Digitalisation and Innovation in the Steel Industry in Poland—Selected Tools of ICT in an Analysis of Statistical Data and a Case Study
Abstract
:1. Introduction
2. Literature Review about Digitalisation in the Steel Industry
- -
- Legacy equipment;
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- Uncertainty about the impact of digitisation on jobs;
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- Issues connected with data protection and safety.
- Problems with the integration of new processes and technologies with site workers, which is especially important in the case of older employees;
- Big gaps between workers which are now employed and the prospective employees in the case of knowledge transfer;
- Lack of investment in education and training from steelmaking companies as well as an insufficient number of others types of training provided by companies.
3. Materials and Methods
- Cloud computing refers to ICT services that are used over the Internet (Virtual Private Networks (VPN) connections are also included) to access software, use certain computing power and store data.
- A broadband connection is a type of connection characterised by a high speed of information flow, measured in Mb/s (megabits per second). Broadband access is enabled by, among others: DSL family technologies (ADSL, SDSL, etc.), cable TV networks (cable modem), satellite connections and wireless connections via a modem or a 3G phone.
- Mobile Internet connection is a type of connection of mobile devices connected to the Internet via mobile telecommunications networks for business purposes.
- Information systems—use of ERP and CRM.
- Innovativeness—enterprises innovating within the scope of product innovations and business processes in the industry for the last 3 years in the field of metal production, as well as enterprises which introduced new or improved products or business processes: in total, with 50–249 employees or with 250 and more employees, new or improved products and new or significantly improved business processes (in % of the total number of enterprises).
- Sources of financing of outlays (in PLN million): own; acquired from abroad; credits, loans and other financial liabilities from financial institutions; national, from institutions disposing of public funds.
- Share of the net revenue from sales of new or improved products of the net revenue from sales in industry in the division of metal production: products—in percentage—introduced to the market in the last 3 years.
4. Background for the Analysis
4.1. The Steel Industry in Poland
4.2. Digitalisation in the Steel industry in Poland
- Low production scale, which translates into no need to introduce processes related to robotisation;
- A specific production profile where robots are not needed;
- Not taking into account robotisation in the company’s development plans;
- Financial barriers;
- No need to develop production processes.
4.3. Digitisation in Steelworks—A Case Study of the Corporation ArcelorMittal Poland
5. Steel Digitalisation in Statistics
Results of Analysis
6. Discussion and Conclusions
- The level of digitalisation of the steel sector in Poland is differentiated in terms of the use of particular ICT tools in enterprises and is as follows: the share of enterprises having computers is almost 100%, while 98.5% of the Polish steel enterprises are Internet users, of which 92% are broadband Internet users and 59.5% of the researched enterprises are mobile Internet users;
- Cloud computing—the purchase of this service by steel companies is small because it is a new ICT tool; 12.6% of metallurgical users have been reported to use it so far;
- ERP and CRM are popular information systems; these systems are installed in every third company (metallurgical companies also use SAP systems);
- The relation of digitalisation to innovation is 2 to 1;
- Investments in the steel industry in Poland are financed mainly from the companies’ own resources (86% share of the total financial sources).
