THE PROJECT

The IoT4DigitalTwin project is part of the European IoT4Industry initiative within the Horizon 2020 programme. Geprom Connecting Industries and Gefasoft GmbH have formed a consortium with the aim of implementing a digital twin in Celsa (a private Spanish multinational and leader in the metallurgical sector) and continuing to advance in the field of industry 4.0 with more flexible, personalised and efficient processes.

The main objectives of the IoT4Industry call are to increase productivity, profitability and innovation capabilities of SMEs by accelerating their access to industry 4.0 and digital transformation. It also seeks to improve market access to new products and services provided by technology SMEs, strengthening their innovation and growth.

European industry is in a constant process of modernisation. Internet of Things (IoT) technologies have already entered manufacturing and this trend will increase in its different phases and processes of Industry 4.0. Europe is continuously promoting investment in plant modernisation, which includes the introduction of new ICT technologies and in particular IoT, Big Data, Artificial Intelligence and Cybersecurity.

IoT4DigitalTwin is a 12-month project that will end in November 2020 with the final achievement of a standard and easily scalable product and technology that can be quickly replicated in other production centres and other sectors.

The aim of the IoT4DigitalTwin project is to give a boost to the digital transformation of industrial processes within the steel industry, covering everything related to the production process, management of factory personnel, manufacturing resources, final products and industrial tasks. By means of new tools based on IoT, it is intended to improve productivity and profitability, guaranteeing the effective execution of manufacturing operations at Celsa’s facilities.

The fundamental objectives covered by the project are:

  MES LEGATO SAPIENT
Data capture through the Legato Sapient MES system, which will allow to control, manage and monitor production in real time.

  DIGITAL TWIN
Creation of a Digital Twin, which will make possible the virtualization of the production centre, improving the efficiency of new investments without altering the real production process.

  STANDARDIZATION AND SCALABILITY
The final result is a standard and easily scalable product and technology that can be quickly replicated in other production centres and other sectors.

  ISO
Regulatory compliance and safety approach (ISO-10218), EC Machinery Directive 2006, ISO/TS 15066.

The collection of all the factory data necessary for the development of the Digital Twin at Celsa will be carried out through the Legato Sapient MES system.

  Legato is a flexible, scalable and modular MES system that allows a factory, or a set of factories, to be managed, controlled and monitored simultaneously in real time.

  The Legato platform provides real-time information on the production process (stocks, quality, order planning, breakdowns, production management, traceability, energy management, efficiencies and yields, etc.), and robustly integrates with platforms such as ERPs and other planning systems.

  The system consists of more than 24 independent modules aimed at increasing efficiency and reducing costs, which are implemented according to customer needs.

  The captured data is processed and stored in real time and converted into customized reports for analysis and decision making.

A Digital Twin is a digital representation and simulation that makes predicting the different flows of the production processes possible, building a virtual factory in parallel that allows decisions to be made and errors to be corrected before they happen. The main factors needed to implement a digital twin are process automation, data capture for production monitoring and control, technologies such as Machine Learning or Big Data, and a digital culture with connected people that guarantees the success of this 4.0 technology.

Currently the concept of Digital Twin continues to develop and face the various technological barriers that it encounters and that make it difficult to incorporate it easily into the industrial fabric. One of the main difficulties that the Digital Twin must face is the technical difficulty of massively monitoring all the processes of a factory, and all the systems and equipment that this entails. This is where the specific project for Celsa and the solutions it provides will be technically very innovative and will cover the proposed objectives.

The IoT4DigitalTwin project is committed to incorporating digitalization to improve Celsa’s production processes, in addition to acting as an ally to ensure their commitment to sustainability and circular economy. Especially in a context as complex for the steel and industrial sector as it is today, where there are major challenges such as high energy costs and a highly competitive context at the global level.

Celsa Group has always made a clear commitment to innovation in their products and manufacturing processes. This is, for example, their commitment to the incorporation of enabling technologies from industry 4.0, which allows to increase the added value of the products they manufacture, broaden sales diversification and have greater interaction with the end customer, thus promoting the company’s competitiveness.

The project is scheduled for completion in November 2020, with the ultimate goal of providing Celsa with a complete digital twin project. It will contemplate a set of integrated solutions to increase the efficiency of operations and thus advance in their firm commitment to industry 4.0.

Specifically, the IoT4DigitalTwin project seeks the following benefits:

            Increased efficiency and productivity of operations.
            Reduction of operating costs.
            Ability to group and display production data in real time.
            Ability to observe the historical and current profile of the process behaviour.
            Real-time positioning of operators.
            Real-time monitoring of the production process.
            Virtualization of the process.
            Make decisions avoiding production stops and minimizing risks.
            Capacity to test modifications without introducing changes in the plant.
            Optimize logistics and production parameters.
            Elimination of paper use.
            Better KPI calculation and real time reporting.
            Continuous improvement of the production process.
            Scalable and standard product.
            Compliance with regulations.

CASE STUDY

CONSORTIUM MEMBERS

Gefasoft GmbH is a German software company that works around the concept of “intelligent production”. Their SCADA and MES systems for the industry seek to bring innovation through continuous improvement with the consequent reduction in costs. The solutions they offer have already been implemented at an international level in industries such as the automotive, pharmaceutical, food, and energy, among others.

Geprom Connecting Industries is an innovative and dynamic engineering company dedicated to the development and integration of high added value technological solutions in the field of industry 4.0 and industrial automation, focused on the areas of production, maintenance, logistics and quality. Geprom has developed projects for top-10 clients in sectors such as automotive, food, pharmaceutical, and chemical, among others.

CELSA Group is the first private industrial group in Spain, they have nearly 33,000 employees and operate in 11 countries. They have six large business groups with steel mills, rolling mills, processing plants, distribution, service and recycling companies. They operate mainly in the construction, naval, energy and automotive sectors, with a clear commitment to innovation and sustainability.

LATEST NEWS

17 November 2020

Geprom and Gefasoft are virtualizing Celsa’s production processes with the creation of a digital twin to make decisions in real time and avoid errors before they occur. 

11 March 2020

On March 3-5, the Advanced Factories fair took place at the CCIB in Barcelona. For the third consecutive year, Geprom, as a member of the consortium of the IoT4DigitalTwin project, presented their innovations for the digitalization of the industry.

8 January 2020

The IoT4DigitalTwin project is part of the European initiative IoT4Industry within the Horizon 2020 programme. Geprom Connecting Industries forms a consortium with Gefasoft GmbH to digitalise and implement a digital twin in Celsa and thus advance towards industry 4.0.

23 October 2019

The European project IoT4DigitalTwin, led by Geprom Connecting Industries and Gefasoft GmbH, has held its kick-off meeting at the Celsa facilities in Illescas. The meeting represented the official launch of the project and was attended by representatives of all the members of

Contact

info@iot4digitaltwin.eu

European Union's Horizon 2020 Programme

This project has received funding from the European Union’s Horizon 2020 research and innovation programme under grant agreement No 777455.