Analytics & Data Management

Analytics starts with Data Management.  Data generated by sensors, production systems, and other sources are often isolated in silos. Data is the fuel for Analytics and the challenge is bringing data from these disparate sources together into a central storage location. The storage mechanism must be scalable to accommodate a growing volume while providing fast access for data manipulation and analysis.  Kiss Technologies has developed a comprehensive set of services to accomplish this.

With this framework in place, we are ready to take on your continuous casting priorities through Analytics.  We can examine a full range of caster related issues from reducing breakouts to process optimizations. After discussing your specific requirements and goals our data scientists will determine the data set and analytics methods that will provide results – through data.
 
Analytics takes the Guesswork out of casting.

Product Quality

Steel producers are responsible to meet higher quality standards and produce more tons of quality steel. There are hundreds of variables and interactions continuously taking place in the mold that impact quality.  But without process feedback, you can only react to cracks or inclusions rather than managing for quality.

Quality is formed in the mold.  Is there proper lubrication? Is the heat transfer uniform across the mold face? What are the friction levels and is the shell forming correctly? Is the meniscus stable? These are critical questions you need to know for a predictable result. Unfortunately, the answers to these questions often come in the form of cracks, laps, inclusions and other surface defects.

Kiss Technologies offers products and services which provide actionable data for quality management. The KT500 OnlineMOMS System places sensors on the mold table to measure oscillation characteristics and stability.  The KT500 Friction Module measures friction between the mold and the steel strand providing feedback on lubrication and shell formation. High-resolution fiber temperature sensors installed in the coppers with the KT900 TemperaturePROFILE System produce a thermal map spotlighting heat transfer, cold and hot spots. Using CasterANALYTICS, our engineers will analyze the data set for insights yielding predictable and consistent quality results.

We take the guesswork out of Product Quality.

Mold Oscillation Measurement

The oscillator is the workhorse of the caster and plays a vital role in cast stability and steel quality. From our experience, many casting problems stem from faulty oscillator conditions which can be quickly corrected and even prevented if identified. However, many managers still resort to trial and error problem solving with a predictable result – problems remain, and production losses continue to mount.

There is a better way. Kiss Technologies provides onsite Mold Oscillator Measurement Services or MOMS to measure your oscillators, interpret the data, and present our expert recommendations on top performance. We measure your oscillators in both cold and casting conditions for a comprehensive overview allowing informed decision making. Problems are often pinpointed on the spot, saving days and even weeks of lost production or quality claims. 

Forward-looking steel producers are implementing MOMS as a regular part of their maintenance program to stay ahead of the problems. Oscillators should at least be measured annually but the trend is moving towards quarterly testing since conditions can change quickly. Make informed decisions on oscillator maintenance with data to back it up. Change out oscillators based on condition and not just cast time.  Schedule priority maintenance for components showing signs of short-term failure. Work informed with data saving time, money, and resources.

Call or contact Kiss Technologies today for more information and scheduling.  Please refer to our white paper “The Importance of Mold Oscillation” for further information.

We take the guesswork out of mold oscillator maintenance and performance.

Yield Optimization

Improving yield is a challenge that steel producers face daily and production demands continue to increase. Plus you feel the strain because your engineering resources are limited and your remaining staff is focused on the day-to-day operations, leaving little time for troubleshooting and performance improvement. To compound your dilemma, you only have established casting practices to rely on which are already at their limits of performance. A fresh perspective is needed. Kiss Technologies offers solutions for increasing yield in two key areas – gaining maximum yield from the ladle to the mold and increasing cast speed without risking downtime and quality downgrades.

Our KT2000 LadleSLAG System manages the flow of steel from the ladle into the tundish. The KT2000 is designed to maximize your yield while still maintaining the cleanliness of the steel. A difficult balance, but we’re experts at it. YieldANALYTICS is a performance analysis application that compiles statistics on a heat by heat basis to identify areas for improvement. 

Increasing cast speed and throughput is another area of opportunity for optimizing steel yield.  Blindly increasing cast speed risks potential caster downtime and quality issues. Our KT500 OnlineMOMS System with Mold Friction provides feedback on conditions in the mold leading to downtime. Using CasterANALYTICS we will work with you to analyze the data to find the right conditions for casting faster while minimizing risk.

There are several opportunities for optimizing yield at the caster. Contact Kiss Technologies to start the conversation.

Process Improvement

Your casting practices have been passed down over the years. They are a collection of workarounds, assumptions, and lessons learned that form the rules for running your caster. The caster runs well for periods of time but then for no apparent reason your quality problems reappear, or unexpected caster faults lead to downtime and lost production.  What conditions have changed and what proactive steps can you take to prevent future occurrences?

The starting point is to evaluate the long-standing casting practices. Today’s market conditions may require you to cast a different grade mix than in the past. You’re asked to cast faster for throughput pushing the performance limits of your equipment.   Past practices may not be adequate given the new requirements and may need to be augmented or revised.

Kiss Technologies has the know-how and the resources to evaluate and improve your casting process – through data-driven decision making. Our KT500 OnlineMOMS and KT900 TemperaturePROFILE Systems produce a stream of key process data. Using CasterANALYTICS modeling techniques we will work with you to refine your process to meet current requirements. You don’t have to accept downtime, breakouts, quality downgrades as a normal part of casting.

We take the guesswork out of Process Improvement.