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Acknowledgments
Conflicts of Interest
Abbreviations
ADSL | Asymmetric Digital Subscriber Line |
AI | Artificial Intelligence |
AMP | ArcelorMittal Poland |
BF | Blast Furnace |
BFN | Blast Furnace Network |
BOF | Basic Oxygen Furnace |
CAx | Computer Aided |
CMC | Commercial Metals Company |
CPPS | Cyber Physical Production Systems |
CRM | Customer Relationship Management |
DSL | Digital Subscriber Line |
DTC | Dynamic Capability Theory |
EC | European Commission |
ERP | Enterprise Resource Planning |
FP7 | Seventh Framework Programme |
GDP | Gross Domestic Product |
GUS | Głowny Urząd Statystyczny—Statistics Poland |
HIPH | Hutnicza Izba Przemysłowo-Handlowa—Polish steel Industry |
IC | Information and Communication |
ICT | Information and Communication Technologies |
ID | Identification number |
IoT | Internet of things |
IT | Information Technology |
KET | Key Enabling Technologies |
KPI | Key Performance Indicator |
LCA | Life Cycle Assessment |
LED | Light-emitting diode |
M2M | Machine to Machine |
MES | Manufacturing Execution System |
ML | Machine Learning |
MRP | Material Requirements Planning |
MRP II | Manufacturing Resource Planning |
PLN | Polish Zloty |
PUDS | Polska Unia Dystrybutorów Stali—Polish Union of Steel Distributors |
QR | Quick Response |
RFCS | Research Fund for Coal and Steel |
RFID | Radio Frequency Identification |
SAP | Systems, Applications and Products in Data Processing |
SDSL | Symmetric Digital Subscriber Line |
SR | Social Responsibility |
VPN | Virtual private network |
WCM | World Class Manufacturing |
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Technology | Characteristic |
---|---|
Internet of Things | Internet of Things in the steel industry refers to the use of many electronic devices and an inter-networking work environment. Steel industry organisations use sensors, actuators and other types of digital devices, which are networked and connected between themselves with the main purpose of implementing a system based on an Internet of Things architecture. This type of system consists of four layers: network, sensing, application and service resource layers. This type of system was implemented in many real steel casting production lines [76,81]. |
Big data analysis | In the steel industry, the conventional way of managing the data can have nowadays some difficulties in the process of finishing the storage, capture, analysis and management of large volumes of structured and unstructured data. The new method of big data analysis is related to new algorithms based on historical data, which can be used to identify quality problems and for reducing the failure of products. In the steel industry sector, the big data solutions are used in many organisation for monitoring the quality of the products. The technology can enable new processing modes to obtain significant, new information from different data types. In this way, we can understand the data in-depth and make better decisions on the basis of them [76]. |
Cloud computing | Cloud computing use in the steel industry give on-demand computing services. Those type of services have a high level of reliability, scalability and availability in a steel industry environment. Using this technology, all data can be treated as a service [82]. |
Robotisation of production processes | The use of technology based on the use of humanoids in the steel industry in order to perform operations is especially important in the field of assembly and packaging. It is widespread due to the higher demand for better quality, faster delivery time and the reduction of cost in the steel industry. In many organisations with business activities in the steel industry, the use of robots leads to an increase of the surface quality of the steel products and minor improvements of the whole production process [76,83]. |
Simulations | Organisations in steel sectors can use new technology to try doing simulations to find a way to optimise the production processes. For example, decision support systems are used in the steel industry to investigate the potential changes in design operations. The simulations use many statistical and mathematical methods [84]. |
Augmented reality | Organisations in the steel industry are using the digital solution in augmented work, maintenance and service. In the steel industry, organisations are using remote guidance to apply the fourth dimension. This technology usage can enable steel industry companies to improve the level of the maintenance services. Those organisations use remote maintenance equipment based on a remote connection used by technicians virtually connected to the system. The usage of augmented reality can result in decreasing travel costs and operation times. Additionally, this technology solves problems more quickly [76,85]. |
Cyber security | Cyber security is an important problem for organisations in the steel industry. The technology is especially important for Internet-based services and in every situation when computers or equipment are connected to the Internet. With the increase of Internet of Things usage, almost all equipment can be connected to the Internet, which leads to an increased role of cyber security in organisations [86]. |
Customisation and personalisation of production | Among steel industry organisations, we can spot an increasing number of vertical integration usage. This leads to an improvement of communication between the supplier and the organisation and also the organisation and its customer. The online connection between them and the faster data transfer can enable an intelligent factory solution as well as personalised customer manufacturing [87]. |
Drones and others self-driving vehicles | The steel industry can also benefit from drone usage, especially in logistic processes. This type of technology is based on automated systems of transportation. Intelligent software is used to support the operation of drones and helps steel industry companies to improve processes and make them much faster. In the steel industry, the logistics (supply, disposal and transport of products and raw materials) are a very important part of the industrial processes. The usage of drones and others autonomous self-driving vehicles can lead to better planning and controlling of the internal transport orders. The result of this is an increase of the service and productivity level and a decrease of the costs of logistic processes [76,88]. |
