
frame,” says Lars Scheuermann, responsible for the new repair team. “On
the basis of the customer’s inquiry we
analyze as to whether a repair directly
at their plant (on-site) or in our workshop (off-site) is the best choice.” In
the case of an on-site repair, the technical service experts take care of the
entire repair transaction at the customer’s location.
Further tasks of the technical customer support include plant inspec-
tions and trouble-shooting. Inspections are a prerequisite for the perfect
operation of a facility. In terms of software, the service staff are supported
by the Integrated Maintenance Management System (IMMS) and the Genius CM for plant monitoring.
In the case of an off-site repair, the
component to be overhauled is transported to the workshop after it has
been removed from the plant. Removal
and installation is done by the SMS
Siemag service specialists.
In the new repair center, a service
team will perform the disassembly work
in due time. Subsequently, the technicians will determine and document the
wear condition of the components to be
repaired in a detailed damage analysis.
SERVICE
All customer inquiries on
copper plates end up at the
Technical Service.
Various experts in charge of design,
quality control, assembly and service
are involved in each single repair project. This cross-divisional repair team
analyzes the wear condition and decides on the repair measures to be
initiated. The result thereof will be
submitted to the customer in the form
of a detailed offer. SMS Siemag furthermore supports plant owners in
reducing the components’ wear and
thus extended the usefull life of the
parts.
RELIABLE REPAIR
OF MORGOIL® BEARINGS
35,000 Morgoil® roll-neck bearings
supplied by SMS Siemag speak for
themselves in terms of reliability and
customer satisfaction. “Apart from
spare parts sourcing, we offer the customer further services such as technical assistance and on-site support,”
says Frank Benfer, General Manager
Morgoil® Bearings. “If so desired, we
will technically improve the products
in the course of repairs which helps
keep the customer’s plants competitive.” The services rendered by the
Morgoil® Bearing department cover,
apart from the supply of complete
bearing sets for hot and cold rolling
mills in the steel and NF-metal industry, the following activities:
Off-site repair of bearing bushes,
neck bushes and chocks
Assistance in bearing inspections
Supervision of modernization
measures to adapt existing
bearings to the latest state-of-theart site
On-site services, including training
programs for the operating staff
COPPER PLATE SERVICE
AROUND THE WORLD
Parallel to the incorporation of the former CSP® Copper Plates department,
all customer inquiries worldwide concerning copper plates for conventional
and CSP® casters are now centrally
managed and processed by the Technical Service Division. Jointly with SMS
Millcraft, U.S.A., it offers individual
solutions to the customers. This is especially true for know-how relevant
decisions concerning material and
coating.
Hence, SMS Siemag satisfies the
technical requirements for offering
galvanic NiCo/Ni coating and also
ceramic copper-plate coating (Uni
Guard®) all over the world.
ON-SITE AND OFF-SITE REPAIRS
WORLDWIDE
To offer customers the best possible
service close to their facilities, 39
global service locations are all set up
to provide assistance with either onsite or off-site repairs. New approaches, for example standard repairs or
repair framework contracts.
35.000
Morgoil® roll-neck bearings supplied by
SMS Siemag speak for themselves in terms
of reliability and customer satisfaction.
frank.benfer@sms-siemag.com
27
SERVICE
Top: Hot repairs in the
combustion chamber save time
and money.
Bottom: By isolating the area
to be repaired, large plants can
continue operating.
28
SERVICE
SAVE TIME AND MONEY
Hot repairs in hot blast stoves cut downtimes of blast
furnaces and related costs. Prior to any hot repair, the service team
of Paul Wurth prepares for each individual situation.
H
ot blast stoves in blast furnace plants achieve very
long service lives. Throughout their lives, they are continuously in operation, virtually without
any maintenance. However, towards
the end of the service life, it may happen that the brickwork of the lining
has suffered damage due to wear and/
or there may be some problems with
the ceramic burners. In order to prolong the lifetime for several more
years, repairs may become necessary.
Repairs can be carried out under hot
or cold conditions.
For repairs under cold conditions,
the hot blast stoves must be stopped for
a rather long period because, before the
repairs, they have to cool down and afterwards heated up again. Consequently, minor repairs are disproportionately
expensive and time-consuming. When
the refractory lining in the lower part of
the combustion chamber, at the hot
blast outlet or at the ceramic burner is
to be repaired in the hot state, a heat
shield is installed via the hot blast connecting pipe. This helps to significantly
reduce the time the blast furnace must
be kept out of operation and the costs
associated with such outage.
An endoscopic inspection provides
information as to the extent of the damage and whether a hot repair is possible
or not.
Before starting the hot repair, the hot
blast stoves are isolated from the rest
of the plant and all other openings
which are not required for the repair
are mechanically or electrically locked.
In general, a blast furnace stop of a
single day is sufficient. Depending on
the extent of the repair and the design
concept of the hot blast stove, the heat
shield may be installed via the hot
blast outlet or the opening of the metallic burner. The heat shield separates the repair area from the remaining part of the combustion chamber,
which may remain hot.
READY TO START WORKING IN JUST A
FEW DAYS
The collapsible heat shield is moved
into the combustion chamber and unfolded from outside of the stove using
cooled support beams. As soon as the
heat shield is in the correct position,
cooling fans lower the temperature in
the working area. Due to the small volume of refractory lining in the area to
be repaired, it takes just a few days to
cool the working area down to an appropriate temperature and start with
the repair work.
Depending on the duration of the
repair, it may be necessary to run
some heating cycles in order to prevent the refractory materials from
cooling down below the admissible
temperature range. During these
heating cycles, the refractory repair is
temporarily interrupted and burners
are mounted to the heat shield. This
procedure is used to prolong the
repair time, for example for major
repairs such as the replacement of
complete ceramic burners. After
completion of the repair work, one last
furnace stop is required to facilitate
reconnection of the hot blast stove to
the plant network.
The most critical issues during hot
repairs are health and safety. It is crucial that the workers have a good deal
of experience in hot repairs and receive dedicated training. Specialized
training programs prepare the technicians for the specific project, since
each hot repair is unique. For example, they train on a full-scale model of
the combustion chamber as to how to
install and remove the heat shield. The
experienced specialists from Paul
Wurth devise specific safety concepts
together with the plant operator and
the contractor.
www.paulwurth.com
29
SERVICE
Even at a pump pressure of 680 bars the wedged vessel did not move.
Removing a 4,500 mm-wide trunnion ring segment was inevitable.
30
SERVICE
CHALLENGING
CONVERTER REPAIR
An impending converter failure in the works of Tata Steel Europe in
Port Talbot, Great Britain, required fast and comprehensive repair activities.
T
he service staff of SMS Siemag successfully repaired a
converter in the Port Talbot
works of Tata Steel Europe. In
January this year, Tata started operating the converter again after works engineer Stephen Dawson had first contacted the technical service of SMS
Siemag because of bearing problems
on the suspension in March 2012.
Due to the imminent commissioning of the new blast furnace, the supply of a completely new system was
out of the question to Tata. The company considered several methods of
avoiding that step, either by correcting
the distortion of the bearing through
mechanical machining, by using bearings with greater tolerances, or by
turning the ring.
HARD BUT RIGHT DECISION
The management of Tata asked SMS
Siemag for a local inspection, which
was carried out in May 2012. “Although
in the beginning we found it difficult to
accept this proposal, since the bearing
supplier had been on site several times,
it turned out to be the right decision.”
The records of the SMS experts illuminated the dimensions: “The
long-lasting use of the converter has
left clear marks. High temperatures
were transferred from the vessel to the
trunnion ring and its suspension. There
is a high risk of a vessel crash.” “The
report of our experts showed that Tata
would have to adjust and newly fasten
the trunnion ring without delay. We responded immediately,” explains Dr.
Thomas Germershausen, Member of
the Management Metallurgical Plants
Division.
Tata decided in favor of the lamella
suspension system usual in converter
systems today. Due to the fact that
SMS had immediate access to raw
material it was possible to design, engineer, manufacture, and supply the
new suspension within a mere ten
weeks. In the course of the disassembly work it became clear that the vessel, too, had strong deformations.
Trunnion ring and vessel were in contact, partly over a width of 1.5 meters.
Even a pump pressure of 680 bars
could not move the wedged vessel.
SMS recommended adapting the segments. The experts discovered damage at the fillet welds of the bulkhead
plates and a long crack in an important web plate. Some wall thicknesses
were severely washed out.
Shift teams consisting of welders
from Rowecors and an SMS welding
specialist provided the comprehensive
repair work. In November, after approval by SMS, Tata continued correct-
ing the neck position and placing the
lamella suspensions. Deformations
made the installation of the lamellas
very complicated. After all measures
had been completed and all welds
checked, Tata heated the vessel in
January this year, and the converter
resumed operation.
