shipment

invoicing

sales order confirmation(s)

Strategic Customer Sales & Customer

(Scenario) Marketing Service
Analysis

confirmations

Finance Procurement
sales orders
1.0 2.0 21.0
Production Demand Demand
production & Planning plant conditions Receipt Completion
work order
progress shipped order(s)
estimated requirements accepted
From: product confirmation sales orders
To:
4.0
7.0 4.0
22.0 product inquiry 7.0
9.0
11.0 Production 9.0
3.0 production orders & lineups
Logging & 11.0
12.0 postings Scheduling
Monitoring deviations 12.0
13.0
13.0
14.0
14.0
confirmed shipping requirements

confirmed molten requirements

Human
Resources
Corporate / Supply Chain
planned downtime

Operations / planned
Shop Floor Engineering downtime
Engineering Maintenance Labor
Management
planned
downtime
scrap

5.0 15.0
dross Dross Primary recovery Scrap
Management Management
Dross Processing
Secondary recovery
Company
test results scrap

4.0
molten sample 6.0
Molten Batch
Molten Supplier Lab Testing
molten Creation successful test results
(Sohar Aluminium)

alloyed sample
molten
7.0 sample
Casting &
alloying & fluxing Hot Rolling reroll
ingredients ready to cast

grain refiner,
9.0
additives
Cold Rolling
reroll

hotband 10.0 reroll 12.0

vehicles ASRS Storage Annealing

19.0
11.0
Supply
Trimming
Management
reroll

supply shipments
13.0
Tension Leveling

18.0 17.0
14.0 Finish Packing
Carrier(s) Receiving /
vehicles Slitting finished product
Inbound
Logistics
hotband
8.0 16.0
Hotband Storage Hotband Packing 20.0
Shipping /
packs Outbound
vehicles Logistics
 1.0 Production Planning

confirmations

revised feedback on production constraints

feedback on supply limitations
no
no
estimated requirements 1.3 1.4 yes
1.2
1.1 Feasible Feasible yes Validate Feasible yes Validate Feasible
Customer Validate
Forecast Demand ? ? Production ? Molten ?
yes Shipping Plan
Capacity Supply
no
no
revised feedback on supply constraints
revised feedback on shipping constraints
production &
22.0 work order
Production progress
Logging &
Monitoring

updated production plan

 2.0 Demand Receipt
Sales order confirmations w / “promise weeks”

adjustment request / rejection

22.0
Production plant conditions
Logging &
Monitoring

no

sales order inquiries 2.2 Validate accepted sales orders

2.1 Enter Order 2.3 Create Sales 3.0
Customer Demand Feasible?
Requests yes Orders Scheduling
Feasibility
Sales Order

Total sales order

quantities and net coil
req’s vs. equipment
capacity and material
supply; should apply
same methodology as
product creation product inquiry
1.3 and 1.4

Engineering
 Repeat this “loop” until all demand
(output requirements) is fulfilled by
validated work orders
(i.e. input/output balance achieved
in schedules)

Marriage
3.0 Scheduling
14.0
confirmed sales order promise/ship dates Slitting

confirmed shipping requirements

Production
Order 9.0, 11.0, 12.0
confirmed molten requirements (Cold-End
Processes)
Schedule
2.0 accepted sales orders 3.1 Net
Balanced Process
Demand Production Orders 13.0, 14.0
? yes work orders & lineups area
Receipt & Inventory (Finishing
deviations no Processes)
new output requirements and/or input constraints

22.0 i.e. a form of “backward 7.0

Production planning” driven by Casting &
Logging & Includes detailed scheduling Hot Rolling
Monitoring sitter
marriages
4.0
Molten Batch
Creation
3.2
Molten Supplier 3.3 Schedule 3.4 Schedule
Schedule
(Sohar Aluminium) Caster & Hot Mill Melt Furnaces
Cold-End

As most of the production process

Carrier(s) new input is integrated under one roof, work-
requirements order-driven production (netted by
and/or output product) from end-to-end upon
constraints demand entry should be practical.
“Blind” buffer management (i.e.
Customer work order creation based purely on
current inventory levels,
independent of scheduling) should
not be necessary.