Knowledge management system | In a competitive market, the knowledge management can also be digitalised in the steel industry. The knowledge and experience of the workers—especially technical staff—can represent the basis for improvement. In the steel industry, we spot problems in the distribution of this knowledge. Especially older workers do not have enough digital competencies and should learn from more experienced staff. On the other hand, older technical workers have excellent knowledge about production processes. This knowledge should be digitalised and handed over to younger workers. The digital system of knowledge management usage can enable a better distribution of knowledge between workers within the steel industry organisation as a whole [89,90]. |
Modules | Characteristic |
---|---|
Vizum Workforce | The system is used for vehicle monitoring. The Optitrack system allows for the fully automatic recording of every entry and exit, monitoring of attendance and time spent in them and checking the employee’s reaction to random tests. At the end of the day, an automatic report will show any irregularities identified (e.g., lateness, too long breaks or absenteeism). The Opitrack system is used to detect any potentially dangerous situations, such as falls, fainting, changes in environmental conditions (temperature) or staying too long in certain areas of the site. The Optitrack system allows for a continuous survey of the safety status of people present on site and their knowledge of health and safety. Employees walk around equipped with unattended Vizum ID cards and/or a mobile app on a smartphone. Vizum ID cards are automatically detected by checkpoints. Employees can also reflect and assign themselves to projects on touchscreens. Mobile applications on smartphones send data non-stop from any location. In one panel, you can see the current situation of the entire workforce in individual plants. Summaries and detailed periodical reports of individual employees are updated every hour. |
Vizum Vehicles | The system is used for vehicle monitoring. The Opitrack system enables continuous tracking of location and work of vehicles both in open spaces (field trips) and in closed spaces (warehouses, garages). The Optitrack Vehicles system, besides recording the location and working time, also collects information about the vehicle operator and passengers [114]. The vehicles are equipped with VizumBox devices, whose sensors continuously monitor the immediate surroundings. Maintenance-free and non-invasive so-called position markers are installed in confined spaces. VizumBox devices collect data from motion sensors, GPS data and information about detected position markers in confined spaces and detected Vizum ID cards worn by employees. All data are sent to the cloud. The current status of the entire fleet can be viewed in a single administration panel. Summaries of periodical reports and detailed reports of all vehicles are updated every hour [115]. |
Investments in Digitalisation | Effects |
---|---|
Introduction of a video-based image processing system to analyse converter vibration in the production line [91]. | Better analysis of the vibration—improvement of the production process [91]. |
3D visualisation of the hall [91]. | Better work planning and optimisation of the production area layout [92]. |
The use of drones to observe the areas around the steelworks and belonging to the steelworks [92]. | Better and faster identification of problems in the production line. Improvement of production processes [93]. Allows monitoring of observation areas that are too dangerous to be inspected by humans [91]. |
An IT system for digital product location in warehouses [92]. | Faster identification of products in the warehouse. Faster delivery of the products to production or to the customer [92]. |
The logistic system to monitor the movement of cars on the road and in the car parks of the mill [92]. | Better control over the usage of vehicles. The reduction of the downtime of vehicles [92]. |
The usage of mobile equipment by employees in the steel mill [91]. | Possibility of doing inspections and many others activities remotely. The automatic integration of the scanned information with the organisation’s SAP system [91]. |
Rail production tracking system in the Dabrowa Gornicza mill [91]. | The system allows better identification and monitoring of products. Optimisation of logistic and production processes [91]. |
The system for measuring the filling of the coking chamber after backfilling with a coal mixture [91]. | The optimisation chamber backfilling operations. Reduction of the negative environmental impact of the production process [92]. |
The AMP IT system used for the detection of defects [91]. | Decrease in the number of defects. Better product quality and better customer satisfaction [86]. |
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Gajdzik, B.; Wolniak, R. Digitalisation and Innovation in the Steel Industry in Poland—Selected Tools of ICT in an Analysis of Statistical Data and a Case Study. Energies 2021, 14, 3034. https://doi.org/10.3390/en14113034
Gajdzik B, Wolniak R. Digitalisation and Innovation in the Steel Industry in Poland—Selected Tools of ICT in an Analysis of Statistical Data and a Case Study. Energies. 2021; 14(11):3034. https://doi.org/10.3390/en14113034
Chicago/Turabian StyleGajdzik, Bożena, and Radosław Wolniak. 2021. "Digitalisation and Innovation in the Steel Industry in Poland—Selected Tools of ICT in an Analysis of Statistical Data and a Case Study" Energies 14, no. 11: 3034. https://doi.org/10.3390/en14113034
APA StyleGajdzik, B., & Wolniak, R. (2021). Digitalisation and Innovation in the Steel Industry in Poland—Selected Tools of ICT in an Analysis of Statistical Data and a Case Study. Energies, 14(11), 3034. https://doi.org/10.3390/en14113034