PLEASED ABOUT THE SUPPORT
“The last few weeks and months have
cost us lots of energy. We are so glad
to have been supported by SMS Siemag in this emergency situation which
demanded a good deal of organization,
power of endurance and patience, but
finally it is done. The converter is ready
to go on stream again. Jointly we have
gained valuable experience that will be
implemented when repairing the second converter,” tells Dawson.
Christoph Häusler, General Manager Technical Customer Support at SMS
Siemag: “A converter repair is always a
challenging and exciting experience.
Many of our customers are facing similar problems. We recommend reacting
at an early stage and are gladly prepared to provide advice.”
31
SERVICE
in brief
Ruukki Metals Oy, Finland
DUMA-BANDZINK GmbH
On schedule
In summer 2012, DUMA-BANDZINK
GmbH modernized the air knife sets of
galvanizing line VZA 1 at ArcelorMittal’s
works in Eisenhüttenstadt, Germany.
The first step taken by DUMA-BANDZINK was to renew the electrical plugs
including cables and cable ducts at air
New mandrels for
continuous pickling line
The continuous pickling line at Ruukki Metals Oy in Hämeenlinna, Finland, was
equipped with new mandrels to coil high-strength steel strips. Due to many failures
of the existing roll wrappers at the exit side of the pickling line, Ruukki decided to
replace them by new slotted mandrels. The project was executed in cooperation
with DUMA-BANDZINK GmbH in two steps.
The first part of the task, covering the area of coiler No. 2, was implemented in
December 2011. The replacement was performed while the line was running. The
implementation of the second part, in coiler No.1 area, was carried out during the
summer overhaul in July 2012. Both steps included new mandrels for the existing
coilers as well as auxiliary equipment for threading the strip head and tail ends in
and out. New hydraulic valve stands for both mandrels were also part of the project
and were supplied by DUMA-BANDZINK. “It’s always challenging to add new
equipment to an existing old line, but due to the careful preliminary planning and
good cooperation with DUMA-BANDZINK everything went well and the line was
back in production right on time,” says Mika Inkanen, Project Manager at Ruukki
Metals Oy. After this modernization, Ruukki is able to coil higher-strength strips
with up to 800 megapascals (yield strength) and a thickness of up to 6.5 millimeters.
knife sets Nos. 1 and 2, the second one
to modernize the mechanical angle adjustment at air knife set No. 2. The purpose of these measures was to increase
the availability of the plant and furthermore to simplify air-knife changing operations.
Three weeks before the scheduled plant
downtime in July 2012, air knife set No.
2 arrived at the location of DUMA-BANDZINK. The contracted mechanical and electrical services for the
conversion were rendered within that
period so that air knife set No. 2 could
be returned to ArcelorMittal in due time
for the plant shutdown and then be installed. Thus it was possible to meet the
scheduled date for production restart
on July 23, 2012.
32
Segal SA
Air knives for
higher productivity
Segal SA, domiciled in Ivoz-Ramet, Belgium, awarded DUMA-BANDZINK GmbH
the order to supply four new air knives including all ancillary equipment such as
spare knife lips, air generating system, assembly stand and deposition racks. The
new air knives will be integrated into the existing production line for GI and GA steel
grades in the company’s works in Ivoz-Ramet. The intention underlying Segal’s
decision to use air knives is to increase productivity and quality and at the same
time to reduce the consumption of power and nitrogen
SERVICE
WTB Wuxi, China
Screw press modernized in only
seven months
It took SMS Meer merely seven months to upgrade a screw
press SPKA 11200 for Wuxi Turbine Blade (WTB) in Wuxi, Jiangsu Province, China. After assembly at the new location
SMS Meer replaced the screw and the tierods to make sure
that the press can now resume production reliably and safely.
of the HSPRZ 630 type. Wuxi Turbine Blade is part of the
Shanghai Electric Group producing high-end turbine blades
for global customers of the power industry.
“After the modernization the press is now again state of the
art,” says MoJianqiang, Deputy Director and Chief Engineer
Forging Equipment at WTB. “Whenever we order something
from SMS we can be sure to receive the required quality on
the agreed date.”
In 1994, Wuxi put the clutch-operated forging press with a
hard-on-hard blow force into operation. Production has had
to be relocated since a new residential area is being established at the company’s location. Together with the SPKA
11200 SMS Meer has also relocated a hydraulic screw press
PetroSA, South Africa
DUMA-BANDZINK GmbH
Arc furnace
rapidly repaired
Record breaking
Good cooperation: Thanks to the close cooperation between
the maintenance staff of PetroSA, South Africa, and a service
team of SMS Siemag South Africa, the clamping devices of
the arc furnace at Unit 10 Catalyst Plant were refurbished
within just two weeks instead of four.
The arc furnace in the Mossel Bay works serves to fuse the
materials haematite, mill scale, and promoters to produce
the catalyst used in the synthol reactors. This work included
the movement of huge pieces of equipment to replace seals,
valves and pipes.
In December 2012, DUMA-BANDZINK GmbH was awarded
the order to supply two electrostatic oiling machines, i.e. one
of standard and the other of DOS design. This order represents
the 275th machine of this kind to be supplied by the company.
A success story. The first electrostatic oiling machine was
supplied to Thyssen in 1982. Oiling machines are used in strip
processing lines in the steel and aluminum industries. All
strip widths of common usage at present (600 to 2,400 millimeters) can be reliably oiled by the DUMA-BANDZINK machines which apply film weights of 0.5 to 20.0 mg/m2 for DOS
machines and of 0.5 to 3.0 g/m2 for the standard version.
On this occasion, the entire grease system of the arc furnace
was renewed and the existing grease system completely removed. The lube points of the new system were arranged at
ground level by the service experts of SMS Siemag, which
made them easier to reach.
Jean van Staden, Reliability Manager at PetroSA, congratulated both teams for getting this job done within record time.
“The teams have done a great job,” appreciated van Staden.
33
SERVICE
SPARE PARTS
AND
VALUE ADDED PARTS
34
35
The new gear manufacturing shop at SMS Siemag in Hilchenbach.
HIGHTECH – MADE BY SMS
SMS group invests worldwide in the modernization and expansion
of manufacturing capacities.
36
Manufacturing staff posing for a group photo in the new heavy-duty workshop.
The objective is to further increase customer satisfaction
through shorter lead times and higher productivity. To be
able to offer customers technologically and economically
outstanding plant and mechanical engineering concepts,
the SMS group has been pursuing a twin strategy. On the
one hand, constant investments have been made to expand
and modernize the German manufacturing locations in
Hilchenbach and Mönchengladbach. There, the very sophisticated and hence quality-critical core components of
the plants and machines are developed and manufactured.
On the other hand, the SMS group is further expanding its
presence in key markets, such as China and India, by building manufacturing and service facilities and hiring qualified
personnel. In this way, the group can guarantee that the
local supply and service shares, which are being increasingly demanded by the customers in those markets, will be
of the usual SMS quality. After opening an SMS Meer workshop in Shanghai in 2010, SMS Siemag inaugurated a newly erected workshop in the Chinese city of Zhangjiagang in
2012.
37
SERVICE
»PERMANENT PRODUCT IMPROVEMENT IN AN INTERPLAY BETWEEN PRODUCTION AND PLANT ERECTION IS COMMON EVERYDAY PRACTICE. IT IS THE
FOUNDATION OF THE ADDED VALUE FOR OUR CUSTOMERS«
Jens Overberg, Production Manager at SMS Siemag
HIGHLY QUALIFIED PERSONNEL
Jens Overberg
Production Manager
at SMS Siemag
10.000
Along with these projects, well over
1,000 employees have received training.
Additionally, SMS Siemag invested in a
new training workshop in Hilchenbach.
Groundbreaking for the modernization of the production facilities at SMS
Siemag in Hilchenbach took place in
2008. “With these measures, we have
given once more a boost to the competitiveness of our manufacturing processes at that location,” says Jens
Overberg.
SMS Siemag invested in the construction of new buildings and workshops covering a floor area of over
10,000 square meters. Facilities for
welding and tube production, a painting shop, a warehouse and manufacturing shops for gears and hydraulic
equipment were newly established.
Moreover, various new machine tools
were purchased. Building of the last
hall will be completed in 2013: a modern dispatch and surface finishing
center. “Through the new dispatch area, the space available for workshop
assembly activities has been significantly expanded,” explains Production
Manager Overberg.
However, in plant engineering it is
not sufficient to just purchase new
machinery and build modern workshops. At least not if you design and
build high-tech equipment, as the
companies of the SMS group do. SMS
analyzed its production processes and
implemented major changes in certain
areas. Both SMS Siemag and SMS
Meer established new manufacturing
cells, which have markedly cut the
manufacturing cycles for certain components.
