Fero Labs AI for Steelmakers: Benefits and Use Cases

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style="background-color:transparent;color:#000000;">Fero Labs' AI-powered software offers </span><a href="https://craft-ferolabs.files.svdcdn.com/production/PDF/Fero-Labs-for-Steelmakers-2024.pdf?dm=1730904249"><span style="background-color:transparent;color:#000000;">significant advantages</span></a><span style="background-color:transparent;color:#000000;"> for the steel industry, enabling faster and more effective process optimization and issue resolution to increase speed to solution and minimize unnecessary expenditure.</span></p><p><span style="background-color:transparent;color:#000000;">Current analysis </span><a href="https://www.ferolabs.com/insights/post/10-ways-fero-labs-ai-accelerates-lean-six-sigmas-speed-to-solution"><span style="background-color:transparent;color:#000000;">methods</span></a><span style="background-color:transparent;color:#000000;"> utilize excel forms or minitabs to identify issues and find solutions. However, these solutions are too slow and offer limited complexity.</span></p><p><span style="background-color:transparent;color:#000000;">By supporting a steel plant with Fero’s powerful Catalyst AI, Process Engineers and Metallurgists can diagnose and resolve issues faster without changing their trusted workflow or losing the scientific rigor they rely upon. Production anomalies will be detected early, before they impact operations and require urgent intervention.</span></p><p><span style="background-color:transparent;color:#000000;">In the short term, engineers using the Fero platform will improve their bandwidth by performing their tasks faster and more accurately. Longer term, engineers will be able to use this expanded capacity each day to focus on activities that further cut costs and increase speed to market, without constant disruption to solve unexpected issues.</span></p><p><span style="background-color:transparent;color:#000000;">Here are some specific use cases and the benefits of using Fero Labs:</span></p><h5><span style="background-color:transparent;color:#000000;"><strong>Alloy Reduction and Cost Savings</strong></span></h5><p><span style="background-color:transparent;color:#000000;">Fero Labs helps steel manufacturers optimize alloy additives in real-time, leading to substantial cost savings and improved sustainability:</span></p><ul><li><span style="background-color:transparent;color:#000000;">At Gerdau's Petersburg mill, engineers reduced raw material costs by $3 per ton of steel.</span></li><li><span style="background-color:transparent;color:#000000;">Over 500,000 pounds of manganese, carbon, niobium, and vanadium were conserved.</span></li><li><span style="background-color:transparent;color:#000000;">The average steel plant sees $1-$6 per ton in raw material savings within six months of deploying Fero.</span></li></ul><p><span style="background-color:transparent;color:#000000;"><strong>Why Fero is faster and better:</strong></span></p><p><span style="background-color:transparent;color:#000000;">Fero software recognizes that every heat composition is different. Fero's live recommendations are delivered in under a minute, showing engineers exactly how much of each alloy to add. This real-time optimization allows for immediate adjustments, minimizing waste and maximizing savings much faster than traditional methods.</span></p><p><span style="background-color:transparent;color:#000000;"><i><span class="text-orange-500">“Fero tells us the lowest amount of alloys we can use to pass, so we can optimize in real time.” - <strong>Process Engineer</strong></span></i></span></p><h5><span style="background-color:transparent;color:#000000;"><strong>Quality Improvement</strong></span></h5><p><span style="background-color:transparent;color:#000000;">Steel manufacturers can use Fero software to enhance product quality while maintaining efficiency:</span></p><ul><li><span style="background-color:transparent;color:#000000;">Fero software can be adapted to any quality use case, from controlling casting conditions to minimize surface defects, to adapting to feedstock variability to minimize fractures in wire rods.</span></li><li><span style="background-color:transparent;color:#000000;">Gerdau observed a 15% reduction in quality variation in production using the Fero machine learning workflow, enabling the company to deliver the product quality that their customers expect.</span></li><li><span style="background-color:transparent;color:#000000;">Engineers can easily integrate and merge data from various process, lab, and quality-related databases to analyze specific product and grade types.</span></li><li><span style="background-color:transparent;color:#000000;">Fero’s powerful Catalyst AI and process engine enables engineers to use much larger and more complex data files which helps to pinpoint issues faster.</span></li></ul><p><span style="background-color:transparent;color:#000000;"><strong>Why Fero is faster and better:</strong></span></p><p><span style="background-color:transparent;color:#000000;">Fero's ability to evaluate multiple nonlinear relationships between data points allows for more comprehensive quality control than traditional analytical tools. This leads to faster identification and resolution of quality issues.</span></p><p><span style="background-color:transparent;color:#000000;"><i><span class="text-orange-500">“With Fero Labs, we developed a model that dynamically predicts mechanical yield and tensile strength and tells us the most cost-optimized chemistry, so we can achieve and exceed our limits without overshooting.” <strong>- Carlo Travaglini, Director of Technology, Gerdau</strong></span></i></span></p><h5><span style="background-color:transparent;color:#000000;"><strong>Production Flexibility and Adaptability</strong></span></h5><p><span style="background-color:transparent;color:#000000;">Fero Labs enables steel plants to quickly adapt to changing conditions:</span></p><ul><li><span style="background-color:transparent;color:#000000;">The software provides dynamic targets that can fluctuate from heat to heat, allowing for real-time optimization.</span></li><li><span style="background-color:transparent;color:#000000;">Engineers retain operational control by building and training no-code models in minutes within the Fero platform, and streamlining change requests to Operators so nothing slips through the cracks.