SOFTWARE SUITE FOR INTELLIGENT COLD ROLLING MILL OPERATIONS

SOFTWARE SUITE FOR INTELLIGENT COLD ROLLING MILL OPERATIONS

Integrated Digital Solutions by YOGIJI DIGI

1. Overview

YOGIJI DIGI provides a comprehensive digital software suite designed to enhance the performance, efficiency, and reliability of the Cold Rolling Mill. This suite integrates advanced process control, real-time monitoring, AI-driven optimization, and maintenance intelligence into a unified ecosystem. The software suite includes: • AGC Human Machine Interface (HMI) • AI-Based Pass Optimization & Process Suggestions in the AGC HMI • Web-Based AGC HMI with Online Reporting, Dashboards & AI-Chatbot (Yogi) • YD Coil UI for Live Mill Monitoring, Downtime & Maintenance Notifications Together, these solutions transform mill operations from reactive control to proactive, data-driven optimization, enabling improved productivity, reduce energy consumption, enhanced equipment reliability, and superior product quality.

2. AGC Human Machine Interface (HMI)

2.1 Functional Overview

The AGC HMI provides operators and supervisors with a real-time interface to monitor, control, and optimize the rolling process. Designed for high responsiveness and usability, the system ensures precise thickness control and stable mill operation. Key capabilities include: • Real-time process visualization with updates as fast as 50 milliseconds • Display of entry/exit thickness deviations and tolerance compliance • Pass-wise monitoring and reporting for each coil • Intuitive operator interface for rapid decision-making • Fully customizable layouts tailored to plant requirements • Cross-platform compatibility for Windows and macOS environments

2.2 Operational Benefits

  • Improved thickness accuracy and process stability
  • Reduced operator workload through intuitive visualization
  • Faster response to process deviations
  • Enhanced traceability through automated reporting

3. AI-Based Pass Optimization & Process Suggestions in the AGC HMI

3.1 Intelligent Benchmarking

The AI Pass Optimization module continuously analyzes historical coil performance to establish benchmarks for similar coil categories based on:

  • Entry and Exit Thickness
  • Material Grade
  • Width and Coil Weight
  • Process parameters

For each coil group, the system stores the best-performing combinations of:

  • Number of passes
  • Average rolling speed
  • Productivity (tons/hour)
  • Energy consumption (kWh/ton)

3.2 Real-Time Advisory at Schedule Start

At the beginning of a rolling schedule, the system compares planned parameters with historical benchmarks and provides actionable recommendations, such as:

  • Optimal number of passes
  • Suggested rolling speed
  • Expected productivity improvement
  • Estimated energy savings

These suggestions appear as non-intrusive popup notifications within the HMI, allowing operators to make informed decisions without disrupting workflow.

3.3 Key Benefits

  • Increased throughput through optimized pass planning
  • Reduced energy consumption per ton
  • Consistent performance across shifts and operators
  • Continuous improvement through self-updating benchmarks

4. Web-Based AGC HMI & Remote Monitoring

4.1 Remote Access & Visualization

The Web-Based AGC HMI extends mill visibility beyond the control room by enabling secure, browser-based access to real-time mill performance and reports. Core features include:

  • Secure login for authorized users
  • Real-time visualization of the AGC HMI Online
  • Remote monitoring from desktops, tablets, and mobile devices
  • Cross-platform compatibility across operating systems
  • Access to Reports and Visualization Dashboard Online

4.2 Operational Advantages

  • Remote decision-making by plant management
  • Faster troubleshooting and support
  • Improved collaboration across departments
  • Reduced dependency on physical presence in the control room

4.3 Comprehensive Reporting Capabilities

The reporting platform provides real-time analytics and downloadable reports for both the Cold Rolling Mill and downstream process lines. Key reporting modules include:

  • Coil-wise Daily Report, Detailed Coil Report and Pass-wise AGC Report
  • Energy consumption analysis for CRM and process lines
  • Thickness accuracy and tolerance compliance tracking
  • Time utilization analysis
  • One-click Download for offline analysis

4.4 Interactive Dashboards

The interactive dashboard provides unified visibility into:

  • Energy and power consumption trends
  • Productivity and throughput metrics
  • Thickness distribution and process stability
  • Shift-wise performance insights

4.5 AI-Powered Assistant – Yogi

The Web-Based AGC HMI platform includes Yogi, an AI-powered chatbot integrated directly into the dashboard environment. Yogi acts as a virtual process expert, enabling users to interact with mill data using natural language.

Key capabilities include:

  • Natural language queries for instant insights (e.g., production, energy, thickness trends)
  • Real-time access to dashboard and reporting data
  • Context-aware responses based on current mill performance
  • Quick retrieval of coil-specific, shift-wise, and historical information
  • Intelligent reasoning for identifying trends, anomalies and deviations
  • Optimization suggestions for improving productivity, energy efficiency, and process stability

Yogi eliminates the need to manually navigate multiple reports by delivering precise answers instantly, improving decision speed and operational efficiency.

4.6 Business Impact

  • Identification of energy optimization opportunities
  • Improved production planning and scheduling
  • Enhanced process transparency for management
  • Data-driven continuous improvement initiatives
  • Faster decision-making through AI-assisted insights and conversational data access

DASHBOARD

DAY WISE COIL REPORT

COIL DETAILED SUMMARY REPORT

YD Coil UI – Live Mill & Maintenance Intelligence

5.1 Real-Time Mill Visualization

The YD Coil UI provides a live dashboard of the active coil with real-time process parameters, including:

  • Power consumption
  • Productivity metrics
  • Tension values
  • Mill Speed
  • Equipment Maintenance Life

5.2 Maintenance Monitoring & Alerts

The system integrates maintenance intelligence by tracking equipment life and maintenance schedules. It proactively notifies maintenance teams via email alerts when:

  • Equipment reaches 75% of service thresholds
  • Maintenance is overdue

This enables a transition from reactive to planned maintenance.

5.3 Level 2 Data Integration

To improve mill availability and accountability, the UI includes a downtime tracking workflow:

  • Automatically detects mill idle events beyond a configured threshold
  • Allows operators/engineers to log the downtime reason with category/subcategory and comments
  • Captures “logged by” details (operator/engineer) with timestamped records
  • Stores downtime history in a structured CSV log and enables review/export via the UI

5.5 Benefits

  • Reduced unplanned downtime
  • Improved equipment lifespan
  • Enhanced accountability and traceability
  • Better coordination between operations and maintenance

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