The new horizontal turning and milling center from Weingärtner, which is
used in Hilchenbach for machining
SMS Siemag invested in the construction of
new buildings and workshops covering a
floor area of over 10,000 square meters.
The new SMS Siemag painting shop in Hilchenbach.
38
A modern turning and milling center shortens machining cycles.
coiler parts, is only one of many examples of cellular manufacturing that creates obvious added value for the customer. This machine combines the
formerly separate processes of turning,
milling and gear cutting in one unit.
Machining of a coiler mandrel can now
be accomplished in fewer process
steps. As a result, the cycle time has
been reduced by more than 40 percent.
The process stability is a 100 percent to the benefit of our customers. The
unit is located in the machining shop,
which can now handle work pieces of
up to 130 tons weight. The insights and
strategies of Hilchenbach are transfered to all workshops of SMS Siemag
in the world.
Also SMS Meer invested in a comparable and even newer machine from
Weingärtner. Since 2012, a five-axes
machining unit for combined turning
and milling has been in operation in
Mönchengladbach. It is no longer necessary to switch between two machines. This saves time and money.
“On top of that, the maintenance effort
is reduced by 20 percent,” adds
Heinz-Joachim Gietmann, Manager
Production at SMS Meer.
The hydraulics test field assures the quality of the controls.
The new manufacturing cells in
Hilchenbach and Mönchengladbach
improve the synchronization of processes. Long transport and waiting
times are prevented. At the same time,
the parts to be processed are controlled according to the pull principle,
i.e. only those parts needed for the
next downstream process step are
made available and machined.
At Hilchenbach, SMS Siemag also
renewed the manufacturing facilities
for hydraulic equipment. Whereas the
facilities used to be distributed over
several bays, they are now concentrat-
Manufacturing ﬂow in the hydraulic equipment shop at SMS Siemag.
39
The new workshop in Mönchengladbach.
Heinz-Joachim
Gietmann
Production Manager
at SMS Meer
40
ed in one workshop. Here the work
flow is now characterized by a streamlined process flow from the input material through to product shipment and
by the concentration of all assembly
and testing activities in one workshop.
“This is modern production, as we
know it from the automotive industry,”
comments Weis.
For enhanced quality assurance,
SMS Siemag built a new test field for
testing and presetting hydraulic controls. “This markedly cuts the commissioning phase at the customer’s site,”
adds Weis. “Here, we also make and
test parts for SMS Meer.” This is an example of how closely the two Business
Areas work together. “We maintain
regular dialog and carry out joint projects,” says production expert Gietmann from SMS Meer.
A great value added provided by
these two German manufacturing locations is the close link between development, design and manufacture.
This creates synergies that many
competitors lack. “Our plant designers
or developers can simply go “next
door” to talk to their colleagues in the
manufacturing shop to discuss whether a new idea would be practicable at
all,” explains Weis. This guarantees
that the customers receive plants that
are innovative and mature at the same
time. While SMS Siemag will have
completed its modernization activities in Hilchenbach by
the end of the year, in Mönchengladbach there will be more
major expansion activities to come. The new heavy-duty
workshop 1A, with a floor area of 4,000 square meters, was
already inaugurated in 2012.
“With the new workshop and the new machines, we are
responding to the growing requirements of our customers
who, for example, want to produce ever larger parts on our
plants,” says Gietmann.
But the workshop is only a part of the investment. “We
will be replacing about 75 percent of our machine pool.
With the new machines, we will be able to manufacture also
complex parts of up to 200 tons in weight more economically in the future,” adds Gietmann. “And we also make key
components for our spare parts service.” This project will
be completed in 2015.
However, SMS Meer and SMS Siemag invest money not
only in machinery but above all in the training and further
education of qualified personnel. At SMS Meer, the complete manufacturing staff of some 300 received and are still
receiving training as part of the modernization activities in
the production facilities. This is almost 100 percent of the
production staff. In addition to technical subjects, “change
processes” are being thoroughly dealt with. “We involve all
employees in the implementation of the changes to come,”
explains Gietmann. In Hilchenbach, some 800 technicians
and engineers were trained this way. “Our employees are
crucial to the quality of our products,” agree Gietmann and
Weis. For example in 2010, SMS Siemag built a new training
workshop for apprentices in Hilchenbach. This is a guarantee for qualified junior staff, to the benefit of the customers.
Every year, about 80 young people start an apprenticeship
here in this workshop alone. At SMS Meer, the training department was completely repositioned. For example, a new
turning and milling center is being set up in the training
SERVICE
»WITH THE NEW WORKSHOP AND THE NEW MACHINES, WE ARE
RESPONDING TO THE GROWING REQUIREMENTS OF OUR CUSTOMERS
WHO, FOR EXAMPLE, WANT TO PRODUCE EVER LARGER PARTS ON OUR
PLANTS.«
Heinz-Joachim Gietmann, Production Manager at SMS Meer
workshop to familiarize the young trainees with the latest
machining technologies.
Nevertheless, SMS does not only rely on its domestic locations. The quality-critical core products – especially for
new equipment – are made in Mönchengladbach and
Hilchenbach. Standard parts, on the other hand, are manufactured in workshops outside Germany. For this purpose,
SMS Meer opened a new workshop in Shanghai in 2010 and
SMS Siemag in Zhangjiagang in 2012. “Through this, our
group can guarantee that the local supply and service
shares, which are being increasingly demanded by our customers, have the usual high quality standards of SMS,” says
Burkhard Dahmen, President and CEO of SMS Siemag.
The high SMS quality standards are guaranteed thanks
to the close connection of all manufacturing facilities
spread throughout the world. “We maintain regular dialog
with all locations and carry out joint training activities for
their staffs,” says Gietmann. “At the manufacturing facilities in Shanghai, German manufacturing specialists work
side by side with persons assigned from Germany to take
charge of the supplier management. For example, we lent
the workshop in Shanghai a foreman from the SMS Meer
workshop in Mönchengladbach for one year to support the
activities there.” Also the workshop manager assigned to
the SMS Siemag workshop in China for three years is a
foreman from Hilchenbach.
With their investments in worldwide manufacturing capacities, SMS Meer and SMS Siemag are further consolidating their position as a leading supplier of plant and machinery for the production and processing of steel and NF
metals, guaranteeing high-tech “Made by SMS”.
The SMS Meer workshop in Shanghai is to be further expanded.
In 2012, SMS Siemag opened a workshop in Zhangjiagang, China.
41
SERVICE
Fresh power
from the substitutes’ bench
Original spare parts offer
safety, long cycle times
and operational efficiency.
T
he targeted use of maintenance budgets reduces operating and maintenance expenses. SMS Siemag and
SMS Meer accompany their customers throughout the entire lifetime of all
production lines. “Being a system supplier we are able to provide all required
parts from one source,” says Viola
Frenyo, Member of the Management
Service Division at SMS Siemag. In addition to standard and catalog parts,
SMS supplies major spare parts such
as gear units and coiler mandrels.
Customers benefit from premium
quality and short delivery periods.
“The delivery time for electrical spares
may be less than four hours,” says Jan
Heimann, General Manager Spare
Parts at SMS Siemag.
INDIVIDUAL WAREHOUSE MANAGEMENT
Spare part:
special antifriction
bearings by
SMS Meer.
42
In coordination with the customer, SMS
experts prepare individual stock-keeping concepts. “If so desired by the customer, we will invest in the spare parts
inventories and operate the store. Such
solutions have been implemented for
several customers worldwide,” says
Heimann. In Bahrain, too, SMS
Meer took responsibility for the
spare parts management and
warehousing for the minimill of
United Steel Company. “This
concept of safeguarding
spare parts supply offers an
all-round carefree package.
The customer concentrates
on his core business and
SMS Meer takes care of the
rest,” explains Dr. Dirk Oedekoven, Head of Product Management Service. Frenyo points
out another advan-
tage of the SMS spare parts service:
“We closely cooperate with the design
and development departments. Advancements directly benefit our customers.” To give an example: the new
flat-neck spindle with oil-air lubrication
system to extend the spindle life.
It has been operating successfully at
Ilsenburger Grobblech GmbH for some
time. “Our advancements and adaptations of spares to suit new market requirements undergo stringent quality
controls,” says Frank Jansen, Head of
Spare Parts Service at SMS Meer.
A further point is the overaging of
spare parts. SMS Siemag and SMS
Meer both supervise the availability of
units and systems on the market on
behalf of the customer. This service is
particularly important for electrical
components with a short product life
cycle. If such a product is no longer
available, SMS will search for alternatives and place them at the customer’s
disposal. “If the components can no
longer be procured we will accumulate
spare parts inventories to safeguard
operation of the customers’ plants,”
says Heimann.
