May 2024 Volume 6

MATERIALS

Metallus simultaneously embraces the use of robotic technology to handle tasks deemed too dangerous for human workers, particularly in extreme conditions and environments. This includes the deployment of drones equipped with high-resolution cameras that enable thorough inspections of otherwise inaccessible areas of the plant, such as towering aerial platforms or narrow, confined spaces within the machinery. These drones can safely and swiftly gather critical data for the purposes of analyzing structural integrity and identifying abnormali ties. Some specialized robots are crafted from advanced heat-resistant materials, being designed to navigate near furnaces and high-temperature zones. These enhancements underscore a commitment to main taining a flexible, robust operational framework that adheres to the highest standards and positions Metallus to adeptly respond to the dynamic needs of the forging market, ensuring utmost satisfaction and value for customers. Technological advancements are transforming the entire steelmaking process, from basic operations to complex analytical tasks. Auto mation acts as the powerhouse, while artificial intelligence (AI) serves as the cerebral component. AI utilizes extensive data sets to extract insights that were once unattainable but are now crucial for enhancing process optimization, predictive maintenance, and deci sion-making. Adopting AI technology is about more than just enhancing efficiency and reducing costs; it's fundamentally about employee well-being. In 2023, Metallus launched an innovative project to implement state-of the-art technology aimed at monitoring employee movements under difficult conditions such as low visibility, dust, dirt, and high heat. Metallus partnered with a software AI firm to enhance its camera network by incorporating AI technology. This advanced system provided real-time monitoring of employee positions in operational "red zones," identifying potential hazards instantaneously. Metallus gathered critical data that not only highlighted areas needing addi tional training but also guided strategic investments to mitigate risks in specific areas. A key element of this initiative was the use of a digital twin—a virtual model of daily operations—which facilitated ongoing improvement efforts and strengthened a safety-first culture within the organization. Looking ahead, Metallus remains steadfast in harnessing new tech nologies to improve overall performance and substantially reduce risks across crucial aspects of its operations, exemplifying the steel industry’s broader commitment to innovation and safety. Looking to Infinite Possibilities While the industry is well established and highly competitive, stra tegic investments can create opportunities for lasting differentiation. For Metallus, making these investments is essential to effectively serve the industries it caters to. In the automotive sector, for example, the development of high-strength, lightweight steel grades enables the production of vehicles that are safer, more fuel-efficient and that

Current labor shortages present complex issues arising from an aging workforce and changing demographic patterns that have resulted in fewer people choosing careers in heavy industry. The integration of automation and AI into steelmaking processes is a potential game-changer for the industry. Automation opens the door to upskilling and reskilling opportuni ties. As routine tasks become automated, employees are freed up to engage in more value-added activities. This helps in retaining talent by offering more fulfilling roles and in attracting a new generation of workers more attuned to technology-driven environments. Consider that 35% of manufacturing jobs would be left unfilled even if every experienced individual in America was employed, according to the U.S. Chamber of Commerce. By 2025, 22% of skilled manu facturing workers are expected to retire, increasing the labor gap.2 The strategic adoption of automation within the steelmaking industry is not about diminishing the workforce but rather about complementing and enhancing human capabilities. By doing so, the industry can elevate the value delivered to forgers by ensuring a consistent supply of high-quality steel, tailored to meet their precise specifications. Safety To further improve safety, Metallus has integrated advanced automa tion systems within its logistics and inventory management opera tions. This includes the deployment of automated guided vehicles (AGVs) equipped with sophisticated navigation tools, such as laser guided sensors and data processing units, enabling them to maneuver precisely and autonomously through the intricate layout of a steel manufacturing facility. By efficiently transporting raw materials, intermediates, and finished products between various production stages, AGVs significantly enhance the flow of operations. Their use also minimizes human involvement in potentially dangerous material handling tasks. Additionally, the automation of these processes has led to a marked improvement in inventory accuracy, ensuring optimal stock levels are maintained.

FIA MAGAZINE | MAY 2024 52