Resources · Steel Twin
Steel Twin: guides, playbooks and tools.
Everything we have written about the problems Steel Twin solves, in one place.
Blog posts
- When Every Steel Shop Hits Its Number, and Margin SlipsIntegrated steel plants measure each shop well, but margin leaks between shops: a converter hits tap-to-tap while the caster breaks sequence. Steel Twin traces every heat from charge to coil on heat_id and ranks holds, constraints and energy variances across shops by cost in one action queue the shift can act on.
- Stale Plant Data Should Look StaleA plant screen that shows old data in the same way as live data invites wrong decisions. Steel Twin joins seven systems that update on different clocks, keeps each event’s source timestamp and quality flag so stale data is never hidden, and replays every shift with what the controller could actually see.
Guides
- Heat Genealogy in Steel Plants: Charge to CoilHeat genealogy links each steel heat from charge, steelmaking and ladle treatment through casting, testing and rolling to the coil and its sales order. It needs one key, usually the heat number, joined across historian, MES, LIMS and ERP, with each event keeping its source timestamp.
- Quality Holds in Steel: Re-treat, Regrade or DivertA quality hold stops steel moving on until someone decides: re-treat, regrade, divert to another order, release with concession, or downgrade. Decide faster by catching holds earlier, pricing each option against the affected order, checking similar past heats and recording the decision against the heat.
- Steel Plant Energy vs Norm: Tracking by ShiftAn energy norm is the expected power, oxygen, fuel gas or steam per tonne for a unit and product. Track the variance by unit and shift as it runs, using meter data against MES production, push significant variances to the shift controller and flag stale readings instead of hiding them.
Playbooks
- Steel Plant Shift Review: A Replay-Based PlaybookA steel plant shift review works when it replays the shift with sourced events, ranks issues by cost rather than noise, checks how each shop’s decisions affected the next, reviews recorded decisions on holds and alerts, and assigns actions with owners and due dates that open the next review.
Comparisons
- Steel Plant MES vs a Digital Twin Control RoomAn MES executes and records production shop by shop; a digital-twin control room joins MES, LIMS, historian, ERP, EAM and energy data on the heat number into one live plant flow with holds, energy against norm and a ranked action queue. The twin sits on top; nothing has to be ripped out.
The product behind these guides. Steel Twin — Every heat, traced to the coil. Book a 30-minute working session.