The spare parts service is not limited to delivery. SMS experts render
support on site for installation and removal of the parts as they know the
plant best. The advantages are short
downtimes and a reliable restart of the
facility. “And in addition, we give valuable advice for maintenance,” adds
Heimann, “that help plant operators
continue to focus basically on their
core business.”
Frank Jansen
frank.jansen@sms-meer.com
Jan Heimann
jan.heimann@sms-siemag.com
A good team: Wolfgang Goerke, ArcelorMittal, and Dr. Dirk Oedekoven (r.), SMS Meer.
WAREHOUSE IN DUISBURGRUHRORT, GERMANY, OPENED
MEERcare®: Since 2013, SMS Meer has been operating a warehousing project in
Duisburg-Ruhrort for the wire rod mill of ArcelorMittal.
It consists of a consignment warehouse with more than 600 places requiring sophisticated planning and logistics. “The warehouse helps us since
we are now able to focus on our core
business,“ says Wolfgang Goerke,
Project Manager at ArcelorMittal.
Together with a global logistics
partner the experts from SMS Meer
Service manage the warehouse in
close proximity to the plant. The benefit to the customer: he pays only after the parts have been withdrawn.
This means a significant cash-flow
advantage. Deliveries take place within one day, and on demand express
deliveries are possible within 90 minutes – also during weekends when
most of the scheduled servicing measures are performed.
“In addition we offer on-call duty
around the clock and on weekends
which means a 24/7 service is available,“ adds Dr. Dirk Oedekoven, Head
of Product Management at SMS Meer.
Oedekoven and his team have every interest in the success of this project. “In
warehousing we see real potential,“ he
reports. The advantages of SMS Meer
warehousing are obvious: permanent
availability of all agreed parts and automatic replacement is taken over by
the experts of SMS Meer. The customer, here ArcelorMittal, is focusing on
its core business and not on logistics
and warehouse management. Last but
not least, working capital is hardly affected and the customer therefore
saves time and money.
Dirk Oedekoven
dirk.oedekoven@sms-meer.com
43
SERVICE
Customer-oriented with eService
With eService SMS Meer now offers customers the possibility to order spare
parts online around the clock in an easy and comfortable way.
A
cooperative and trusting relationship with customers was of prime importance already in the
concept phase of eService. In dialog with the customers, a program was created satisfying the expectations of modern management. “We expect from our
business partners that they are up-to-date, offering us
quick access to information about the renewed procurement of spare parts or possible services. Here, modern
Web tools are a must. We are very pleased to see that SMS
Meer is undertaking necessary steps to continue to be
ahead of time.” These were the first reactions from customers in the American market, encouraging SMS Meer in
its intentions.
Apart from the considerations with regard to a user-friendly system, SMS Meer has also integrated the various function areas within the organization of the customer.
Specific functions were planned and implemented offering
added value to individuals with different responsibilities.
This includes for example the areas maintenance, purchasing, and also general management. Via a personalized display, the customer may look at service reports of previous
maintenance and servicing measures. Future inspection
and maintenance measures as well as a machine-specific
demand for spare parts can be effectively planned for the
long term. Purchasing will also benefit from this. Machine
drawings and parts are interlinked enabling the customer to
find the required parts quickly. He can see information on
parts availability and dispatch status at a glance. “The decisive factor for us was to develop relevant competence-specific functions to help our customers to work more efficiently,” stated Gary Olden, Vice President Spare Parts Service.
The consistently positive feedback of the initial users shows
that Olden and his R&D team are right.
44
i
ONLINE
SERVICES
The online program is shown in
the table below:
User-friendly system/interface
building on experience with B2C
eCommerce systems
Practically oriented solution to
quickly identify and order required
parts from SMS Meer and other
renowned vendors
Access to key information such as
assembly drawings, bills of materials and recommended spare parts
Customers interested in SMS
Meer eService can
register under
the following link:
http://eservice.smsmeer.com
The Equipment Exchange Program cuts
spare parts inventories.
The equipment delivered by Paul Wurth
is of the latest state of the art.
NEW FOR OLD
The Equipment Exchange Program offered by Paul Wurth provides
customers the benefit of extending the availability of their existing plant and
equipment in a cost-efficient way.
P
aul Wurth customers wishing to extend, in a
cost-efficient way, the availability of their existing
plants may take advantage of the Paul Wurth
Equipment Exchange Program. This program
provides additional operational safety at low cost because
reconditioned equipment can be delivered quickly or justin-time as a preliminary service prior to the delivery of the
replacement part.
Since the late 1990s, Paul Wurth has been offering its
customers a program for exchanging worn equipment
with replacement units. Customers participating in the
program may receive, for example, a reconditioned gearbox prior to returning their own gearbox to Paul Wurth for
reconditioning.
THUS THE CUSTOMER WILL NEVER ENCOUNTER AN
OUT-OF-STOCK SITUATION
This provides the customer the flexibility to keep the old
gearbox as a back-up for emergencies until the new one
has arrived and increases planning security, as there is always a back-up in case of equipment failure. The difference
compared to a usual reconditioning service is that the customer is never without a spare part. In other words, he can
reduce its spare part inventory as he
no longer needs to keep extra parts to
bridge the time until the new equipment is delivered.
Last but not least, this will decrease
equipment in stock and operating capital. At the same time, the Equipment
Exchange Program saves costs compared to the purchase of new equipment.
While, in many cases, the parts to
be replaced are no longer of the latest
standard, the equipment delivered by
Paul Wurth is of the latest applicable
state of the art and design. This will
result in an increase in output and a
longer service life.
Paul Wurth assures the quality by
extending the same warranty on that
equipment as for comparable new
equipment.
i
In practice
Many customers
have made use of the
Equipment Exchange
Program.
For instance, at Tata
in the United Kingdom
and at BlueScope
Steel in Australia
drive gears of chutes
were exchanged, at
ArcelorMittal Tubarão,
Brazil, and US Steel
Fairfield, U.S.A.,
planetary gearboxes
and at ArcelorMittal
Vanderbijlpark, South
Africa, tilting gears.
45
SERVICE
Top: Mold plate
coating using the
UniGuard® process.
Bottom: Copper
plate of a mold.
i
Coatings
Special coatings
prolong the longevity
of components.
Important applications
include the coating of
copper plates (continuous casting molds),
chromium-plating of
work rolls (cold rolling)
and the coating of sink
and furnace rollers in
strip processing lines.
46
SERVICE
Special coatings for
longer service lives
Coatings applied to rollers and molds
help reduce operating costs and increase
the product quality.
T
here is fierce competition between the operators of steelmaking and rolling plants.
Only those operators who
continuously maintain, refurbish and
optimize their plants by servicing key
equipment on a regular basis can
stand up to this competitive squeeze.
The coating of plant components such
as rollers or molds prolongs their service lives and helps to assure the product quality. For this, the SMS group
with its worldwide service centers is
the ideal partner.
SMS Millcraft, which is part of the
service network, has many years of experience in the coating of plant components. Thanks to this know-how,
which is available at all service centers
of SMS Siemag, it is possible to give
equipment parts crucial to product
quality a finish that makes them more
resistant to wear.
For example, in order to extend the
life cycle of a mold plate, the plate surface must be given a wear-resistant
surface. By electroplating, nickel or a
nickel-cobalt alloy is applied to the
surface in an electrochemical process.
The resulting wear-resistant coating
gives the material a high surface quality and superior antifriction properties.
A mold with such a coating attains an
up to 30 percent longer life.
A breakthrough development in this
area is the UniGard® process, which
achieves hardness values higher than
1,000 HV. The surface coating applied
by a computer-controlled high-velocity
oxygen fuel (HVOF) process is mainly
made up of tungsten carbide (WC). The
result is an extremely hard, heat- and
wear-resistant plate surface, doubling
the longevity of an uncoated mold. The
maintenance effort decreases, while
the production capacity is markedly
raised.
FOR EACH COMPONENT THE RIGHT
METHOD
SMS Siemag also offers modern processes for applying coatings to the surfaces of rollers and rolls. From build-up
welding of segment rollers through to the
coating of work rolls for cold and hot rolling mills and rollers in strip processing
lines, SMS Siemag offers the optimum
method for each component. For segment rollers, different submerged-arc
welding techniques, particularly suitable
for long rollers, are used. Also here, the
objective is to prolong the service life and
reduce maintenance costs in the process
through a harder material surface. This
cuts operating costs, minimizes downtimes and improves the strip quality. The
same applies to rollers in downstream
strip processing lines.
For work rolls, chromium plating is
the surface coating of choice. The
hardness, corrosion-resistance and
the resulting low abrasive wear of
chromium-plated surfaces extend the
service life four times over.