Engineering

planned downtime

Maintenance
planned downtime
 scrap

5.0 15.0
Dross Scrap
Scrap alloy, form
Need to determine Management Management
alloying
requirements via the
batching model
before proceeding 4.0 Molten Batchmaking

sequenced work order 4.1

(molten batch) Cold Charge
3.0 Batch
Scheduling
Batch
cold charge
Melt WO loaded
dross
4.2
Hot Charge
Molten Supplier Molten Batch
(Sohar Aluminium) (multiple crucibles)
22.0
Crucible(s) melt time Production
elapsed Logging &
Monitoring
19.0 4.3 Alloy Batch
alloying & fluxing
Supply
ingredients
Management Alloying complete
fail (updated composition)

4.4
Skim Batch

skimming complete

4.5 molten sample 6.0 test

Sample Batch Lab Testing result

pass (composition logged)

Casting WO
7.0
sequenced work order 4.6 alloyed Casting &
(casting) Pour Batch molten Hot Rolling
yes

furnace
empty?

no
 15.0
5.0 Dross Management primary recovery
Scrap
Management

4.0 secondary recovery

5.3 Recover Dross dross Dross Processing
Molten Batch 5.1 Weigh Dross 5.2 Store Dross 5.4 Ship Dross
dross (Primary) Company
Creation dross dross
Dross Lot Dross Shipment

18.0
Receiving / vehicles
Inbound
Logistics
 6.0 Lab Testing

test results (pass or fail)

4.0
Molten 6.2
Batchmaking molten Perform Molten
Testing Corrective action
depends on coil’s
Test Result current state, but
usually, this means
“scrap the coil”!

molten sample 6.4

6.1 sample Take Corrective
Receive Sample type Action

7.0 solid/sheet sample Sample

Casting &
Hot Rolling

fail
9.0
6.3
Cold Rolling
solid / sheet Perform Sheet test result
Testing
Test Result
11.0
Trimming

pass (certification) 20.0

Shipping /
12.0 Outbound
Annealing Logistics

13.0
Tension Leveling

14.0
Slitting
 sample 6.0
Lab Testing

7.0 Casting & Hot Rolling

scrap 15.0
Scrap
Management

4.0
7.1
Molten Batch
alloyed Cast and Roll cast &
Creation
molten rolled hotband 9.0
metal 7.2 Hotband Storage
Produce Coil

Coil Drain
19.0 remaining cast scrap
sows?
Supply
Management grain refiner,
additives Backup roll changes occur
yes more to 7.3
no less frequently, and are
cast? Stop Cast
performed in parallel with
other mill maintenance

7.4 22.0
roll changes
Change Work Production
needed?
Rolls Logging &
Monitoring

idle mill change complete

7.5 yes
different than 7.6
3.0 Prepare preparation complete
previous cast? Change Over
Scheduling Next Cast

casting work order no

ready to cast
 8.0 Hotband Storage

8.4
9.0
Transfer Hotband
Cold Rolling
to Cold Mill

(semi-)finish shipping Manual

Manual

8.1
7.0
Transfer Hotband 8.2
Casting & destination
to Hotband Cool Hotband
Hot Rolling hotband hotband
Storage ready for next job

hotband packing
Manual

8.3
Transfer Hotband 16.0
to Hotband Hotband Packing
Transfer Car
 6.0
coil sample
Lab Testing

9.0 Cold Rolling

15.0
scrap Scrap
head scrap Management

Pup Coil

tail scrap 9.5

Acceptable
Inspect Output no
Posting ?
Coil
yes
8.0 9.1 9.2 9.3 9.4
coil
Hotband Storage hotband Load Coil Unwind Coil Roll Coil Rewind Coil