</span></li><li><span style="background-color:transparent;color:#000000;">Operators can easily view and implement recommendations through dedicated monitors in central pulpit locations.</span></li></ul><p><span style="background-color:transparent;color:#000000;"><strong>Why Fero is faster and better:</strong></span></p><p><span style="background-color:transparent;color:#000000;">The ability to adapt quickly to changing conditions is crucial in steel production. Every minutes running sub-optimally requires unnecessary energy expenditure and can impact product quality. Fero's real-time recommendations allow for immediate adjustments, resulting in faster optimization compared to traditional methods that may only rely on historical data or periodic analysis.</span></p><p><span style="background-color:transparent;color:#000000;"><i><span class="text-orange-500">“The biggest challenge we face is the complexity of the plant and process. By using the Fero Labs platform, we can quickly prioritize where value is to be found.” <strong>- Automation Engineer</strong></span></i></span></p><h5><span style="background-color:transparent;color:#000000;"><strong>Energy Efficiency and Sustainability</strong></span></h5><p><span style="background-color:transparent;color:#000000;">Steel manufacturers can use Fero to improve energy efficiency and reduce environmental impact:</span></p><ul><li><span style="background-color:transparent;color:#000000;">Fero’s industrial AI software helps reduce the time it takes to process batches, leading to significant energy savings.</span></li><li><span style="background-color:transparent;color:#000000;">By optimizing raw material usage, Fero contributes to reduced mining and transportation needs, improving overall sustainability.</span></li><li><span style="background-color:transparent;color:#000000;">By relying on Fero software to identify the chemical composition of each heat, steelmakers are able to increase their recycled feedstock with confidence, knowing that Fero’s platform will recommend the lowest amount of additives required to stay in-spec. </span></li></ul><p><span style="background-color:transparent;color:#000000;"><strong>Why Fero is faster and better:</strong></span></p><p><span style="background-color:transparent;color:#000000;">Fero's ability to analyze complex data relationships allows for quicker identification of energy-saving opportunities. The real-time nature of the software enables immediate implementation of these insights, leading to faster results in energy efficiency improvements.</span></p><p><span style="background-color:transparent;color:#000000;"><i><span class="text-orange-500">“By combining (our) process knowledge with Fero Labs’ ML tool, we not only optimized our alloy usage and saved costs – we also reduced the workload on the process engineers and made huge product capability improvements.” <strong>- Jena Kreuzer, Process Engineer, Gerdau</strong></span></i></span></p><h5><span style="background-color:transparent;color:#000000;"><strong>Root Cause Analysis for Rapid Diagnostics</strong></span></h5><p><span style="background-color:transparent;color:#000000;">Fero Labs helps engineers quickly identify and address issues in the production process:</span></p><ul><li><span style="background-color:transparent;color:#000000;">Fero Lab's white-box AI allows users to explore all insights gleaned from the data, including root causes and relationships between factors.</span></li><li><span style="background-color:transparent;color:#000000;">Engineers can identify root causes of issues 90x faster than traditional LSS methods and test solutions in Fero’s simulated environment for increased confidence prior to production deployment.</span></li><li><span style="background-color:transparent;color:#000000;">Running diagnostics within the Fero platform streamlines engineering resources whilst enabling greater visibility and collaboration.</span></li><li><span style="background-color:transparent;color:#000000;">One metallurgist used Fero to identify why their quality tests were providing varied results. Within minutes the platform indicated a non-linear relationship that nitrogen levels were impacting quality test results and what to change to stay in-spec. Previously, this had required two weeks for three dedicated quality engineers to find the same result.</span></li></ul><p><span style="background-color:transparent;color:#000000;"><strong>Why Fero is faster and better:</strong></span></p><p><span style="background-color:transparent;color:#000000;">Fero's transparent AI models provide clear explanations for their recommendations, allowing engineers to quickly understand and address the root causes of production issues. This is significantly faster than traditional trial-and-error approaches or complex data analysis methods.</span></p><p><span style="background-color:transparent;color:#000000;"><i><span class="text-orange-500">“The industrial sector is undergoing a seismic shift, from the transition to renewable energy to the circularity in raw material utilization, all while grappling with increasing labor shortages. Many of the fundamental assumptions that drove efficiency in manufacturing will no longer hold. In this era of transformation, AI emerges as the linchpin propelling the industrial sector into its next stage of evolution.” </span></i></span></p><p><span style="background-color:transparent;color:#000000;"><i><span class="text-orange-500"><strong>- Berk Birand, CEO & co-founder, Fero Labs</strong></span></i></span></p><p><span style="background-color:transparent;color:#000000;">By leveraging </span><a href="https://craft-ferolabs.files.svdcdn.com/production/PDF/Fero-Labs-for-Steelmakers-2024.pdf?dm=1730904249"><span style="background-color:transparent;color:#000000;">Fero Labs' AI-powered software</span></a><span style="background-color:transparent;color:#000000;">, steelmakers are achieving faster and more effective results across their operations, from cost savings and quality improvement to energy efficiency and problem-solving.</span></p></div> <ul class="flex flex-col md:flex-row items-start md:items-center flex-wrap gap-x-5 gap-y-8 mt-5 md:mt-8 justify-left"> <li> <a 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