NEW SPECIFICATION FOR FURNACE
ROLLERS
Sink rolls in the zinc bath of continuous galvanizing lines should always
have a smooth surface to avoid marks
on the strip. Also for this application,
SMS uses HVOF-applied tungsten-carbide coatings. The benefits
are higher hardness values, low wear
and high resistance to corrosion.
For the constantly growing demand
for AHS (Advanced High Strength)
steels, SMS Siemag offers a newly
developed specification for furnace
roller coating. The excellent properties of this coating avoid the occurrence of adhering manganese and
silicon. The MCrAlY coating, which is
sprayed on in a thermal process,
leads to an obvious minimization of
this phenomenon. Additionally, it reduces roughness and hardness losses on the rollers and improves the
strip guiding properties. All these advantages result in an increase in production capacity. No matter which
coating process offered by SMS Siemag is used, it will always translate
into direct value added for the customer. The increase in productive
times and fewer downtimes resulting
in direct cost savings and a higher
product quality safeguard competitive
advantages.
www.sms-millcraft.us
oliver.wiens@sms-siemag.com
47
SERVICE
Safe and durable
connections
Quick-change
coupling locked.
Quick-change couplings for all media
connections in a steel plant.
Together with the company Georg Springmann, SMS Siemag developed a cost-efficient and effective solution that
reduces the time needed for changing media connections
of any kind. As a result, plant availability is markedly increased.
The new quick-change coupling uses a special flange to
connect the ends of two media-carrying hoses or pipes. It
consists of two interconnected coupling segments, which
join and hold the flanges tight, sealing them in the process.
The advantage of this solution over the previous technique
is that only one locking system needs to be opened and
closed. The coupling is secured threefold. As the coupling
is flexibly positioned, connections that are not perfectly
aligned can be easily centered during closing of the coupling.
For new installations and modernization projects. The
convenient mounting method and easy handling of the new
coupling minimize the risk of injury and increase plant
safety. This makes this practical solution a rewarding investment with a very good cost-benefit ratio.
The coupling system is suitable for all media connections on melting and treatment units in a steel plant:
BOF and AOD converters, electric arc furnaces and
secondary metallurgy facilities such as ladle furnaces,
desulfurization and vacuum treatment plants. The quickchange coupling guarantees safe and time-saving changing of blowing lances as well as of pipe and hose connections in steelworks.
stephan.schallenberg@sms-siemag.com
48
Patent pending:
WO 2011/141023 A2
The coupling system is the world’s only TÜVand manufacturing-certified system for the
media oxygen and cooling water.
SERVICE
Reliable rolling oil
quality
Fast and safe with ROCS.
The outcome of the recent rolling oil measurement is on
the desk. How safe are these results? The quality of stainless steel and aluminum strips reflects the purity of the
rolling oil. But is the measuring system really reliable?
With the mobile sensor system ROCS (Rolling Oil Contamination Sensor System), SMS Siemag offers an innovative method for long-term measurement of rolling oil contamination that can be used directly at the plant. Rolling oil
does not only serve for lubricating the roll gap, but also for
transporting the particles incurred in the forming process
to the filter system which frees the oil from the dirt. Regular oil checks ensure the quality of the products. And this
increases the productivity of the plant. The new ROCS by
SMS Siemag provides the plant users with a foundation for
assessment of the filter elements. ROCS offers specific
measures for improving the oil quality which in turn favors
the surface quality of the rolled stock.
the results communicated to the customer, including corresponding recommendations, in the form of a report. The
days are gone when time-consuming and cost-intensive
manual measurements had to be made. ROCS provides
immediate and reliable information on the condition of the
plant and the performance of the filter system.
christoph.haensler@sms-siemag.com
AND THIS IS HOW THE NEW ROCS SERVICE WORKS:
An optical particle counter measures the dirt content of
the rolling oil sample. The moisture content and the temperature are also determined by ROCS. The activities in
the customer’s plant are carried out by a service technician. He will connect the sensors and take care the instrument is operating smoothly. Within 15 minutes, the first
result will be available in the internal laboratory.
For a detailed analysis, ROCS records the measured
data over a period of up to four weeks. Within a short time,
the customer will thus obtain an impression of the current
state of the rolling oil and the running process. The data
will then be evaluated and prepared by SMS experts and
The measuring instrument:
“Rolling Oil Contamination
Sensor”.
49
The new spindle is completely manufactured in the SMS Siemag gear shop.
NEW SPINDLE CONVINCES
BY HIGHER CAPACITY
High-strength materials require greater rolling torques and forces. The new
Sieflex® HT gear-type self-aligning spindle is a key to meeting this demand.
With the new Sieflex® HT gear-type self-aligning spindle it
is possible to reliably transmit drive torques that are more
than 50 percent higher than those previously attainable. Especially in the initial stands of a finishing mill, the HT (High
Torque) spindle allows attaining higher rolling torques and
forces as are increasingly demanded for the production of
high-strength hot strip.
A spindle represents a core element when it comes to
the transmission of drive power from the motor via main
and mill-pinion gear units as well as couplings to the work
roll of a hot-strip mill finishing stand. As a consequence of
the ever higher requirements involved in the production of
50
high-strength grades it is necessary to increase the capacity of the entire drive train. “The space available for the
spindles is set by the work roll diameter which in most
cases cannot be enlarged. For this reason, we had to raise
the capacity of the spindle components to transmit higher
drive torques,” says Klaus Lazzaro, General Manager
Drives/Drive Components of SMS Siemag. The result of
the improved Sieflex® gear-type self-aligning spindle is
the new HT type with a more than 50 percent higher capacity.
The starting point was comprehensive FEM (Finite Element Method) analyses giving detailed information on the
SERVICE
»ADDITIONALLY, WE CHECKED THE CONTACT PATTERN OF THE GEARS.
AFTER TWO YEARS OF USE UNDER TOUGH ROLLING CONDITIONS
THERE WERE HARDLY ANY TRACES OF WEAR.«
Klaus Lazzaro, General Manager Drives/Drive Components, SMS Siemag
loads incurred in the rolling process. The design of the new
HT spindle and, above all, of the gears was carried out on
the basis of these findings. The geometry of the gears was
advanced to the effect that in spite of heavy misalignment
the loads are uniformly distributed to the gear flanks. This
means that even at a misalignment of 3.5 degrees almost
full torque capacity is available.
The first contract covering the installation of HT spindles
was awarded to SMS Siemag by a Japanese steelmaker who
will replace the universal shafts of stands F1 and F2 by new
HT spindles. The investment was split to permit settlement
from the current maintenance budgets. The first Sieflex® HT
gear-type self-aligning spindles with grease lubrication
system will be installed in a hot strip mill in Europe.
SUCCESSFUL FIELD TEST
For a period of more than two years, the newly developed
HT spindle has been tested on the hot strip mill of Salzgitter Flachstahl. Temperature measurements directly at the
gears showed a constant temperature of less than 40 degrees Celsius which proves the low friction between spindle
teeth and wobblers. Klaus Lazzaro: “Additionally, we
checked the contact pattern of the gears. After two years of
use under tough rolling conditions, there were hardly any
traces of wear.”
klaus.lazzaro@sms-siemag.com
Torque capacity of different spindles
Sieflex® HT spindle
160
140
120
USE IN NEW AND MODERNIZED PLANTS
Con
ven
t
100
ion
al g
80
ear
-typ
es
elf-
60
alig
nin
gs
pin
dle
s
40
Torque (%)
In the future, SMS Siemag will equip all new hot strip mills
with HT spindles to make sure they are ready to meet the
ever-rising challenges to be faced in the next few years and
beyond. The HT spindle may be installed in existing plants,
too. A renewal of the drive train permits higher rolling
torques to be transmitted, which is the key towards an extension of the product portfolio in the field of high-strength
grades. The HT spindle can be supplied with two different
lubrication systems, either oil circulation or grease, depending on the customer’s request.
The most important feature
of the HT spindle
is its almost full
torque capacity
up to a misalignment of 3.5
degrees.
180
20
0
1°
1.5°
2°
2.5°
3°
Misalignment
51
SERVICE
PQSC® plugs in use
Tenaris
Mexico
In practice PQSC® piercing plugs are already being used by customers around the
world, for example at Tenaris. Tenaris, leading supplier of tubes and related services for
the world’s energy industry, is already using
PQSC® piercing plugs in its PQF® (Premium
Quality Finishing) plant in Mexico. “We are
achieving great results. With this technology,
we are able to produce in a cost-effective
and environment-conscious manner. At the
same time we can ensure high tube quality
over the long term,” says Miguel Ladron de
Guevara, Operations Director from Tenaris.
With the new piercing mandrel manufacturing machine SMS Meer increases the
manufacturing capacity of the mandrels.
