• Benefits of Surface Inspection
  • Vorteile der Oberflächeninspektion
  • Benefits of Surface Inspection


Value for our customers

 

„The surface inspection system“ is just a "defect image delivery device". However, its reliability combined with the flexible software approach and ISRA VISION Parsytec's deep process application know-how, makes „The surface inspection system“ becoming a key contributor to various process optimization initiatives. Here are just a few examples, to which extent „The surface inspection system“ delivered value to renowned steel producers.


 

 


Corus
Strip breaks at subsequent line reduced by 75%, availability increased by 1%.

 


Duferco
Achieved eligibility to produce automotive-exposed steel two years earlier than initially planned.

 


Mittal Steel
Recovered 70% of previously downgraded material. Reduced manual inspection of tempered coils at the EGL: savings of EUR 300,000 per year.

 


Steel Warehouse
Managed to get a price premium from their customers due to increased quality standards.

 


ThyssenKrupp
Reduction of tandem breaks down to zero within 6 months.

 


USS Posco
90% reduction in tin material strip breaks in 9 months.

 

 


Surface quality is no longer a subjective assessment, but machine generated data with a constant reliability. The resulting data is stored, creating a complete quality documentation for the individual coil as well as for the entire production. The stored data be analyzed with statistics and correlation software. Primarily, the SIS will of course be used as a tool for the inspector and the quality department.


 
The economic effect of this online surface quality control is often underestimated - surface quality control is not yet another cost factor - steel makers actually earn money. Improved quality measurement helps to


 


  • improve control of the process, e.g. faster reaction of processing faults (roll damage, temperature change, etc.) avoidance of disaster events (strip ruptures, etc.) switch of galvanized / galvannealed process or pickling speed
  • improve overall process efficiency, e.g. avoidance of downstream processing of faulty material optimizing downstream processing (repair, downgrading, upgrading) early change of production schedules back-tracing of defects to their creation reducing scrap and unnecessary coil blocking reducing the quality costs (including recoiling activities)
  • improve customer relationships, e.g. reducing the claims delivering documented quality

 



 


An example may illustrate the economic impact of using a surface inspection system, e.g. at a hot mill (example for a CSP type hot strip mill with a capacity of 2 Mill tons/year):

 

(1) Instant Detection of Marks and Rollmarks

 

Reduces tail end inspection from 1 out of 10 coils to 1 of 40 coils

    saves material 

    1,500 t/year

    = EUR 300,000 /year

    saves manpower

    1 person/shift

    = EUR 200,000 /year

     

    Enables instant roll change

      reduces defective strips

        4 coils/week

        = EUR 400,000 /year 

        reduces disaster events

        2 events/year

        = EUR 160,000 /year 



        (2) Objective Overall Quality Judgement

         

        Reduction of accidental and precautious downgrades

          from 0.51% to 0.27%

            200 coils/year

            = EUR 400,000 /year 

             

            Reduction of off-line verification

              saved recoiling/handling
              cost (recoiling,
              pickling line complaints)

                180 coils/year

                = EUR 200,000 /year 


                 


                The overall economic benefit for this mill is EUR 1,600,000/year.

                 

                For cold mills, there are similar observations. ISRA VISION Parsytec has compiled case studies for most of the steel processing lines underlining this striking benefits.


                 


                 

                 

                 


                Contact


                Pascalstraße 16
                52076 Aachen
                Germany
                tel: +49 (2408) 92 700 - 0
                fax: +49 (2408) 92 700 - 500
                info@isravision.com 


                Highlights

                Example benefits from using Surface Inspection Systems:

                Hot strip mills:
                3,200,000 €/y

                Pickling lines:
                1,900,000 €/y

                Hot dip galvanizing lines:
                2,500,000 €/y

                Continuous annealing lines:
                5,500,000 €/y

                Recoiling lines:
                2,500,000 €/y