9.6 no (i.e. pup)

Rollable
Inspect Input Coil
?
Remainder

reroll
10.X
10.X Roll Changes
Pallet Conveyor yes
(i.e. accidental break)

10.0
ASRS Storage Coil
(diversion)

22.0
Production
3.0 Logging &
Scheduling Monitoring
 10.0 ASRS Storage

10.2
Retrieve Reroll from
Furnace Load Station

10.4
10.1
yes Cooling yes Deliver Reroll 10.5
9.0 Retrieve Reroll Cooling Ready for
space to Cool Reroll in yes
Cold Rolling from needed? next job?
available? Cooling Cooling Area
Cold Rolling Mill
ASRS Storage
10.9
no
Deliver Reroll
12.0
no to
Annealing
Furnace Load
Station

yes Cooling space

no needed for
another coil? 11.0
Trimming
no
10.10
TL
Deliver Reroll
job
to
type
TL Transfer Car
13.0
Tension
Levelling

10.6
10.3 10.7 10.8 10.11
Deliver Reroll Next
Retrieve Reroll Cool/Store Reroll Retrieve Reroll Deliver Reroll 14.0
to job
from in Non-Cooling ready for From to Slitting
Non-Cooling type
TL Transfer Car Area next job ASRS Storage Slitter
ASRS Storage

10.12
Deliver Reroll
to
Cold Rolling Mill
 11.0 Trimming

6.0
coil sample
Lab Testing

15.0
head scrap scrap Scrap
edge trim Management

pup coil

tail scrap 11.7 no

loading Acceptable
Inspect Output
Posting done ?
Reroll
yes 11.9
slitting stopped Unload Reroll
11.3 11.4 11.5 11.6
Load Reroll Unwind Reroll Trim Reroll Rewind Reroll
yes
sheet 11.8
slit Slittable no
11.1 Tension Inspect Input
sheet ?
10.0 Retrieve Reroll Leveller Reroll Remainder
ASRS Storage from ready for
TL Transfer Car this job?
no
11.2
Deliver Reroll to yes Note: Intentional length
TL Intermediate (i.e. accidental breaks also possible
Diversion
Staging break) (multi-coil output)

22.0
Production
3.0
Logging &
Scheduling
Monitoring
 12.0 Annealing

reroll

idle furnace

12.6
Prepare Furnace prep complete
Furnace
Load
Posting
12.2 annealed 12.7
12.1 All coils yes loaded
10.0 reroll Retrieve Ready 12.3 12.4 12.5 Deliver Completed
Add Reroll to in load
ASRS Storage Load from Load Load Furnace Perform Annealing Unload Furnace Load to Loading
Furnace Load available? loaded loaded
Station Station
charging charging
machine machine

idle
charging
machine

22.0
3.0 Production
Scheduling Logging &
Monitoring
 13.0 Tension Leveling

6.0
coil sample
Lab Testing

15.0
head scrap scrap Scrap
edge trim pup coil Management

tail scrap 13.7 no

loading Acceptable
Inspect Output
Posting done ?
Reroll 13.9 finished coil
yes 17.0
Deliver Reroll to
13.5 Finish Packing
13.3 13.4 13.6 Finish Packing
Tension Level Sub
Load Reroll Unwind Reroll Rewind Reroll TL stopped
yes Reroll
sheet 13.8
slit Slittable no
13.1 Tension Inspect Input
sheet ?
10.0 Retrieve Reroll Leveller Reroll Remainder
ASRS Storage from ready for
TL Transfer Car this job?
no yes
13.2 (i.e. sub or
Deliver Reroll to accidental
TL Intermediate break)
Staging