52
SERVICE
Premium technology for premium
tubes and pipes
With PQSC® piercing plugs from SMS Meer, tube manufacturers
produce high-quality, resource-efficient products.
P
QSC® stands for Premium
Quality Surface Coating – and
it does what it says: PQSC®
piercing plugs have a special
ceramic coating that increases their
service life and results in improved inside tube surfaces.
The first stage in the production of
seamless tubes is cross rolling. Here,
the billets are rolled over a piercing
plug, turning solid steel billets into
tube shells. The piercing plugs are
subjected to extreme thermal and mechanical loads: during piercing they are
surrounded by red-hot steel and need
to be able to withstand high frictional
forces. PQSC® plugs from SMS Meer
are designed such that they can endure
stresses for a particularly long period
of time. As a result, tube producers
save on tooling costs and can increase
the productivity of their entire plant.
Product quality is improved, too:
PQSC® piercing plugs are able to meet
high demands when it comes to production reliability, freedom from defects and dimensional accuracy during
the forming process – especially for
materials with higher alloy content.
The result is a flawless production process and high quality standard.
meet the exacting requirements to ensure outstanding tube quality. “In a direct comparison with conventional
piercing plugs, the PQSC® plug used to
date has attained a service life that is
approximately ten times longer, for
example when piercing materials
containing 13 percent chromium. Customers save both time and money using our plugs,” says Product Manager
Manfred Topüth from SMS Meer.
Customers can see for themselves
how it performs: “We offer our customers a comprehensive advisory service
and sample plugs for test rolling. Our
experts are also on hand during the test
rolling if need be,” explains Mr. Topüth.
“We optimize the entire system jointly
with the customer. Depending on their
requirements, we are able to manufacture PQSC® plugs of various sizes, contours, and coatings.”
Tube producers can produce perfect
results when the PQSC® plugs are used
in conjunction with the appropriate
PQSC® cooling system. The cooling unit
is adjusted to the temperature curve in
the plug and can achieve a maximum
cooling capacity with a minimal cooling
period. The service life is again increased considerably as a result,
meaning greater cost benefits.
i
SERVICES
PQSC® performance overview
Sample equipment and test rolling
Optimization of the plug contour
based on the application parameters
Specialist support with test rolling
provided by SMS Meer
Optimization of the design and
layout of the entire PQSC® system
Framework agreements
LONGER SERVICE LIFE
The high-quality ceramic coating on the
PQSC® plugs provides a stable, compact protective layer tailored by SMS
Meer to meet individual customer
needs. Consequently, the plug can
www.sms-meer.com
53
SERVICE
CONSULTING AND
MAINTENANCE
54
55
SERVICE
OVERCOMING THE
SALAMANDER
Tapping of the blast furnace salamander is a challenging task. To deal with
this challenge successfully, Paul Wurth offers innovative solutions.
W
hen a blast furnace needs to be relined or a
longer outage is required for other reasons,
it is necessary to evacuate the residual liquid material from the blast furnace immediately after blow-down. Removal of hot metal accumulated
in the blast furnace sump below the taphole, called
salamander, requires special know-how and must meet
the most exacting safety requirements. Paul Wurth has
gained this know-how during the execution of numerous
blast furnace projects worldwide. This allows the company to offer its customers an unparalleled service package which guarantees timely and safe tapping of the
salamander.
A controlled blow-down of the blast furnace and safe
tapping of the salamander necessitate careful and thorough preparation. Detailed process and risk analyses are
used to guard against the occurrence of any abnormal
incidents while the process activities are going on. By
means of mathematical models specifically developed by
Paul Wurth for this purpose, it is possible to calculate the
erosion profile of the hearth lining, precisely determine
the position and drilling angle for the additional tapping
hole in the blast furnace hearth and check the temperature profiles during drilling.
CONTINUOUS MONITORING PREVENTS EXPLOSIONS
The preparatory phase is followed by the installation of provisional devices at the blast furnace proper. These may include equipment for nitrogen or steam injection into the
blast furnace shaft and for efficient water spraying, in order
to safely manage the process of bringing the burden material level down to the tuyere stock and maintain safe internal furnace conditions. This process is carefully controlled
through continuous stockline probe measurements. Also
the gas composition is continuously measured and monitored throughout this process to ensure there is no risk of
explosion due to high hydrogen content.
56
Finally, the additional taphole is
drilled. For safety reasons, the taphole is opened by means of oxygen
lancing. The residual liquid hot metal
is tapped into torpedo ladles.
www.paulwurth.com
Tapping of the salamander.
300
tons of residual material were tapped by Paul
Wurth in 2012 from blast furnace No. 1 at
Ilva’s steelworks in Taranto, Italy. Blowing
down the blast furnace and tapping the salamander for an environmental upgrade of the
steelworks took just one month.
SERVICE
The screenshot shows
the absolute torque
(green) during rolling with
pre-warning (yellow) and
alarm (red).
STABILIZED SYSTEM
The practice-proven Condition monitoring system Genius CM will in the future
work even more reliably and faster. SMS Siemag has perfected
its proven product and recently launched a new release of the system.
G
enius CM is an instrument for
condition-oriented maintenance. Sensors permanently
monitor the condition of critical plant components. To prevent failure of these components and the severe consequences resulting from
this, the number of customers relying
on this type of maintenance strategy is
constantly growing.
The upgraded system convinces
through features such as easier use,
the possibility of mapping highly informative long-term trends and its increased data-processing capacity.
Christoph Häusler, Manager Technical Customer Service, describes the
development process: “During the last
few years, we have been happy to receive proposals for improvement from
our customers. We used that time to
achieve the best possible results in
the long run. Today, we can reap the
rewards.”
In cooperation with suppliers and
customers, a team of technologists,
mechatronics engineers, and software and maintenance experts created the new software and hardware
architecture. They made the overall
system more stable through the application of new installation methods
and modifications in the hardware design.
FURTHER DEVELOPMENTS
The use of higher-performance units allows data to be recorded along the complete production process. The software
processes incoming signals even more
efficiently, reducing the overall requirement of data processing capacity. This
sets free resources for further analyses
while reducing hardware requirements.
The data management accelerates the
retrieval and display of analysis results.
The visualization features now also include a web-based, dynamic graphical
display system. With the cursor, the user may select individual data points. The
measured values relative to these points
pop up immediately. The system also
has a feature to illustrate long-term
trends.
SMS also increased the number of
selectable default reporting modules. At
the same time, reports are freely configurable. The data are instantly processed.
Administrator access for adjusting the
measuring configuration – for example,
by changing the limit values stored in
the system – is web-based.
Wolfgang Scheffel
wolfgang.scheffel@sms-siemag.com
57
SERVICE
in brief
Best Vendor
Tata Steel
honors
SMS Siemag
On February 28, 2013, Tata Steel honored SMS Siemag as best vendor in
recognition of its performance in the
fields of servicing, repairs and maintenance during the year 2012. The certificate was handed over in the course of
an evening event in Jamshedpur.
Tata Steel justified its decision by
stating that SMS Siemag had been a
reliable partner over many years. SMS
Siemag is the main supplier of the new
CSP® line and the new LD converter 3.
Last year, both companies signed a
five-year framework contract to improve and facilitate the sourcing of
spares. Looking towards the future,
this contract safeguards the Indian
customer’s plans as SMS Siemag
keeps the spare parts ready. A further
nominated company for the category of
Best Vendor 2012, apart from SMS Siemag, was SMS Concast.
Tata Steel belongs to the Tata Group,
India’s largest industrial group which
produces more than 28 million tons of
steel per year.
58
MEERconsult® at Schöneweiss & CO GmbH
Potential identified
Schöneweiss & Co. GmbH in Hagen,
Germany, relies on SMS Meer Service:
it took just three days to produce a
comprehensive analysis of the servicing organization and strategy. The result of the audits in Hagen: The Computerized
Maintenance Management System
(CMMS) is to be developed further by
SMS Meer. In addition, the machines
should be increasingly maintained in a
preventive instead of reactive manner.
SMS Meer improves availability of extrusion presses at HMT
Service for continuous
production
HMT Höfer Metall Technik from Hettstedt, Germany, has commissioned SMS
Meer to carry out an alignment check including a mechanical plant inspection, a
strain measurement and a crack test on its 18-MN and 20-MN extrusion presses.
During the alignment check with plant inspection technical measurements
are performed on the presses to evaluate the machine condition. “On the basis
of the service report from SMS Meer we can take decisions for investments in
replacements and expansions more easily and plan our maintenance measures more specifically. This saves time and unnecessary costs and contributes considerably to an increase in our machine availability and to preventive
maintenance,” said Christian Schwarz, Head of Production at HMT. “Although
SMS Meer is not the supplier of our extrusion presses, we have opted for the
service team from SMS Meer. Their many years of experience and an their
excellent service quality convinced us,” Schwarz added.
