Field problems improved through measurement and process control
Period: 2024.09 – 2025.06Stage: Field application and results
- Project
- Rotary furnace process improvement & equipment verification
- Company
- 티지와이aluminum recycling and remelting
- Scope
- Results before and after equipment introductionprocess records kept
Door and tilt overload
Limit sensors · position-limit signals checked · Field photo Duct overheating and flashback
Duct temperature sensor · temperature display and warning checked · Field photo Operating conditions hard to see
Atmosphere temperature and gas flow · live and totalized values checked · Field photo
Field problem → measurement and control item → HMI display and real-motion check
PLC and HMI checked against real equipment motion
Position, temperature and flow signals verified; operating state and per-material production history managed
Equipment verification, process history and blend criteria were connected, laying the basis for higher recovery and a traceable production process.
Key results and improvements
| Indicator | Result | Basis |
|---|---|---|
| Recovery improvementBefore and after equipment introduction | 73% to 85% average | Up 12 ppaverage after introduction |
| Production transparencyMaterial, process and quality history | Production process traced | Raw material, temperature, composition and recovery linked |
| Blend controlWhen composition is checked | Analysis after melting to Blend reviewed before charging | Expected composition computed and judged against criteria |
Challenge
- Door and tilt overload, duct overheating and flashback risk
- Operation that relied on operators' feel, and recovery rates that varied by raw material
- Signal verification and blend-judgment criteria were needed for the new equipment
Work carried out
Field problems and check items
Door and tilt position, duct and atmosphere temperature, gas flow checked
PLC and HMI signal comparison
XG5000 communication and ladder checked against real equipment motion and the HMI display
Process data and integration conditions
Raw material, temperature, composition and recovery managed; MES integration checked
Blend judgment before charging
Expected composition computed from raw-material composition and blend ratio, then judged against criteria
Design decisions
- Field risks turned into concrete check items for position, temperature and flow
- Operating state and raw-material conditions recorded together as a basis for process judgment
- Scope of work
- End to end on my own · field-problem analysis, equipment verification
- Process-history and blend-judgment design, development and documentation
- Coordination
- Reviewed signal and integration conditions with the equipment contractor
- Daily TBM (toolbox meeting) with 7 operators
- Applied skills
- XG5000
- PLC/HMI
- MES
- Excel
Equipment verification & process data
Operating state linked to blend and recovery history
73% → 85% average
Recovery up 12 pp, before vs. after equipment introduction
Links the field result with the history kept for raw material and operating conditions
Equipment state · PLC/HMI
- Position
- Door-closed and lowered limits
- Temperature
- Exhaust and atmosphere temperature
- Flow
- Instantaneous and totalized gas flow
Field verification items
- XG5000 communication and ladder check
- Equipment motion compared with HMI signals
- MES integration items and conditions reviewed
Basis for process judgment · history and blend
Labels on the sheet
- 날짜
- date
- 원료
- raw material
- 공급처
- supplier
- 평균온도
- average temperature
- 원료투입평균온도
- average charging temperature
- 회수율
- recovery rate
The 20-row table is the trace record of raw material, temperature, composition and recovery; it is separate from the before/after average recovery tally.
Labels on the sheet
- 원료
- raw material
- 배합비율
- blend ratio
- 합부판정
- pass/fail judgment
- 화학적 성분
- element
- 배합성분
- blended composition
- 성분 기준 적합 여부
- within the composition criteria
- 적합
- acceptable
- 해당없음
- not applicable
Error against measured composition for this blend example is left to later verification
Before charging · blend judgment
Material composition × blend ratio → expected composition, judged against criteria
During operation · state check
Position, temperature, flow → compared with HMI display and warnings
After melting · result tracing
Material, temperature, composition, recovery → history by condition
Disclosure scope Field photo 4 · Work sheet 2. The photos show the rotary furnace and its HMI screen; the record table's raw-material and supplier cells and the blend sheet's raw-material cells are blank. The duct photo's red mark is in the original.
For more material, please ask by e-mail.
fpdlsdk3115@gmail.com