Slab-Order Re-matching for Steel Plant Utilization
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Solution Overview
Problem
Iron and steel plants face low slab utilization due to irrational slab-order matching, leading to order tardiness, high slab cutting loss, and excessive redundant slab weights, primarily caused by contradictory batch production modes and sub-optimal allocation of open-order slabs.
Innovation Solution
A re-matching method for slab-order is developed using a mathematical model and a multiple neighborhoods based tabu search algorithm, optimizing the matching relationship between slabs and orders, and integrating visual programming technology to improve resource utilization and customer satisfaction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If batch production mode is used to meet customer requirements, then production efficiency is improved, but slab utilization deteriorates due to overproduction
Solution Approach 1:
The system performs preliminary action by re-optimizing the slab-order matching relationship before production and allocation. The mathematical model and tabu search algorithm predict and determine optimal matching assignments in advance, considering equipment capacity constraints and order requirements, thereby preventing overproduction and improving slab utilization before the production process begins.
2Ease of operation
If manual allocation of open-order slabs is performed, then operational simplicity is maintained, but matching quality deteriorates due to lack of complete information
Solution Approach 1:
The patent replaces the manual mechanical allocation system with an automated computer-based optimization system. The mathematical model and tabu search algorithm automatically process complete information about slabs, orders, and equipment constraints to generate optimal matching assignments, substituting human judgment with systematic computational optimization while maintaining ease of operation through automated decision-making.
3Device complexity
If slab-order matching is not re-optimized, then process simplicity is maintained, but resource utilization deteriorates due to irrational matching relationships
Solution Approach 1:
The system implements feedback by continuously re-optimizing the slab-order matching relationship based on current slab inventory, order requirements, and equipment capacity information. The optimization results are fed back into the production planning system to adjust matching assignments, creating a closed-loop system that improves resource utilization through iterative optimization while maintaining manageable complexity through automated processing.
Data Source
AI summary
A re-matching method of slab-order for improving slab utilization in iron and steel plants, comprising the steps of Step 1: formulating a mathematical model according to information of slabs and orders, so as to quantitatively describe the optimization problem of slab-order matching; Step 2: dividing the slabs and orders into groups; Step 3: generating a new slab-order matching relationship for each group of slabs and orders by using a multiple neighborhoods based tabu search algorithm on the basis of the formulated mathematical model, tries to re-optimize the matching relationship with consideration of the original slab-order matching relationship and the load balance of all equipment units, so as to improve the slab-order matching relationship, decrease the slab cutting loss, reduce the redundant slab weight of each order, and improve the integrity of an order, thus improving slab utilization, ensuring to deliver an urgent order on time, and improving the customer satisfaction.