HMT is among the
most successful extrusion companies in Germany and operates an
advanced
extrusion
plant for quality profiles.
In future, SMS Meer will
maintain two extrusion
presses at HMT Höfer
Metall Technik.
SERVICE
Die Experten von SMS Meer warten künftig drei Strangpressen bei
F.W. Brökelmann Aluminium.
F.W. Brökelmann Aluminium signs maintenance contract with SMS Meer
Increase productivity,
avoid downtimes
F.W. Brökelmann Aluminium from
Ense-Höingen, Germany, has concluded a maintenance agreement
with SMS Meer for three extrusion
presses with pressing forces of 20
MN, 23 MN and 25/27 MN. Brökelmann produces high-precision aluminum profiles on the plants. With
the maintenance contract, the company intends to avoid unscheduled
plant downtimes and increase productivity.
To do this, SMS Meer has developed an individual maintenance service program together with the customer. Every month, the condition of
the press is assessed. Based on this
assessment, recommendations for
the servicing measures are made.
At annual intervals, the optimization potential will be reconsidered –
particularly that of hydraulic and electrical processes – and documented.
The yearly scheduled plant downtime of the company is accompanied
by the service experts from SMS Meer
and used for the implementation of
the measures specified.
Wolf-Peter Burock, Head of Maintenance at Brökelmann: “SMS Meer
Service applies the latest technical
and constructive developments from
the new plant business. In this way,
our modern machinery remains up to
date and our efficiency is increased.”
JSC TNK Kazchrome
Strategic
maintenance
SMS Siemag is setting up the maintenance organization for four submerged
arc furnaces (SAF), which are under
construction, at the Aktobe site of JSC.
TNK Kazchrome in Kazakhstan. JSC is
part of ENRC. The main objectives of
this project are to achieve high availability and short response times in the
event of a malfunction. JSC commissioned the Technical Service of SMS
Siemag to set up a service team of
more than 200 persons. SMS Siemag
will install the IMMS® Integrated Maintenance Management System.
Tube and pipe industry in dialog.
Conference in Houston
SMS Meer presented itself at a tube and pipe
conference in Houston, U.S.A.
More than 250 experts traveled to the Steel Tube & Pipe Conference in Houston,
U.S.A. – among them representatives of international tube producers such as TMK
IPSCO, JSW Steel and JMC Steel Group. Key subjects included the growing market
for OCTG tubes (Oil Country Tubular Goods) in North America, gas exploration from
shale (fracking) and an increase of quality requirements in the tube sector. SMS
Meer presented the latest technological developments for the manufacture of
seamless tubes – for example PQSC® piercing plugs, the LASUS® measuring system and the CARTA® technology system allowing customers to improve the quality
of seamless tubes. Moreover, production becomes more efficient and eco-friendly.
With more than 20 reference plants worldwide, SMS Meer is one of the leading manufacturers of equipment for the production of seamless tubes.
59
SERVICE
TRAINING
60
61
SERVICE
KNOWLEDGE FOR
THE DAILY ROUTINE
Participants in the seminars and training courses
as offered by the TECademy benefit from the
high degree of practical orientation and the expert
knowledge of the instructors.
Martin Stachowicz and Ufuk Karvan – from
the classroom to the plant.
A
mere two years after the
foundation of the TECademy
as seminar and training
academy for the worldwide
metallurgical and rolling-mill industry,
the list of satisfied customers is long.
The underlying idea of combining the
process know-how of SMS Siemag,
customer relations and plant familiarity
of the company’s own instructors to a
practice-oriented training concept
seems to be working. Within the fields
of technology, maintenance/repair and
plant engineering, customers may
choose from numerous standard training modules.
However, the strength and the future
focus of this training facility will lie on
individual training units tailored to the
customer’s specific requirements as in
the case of Bilstein Kaltband, Hagen,
Germany. “We determined the seminar
contents together with the TECademy
to make sure that all training measures
were conducted in line with our needs,”
comments Ufuk Karvan, Team Leader
Cause Analysis at Bilstein, about the
training courses he attended together
with Martin Stachowicz as new recruits.
62
The TECademy is very flexible when
providing seminars. In the case of Bilstein, this fact was proven when
scheduling the modules that extended
over three months and by the didactic
implementation of the contents. In addition to courses in Hilchenbach, some
seminars were conducted at the customer’s site. “The training measures
have excellently prepared us for operating the plant and included test components for simulation purposes,”
Karvan sums up.
ACQUIRED SKILLS ALREADY APPLIED
For both participants the benefit of the
TECademy training was the detailed
Practice-oriented learning from experts
using the test components.
plant knowledge of the instructors
from the respective SMS Siemag Divisions. “We had the opportunity to talk
to the persons who had once commissioned the plant. This was ideal and
very useful to me for my later everyday
work,” said Karvan.
“Especially the practical relevance
did us a lot of good. We were given
useful tips and learned how to react in
the case of an emergency, and what
we should avoid when we make changes to the plant. All this could already
be applied during a failure that happened in the meantime,” says Stachowicz who would participate again in
such a method of knowledge transfer.
Ali Saeed Al-Qahtani feels the
same. His employer, Saudi Iron and
Steel Company, delegated him to a
seminar in Hilchenbach to be trained
on the topic “Rolling Technology:
Product Quality and Measuring Methods.” “That was one of the best trainings I have ever enjoyed,” he says, still
delighted.
As it combines theoretical and
practical training, the dual vocational
education system in Germany ranks
SERVICE
Interview
Combining theory
and practice
ThyssenKrupp Rasselstein in Andernach, Germany, produces high-quality packaging steel on plants established
by SMS Siemag. Dipl.-Ing. Andreas Brauer is responsible
for the five-stand cold rolling mill and attended the seminar
“Expertentraining für Kaltband” (Cold Strip Expert Training)
at the SMS Siemag TECademy.
high on the Arabian Peninsula. Hence,
it seemed to be just a matter of time
before the customers in that area
would demand the practice-oriented
services of the TECademy. “It was such
a great experience,” says Al-Qahtani.
“We met the engineers and experts of
SMS who had designed our plants.
Classroom and hands-on relevance
were perfectly synchronized, and we
gained the maximum benefit from our
time in Germany.”
http://tecademy.sms-siemag.com
Herr Brauer, what is it that makes the SMS Siemag
TECademy so interesting to your company?
In 2008, SMS Siemag carried out a comprehensive modernization of the five-stand cold rolling mill at ThyssenKrupp
Rasselstein. This means that the TECademy instructors
have a lot of detail knowledge meeting our technical requirements. That convinced us.
Dipl.-Ing. Andreas
Brauer
ThyssenKrupp
Rasselstein,
responsible for
the five-stand cold
Looking back, what impressed you in particular?
Both the organization of the seminar at the Hilchenbach
premises as well as the communication of the contents
were well coordinated.
rolling mill.
Have you already been able to take advantage from
the instructors’ tips and your learning success in daily
business?
The way of teaching fundamentals, theoretical knowledge
and process modeling as well as application in practice revealed that one is dealing with experts in the field. The parONLINE
ticipants have the opportunity to delve into many aspects
needed for their work, to ask questions and discuss poten- For more informatial daily challenges at the plant. This newly gained knowl- tion on the new
edge is also helpful in day-to-day routine.
TECademy program
please refer to:
Considering the development and innovations in the plant http://tecademy.
engineering sector and also the demands on you as a sms-siemag.com
staff member, what do you think are the future topics on
the training market?
In plant engineering, technical advancement will be a significant step towards success also in the future. Other important
components of training programs should include framework
conditions such as occupational safety and environmental
protection, legal provisions or energy management.
63
Unternehmenserfolg
durch Weiterbildung
SERVICE
TECademy
PROGRAM 2014
Technology
Maintenance
and servicing
Plant
technology
Specialist
field
Specialist
field
Specialist
field
1
2
2 TECHNOLOGY
Wartung
Instandhaltung
The TECademy is an internationally active
customer training academy of SMS Siemag AG,
providing expert knowledge to steel-makers
and rolling mill owners regarding the plants
and processes of the metallurgical and roll
milling industry. The knowledge transfer is
conducted by means of standard programs
and
Expertengruppe
1
individualized measures, ensuring high practicability and applicability. Highest versatility is
offered by e-learning components, use of Virtual Reality and, in the near future, video conferences.
Technologie
basic seminar “From ore to pig iron”
21.-22.01.2014 deutsch | 16.-17.01.2014 engl.