22.0
3.0 Production
Scheduling Logging &
Monitoring
 14.0 Slitting

6.0
coil sample
Lab Testing

15.0
head scrap scrap Scrap
edge trim Management

pup coil

tail scrap 14.5 no

Acceptable
Inspect Output
Posting loading ?
Reroll
done yes 14.7
reroll Deliver Coil to
10.0 14.1 14.2 14.3 14.4
Sub Finish Packing
ASRS Storage Load Reroll Unwind Reroll Slit Reroll Rewind Reroll slitting stopped
sheet 14.6
slit Slittable no finished coil
sheet Inspect Input
?
tooling Reroll Remainder
ready
17.0
Finish Packing
slitting
yes complete
14.8 (i.e. sub or
Setup Tooling accidental break)
Setup
yes Next coil
needs
different
tooling?

no

22.0
3.0 Production
Scheduling Logging &
Monitoring
 scrap

4.0
Molten Batch
Creation
15.0 Scrap Management

7.0 edge trim, pups / whole coils, sows

Casting &
Hot Rolling

edge trim, pups / whole coils, heads/tails

9.0 Scrap Unit
Cold Rolling

15.1 15.2
Receive Scrap Consume Scrap

edge trim, pups / whole coils

11.0
Trimming

edge trim, pups / whole coils

13.0
Tension Leveling

edge trim, pups / whole coils

14.0
Slitting

Many forms of scrap will

have already been
converted at this stage
(e.g. edge trim chopping,
whole coil despooling)
 16.0 Hotband Packing

Packed coil
20.0
hotband 16.1 16.2
8.0 Shipping /
Tilt, Wrap, and Deliver Hotband to
Hotband Storage Outbound
Label Hotband Hotband Shipping packed hotband Logistics
 13.0 17.0 Finish Packing
Tension Levelling

20.0
17.3 17.4
14.0 17.1 17.2 Shipping /
Wrap and Label Deliver Pack to
Slitting finished product Tilt Pack Weigh Pack packs Outbound
Pack Finish Shipping
Logistics
Pack
 18.0 Receiving / Inbound Logistics
18.5 19.0
Receive Supply Supply
Vehicle Management
supply
truck

Assign order to a
vehicle/container
18.6 5.0
supply 18.4 Vehicle
Receive Dross Dross
truck Dispatch Vehicle type
dross Vehicle Management
truck

Vehicle Arrival

18.1 18.2
New Vehicle
Carrier(s) vehicles yes Register New Log Vehicle
vehicle? type
Vehicle Arrival
container or
no flatbed truck

20.0
18.7
18.3 Shipping /
Receive Shipping
Weigh-In Vehicle Outbound
Shipping truck Vehicle
Logistics

container or
flatbed truck

Waste removal
vehicle
 19.0 Supply Management

4.0
alloying & fluxing
Molten Batch
ingredients
Creation

7.0
grain refiner,
Inventory Casting &
additives
18.0 Hot Rolling
supply shipments 19.1
Receiving / Inventory
Add Shipment to
Inbound type
Inventory
Logistics
16.0
hotband packaging Hotband
Packing

17.0
finish packaging Finish
Packing
 21.0
Demand
shipped order(s) Completion

Customer
17.0
Finish Packing shipment

16.0
Hotband Packing 20.0 Shipping / Outbound Logistics
20.1
packs Allocate Packs
Shipment
18.0
Receiving / 20.2 20.3
Inbound vehicles Load Vehicle Weigh-Out Vehicle
Logistics
 21.0 Demand Completion

yes
shipped order(s)
21.0 shipped order(s)
21.1
Shipping / Order(s) 21.2
Update Sales Customer
Outbound complete? Close Sales Order
Order Status invoicing invoicing
Logistics
 4.0
Molten
Batchmaking
22.0 Production Logging & Monitoring

7.0
Casting & production & work order progress 1.0
Hot Rolling Production
Planning

9.0 plant conditions 2.0

Cold Rolling Demand
Receipt

posted operations 22.2 Confirm deviations

11.0 22.1 Update Deviations yes 3.0
Production Order /
Trimming Production Orders ? Scheduling
updated Inventory Plan
production orders

12.0
Annealing

13.0
Tension Leveling

14.0
Slitting