Basic seminar on steelmaking
23.-24.01.2014 | 18.-19.09.2014
••
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Basic seminar on secondary/tertiary metallurgy
27.-28.01.2014 | 22.-23.09.2014
1
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Expertengruppe
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Expertengruppe
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3
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3
Expert training for hot strip and heavy plate
11.-13.02.2014 | 21.-23.10.2014
OUR STRENGTH FOR YOUR SUCCESS:
Technologie
Expert training for aluminum hot strip
Wartung
Anlagentechnik
4.-6.02.2014 | 29.09.-01.10.2014
Instandhaltung
•
Ex
per
tenrun de
2
••
•
•••
••
••
••
•
••
•••
••
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tenrunde
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Ex
••
••
•
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••
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- The well-proven SMS Siemag quality
- The sound expert know-how of our own
The digital workshop –
instructors
CSP plants and hot rolling
- Practice-oriented knowledge transfer and
QUALITÄT VERBINDET 10.03.2014
– KUNDENTRAININGS
BEI SMS
| 5.11.2014
high applicability of the contents
- Versatility through seminars & e-learning
www.sms-meer.
mittlung und
Mit den Trainings von SMS Siemag
SMSworkshop
The und
digital
– fundiertem Expertenwissen. Necomponents
Ex
per
tenrunde
3
••
•
com/meercoach
ben standardisierten
Trainings bietet die SMS
Meer können Betreiber von Stahlanlagen
ihr rolling
hot and cold
of aluminum
auch individualisierte Schulungen direkt
Wissen erweitern. Dadurch werden 12.03.2014
ungenutzte group
|
7.11.2014
karsten.weiss@sms-siemag.com
Anlagenpotenziale erkannt, die Fähigkeiten der vor Ort beim Kunden an. Auf den Internetseiten
http://tecademy.sms-siemag.com
TECademy
Mitarbeiter verbessert und somit
der WertPractical
day der
on hot
rolling(SMS Siemag) und von MEER®
schöpfungsprozess im Unternehmen24.09.2014
optimiert. coach
(SMS Meer) finden Sie das passende An| 12.11.2014
Anlagenbetreiber profitieren von der bewährten gebot für Ihr Unternehmen. Schauen Sie rein
http://tecademy.
SMS-Qualität, einer praxisnahenExpert
Wissensverundfor
nutzen
training
coldunsere
strip Stärken für Ihren Erfolg.
sms-siemag.com
18.-20.03.2014 | 28.-30.10.2014
Expert training for aluminum cold strip
11.-13.02.2014 | 21.-23.12.2014
64
01_SMS_Umschlag.indd 1
PREMIUM
TRAININ
for the m
G
etallurgic
al and rollin
g mill ind
2014 PROG
ustry
RAM
The digital workshop –
cold rolling and strip processing lines
11.03.2014 | 06.11.2014·
Basics of strip processing lines
25.-26.03.2014 4.-5.11.2014
Basics of materials technology
30.-31.01.2014 | 25.-26.09.2014
MAINTENANCE AND SERVICING
MORGOIL® –
Basics of oil film bearings
20.-21.02.2014 | 6.-7.11.2014
Media systems
SMS Siemag hydraulic systems
10.-14.03.2014 13.-14.11.2014
Basic course on “The roll as a tool”
2.-3.04.2014 | 19.-20.11.2014
Basic course on roll workshops
7.,14.02.+21.03.2014 | 2., 24., 31.10.2014
PLANT TECHNOLOGY
Basics of ﬂatness measuring
4.04.2014 | 10.12.2014
Dates
Technological Control Systems
X-PACT/PROBAS
Basics
7.-11.04.2014 | 24.-28.11.2014
Advanced course
6.-8.05.2014 | 2.-4.12.2014
Servicing
13.-15.05.2014 | 9.-11.12.2014
Safety strategies – learning on a model
Energy efficiency in metallurgical technology
28.-29.01.2014 | 23.-24.09.2014
E-LEARNING
From steelmaking to the finished product
Hot strip and heavy plate production
Module 1 – The basics and plant technology
Module 2 – Hot strip production processes
Module 3 – Heavy plate production processes
BUSINESS EXPLORATION SERIES
65
SERVICE
Ayan Ascioglu (left)
from SMS Meer
explaining the new
mill moduli, type CL
200, to Sören Hische
from ArcelorMittal
Hamburg.
MEERcoach® training on mill moduli
Within the framework of a MEERcoach® training, four employees
from ArcelorMittal Hamburg, Germany, participated in
a two-day training course in the workshop of SMS Meer.
P
roper handling of mill moduli of the CL 200 type
was the focus of this hands-on training. SMS
Meer’s trainer Ayan Ascioglu shared the plant
manufacturer’s know-how with the experts from
Hamburg. Installing plain bearings, assembling roll
shafts, completing mill modulus housings with roll shafts,
measuring bearing clearances – these were just some of
the issues clearly communicated by him. The issues also
included fundamental principles because mill moduli not
only determine the diameter of the rolled stock but are
also essential for the quality of the end product. Without
proper maintenance and servicing of the components not
only quality problems may arise – but in the worst case, a
total failure of the plant may happen.
With proper know-how gained during a MEERcoach®
training course, interested members of customer’s
66
staff – in this case from ArcelorMittal – are able to effectively prevent these undesirable surprises. Dipl.-Ing. (FH)
Sören Hische, Plant Manager at ArcelorMittal, was impressed: “A top training conveying in-depth knowledge. In
our Hamburg plant, mill moduli from SMS Meer have been
in use for decades.” Friedrich Kauz, a participant from
ArcelorMittal, said: “Personally, I really enjoyed getting to
know different methods of work.”
A very positive feedback from the participants was the
main reason that also ArcelorMittal Ruhrort has already
requested a mill modulus training course.
SERVICE
MEERcoach® training
course successfully
completed: After that, all
the participants received a
certificate.
Conticon staff members Raul Valadez Revilla
(l.) and Jorge Mertinez Razo in Aachen.
Training for
the future
Improved production
with SMS Meer
Technicians from Mexico
visiting SMS Meer.
MEERcoach® training at Mopani Copper Mines
in Zambia.
Two plant operators of the Mexican
company Conticon took part in a
MEERcoach® training organized by
SMS Meer in Aachen, Germany. To
allow the producer of copper wire rod
to optimize his CONTIROD® plant, the
operators deepened their product
knowledge and learned technical details from SMS Meer. An equipment
check in Mexico with MEERcare® has
shown that: the 28-year-old plant offers more potential and could be
more productive.
“The training course was an important experience. To learn about
and understand the process fundamentals is a great advantage for us.
We are now well prepared for the future,” said Raul Valadez Revilla from
Conticon. Lothar Lückhof, Trainer
and Designer at SMS Meer: “It is not
only important for us to convey knowhow. We also place great weight on
the fact that the participants are provided with lasting support.”
Mopani Copper Mines in Kitwe, Zambia, produces 85 tons of copper anodes per hour on its anode casting
wheel – a decent output, but one that
can still be improved. Well-trained
personnel are the key to exploiting the
full potential of the machines and
plants. In a five-day MEERcoach®
training course, the experts from SMS
Meer passed on a wealth of valuable
tips and tricks to the employees of
Mopani.
On-the-spot training directly at the
machine – that is the hallmark of the
individual training provided by MEERcoach®. The participants had the opportunity for a full week to find out all
they wanted to know about the anode
casting process and the finished product.
The experts from SMS Meer
showed the technicians where the focus has to lie during daily operation
and maintenance. During realtime
operation it immediately became obvious to the experts where improvements were necessary.
MEERcoach@sms-meer.com
New concepts – new successes
As one highlight, SMS Meer presented
a new material for coating the moulds.
Together with the Mopani colleagues,
they prepared two abode moulds with
the new material and carried out a
test run. Mopani will now continue the
tests with the new coating on their
own.
For Mopani the training course was
a huge success. The employees were
able to further their technical knowhow and to learn about new things
such as programming.
67
SERVICE
MEERcoach
PROGRAM 2014
®
How are machines and plants operated, maintained and
overhauled in a technically correct manner? The employees from SMS Meer share their expert knowledge with the
customers. With MEERcoach®, SMS Meer provides its customers with a selection of training courses with the aim of
strengthening their expertise as plant owners. SMS Meer,
namely, being a partner for the plants and machines, is simultaneously also a partner for the employees of the customers. In being such a partner, SMS Meer relies on a lively exchange with the customers and on modern,
practice-proven training formats. All measures focus on
everyday practical operation. The standardized trainings
take place at SMS Meer in Mönchengladbach and are conducted in German. If requested, the trainings can also be
conducted individually at the customer’s place in English.
68
OUR SOLUTIONS FOR YOUR SUCCESS
The practice-proven SMS Meer quality
Individual and standardized trainings
E-learning according to the blended learning concept
MEERcoach® training assessment for the needs-based
further development of your employees
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Mit den Trainings von SMS Siemag und SMS
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