Metallurgical additives for steelmaking

Challenges

As a producer of metallurgical additives for steelmaking, many manufacturers face the challenge of mixing various raw materials to create blends that meet specific client requirements. Historically, this was done through complex and manual Excel workflows, which could take several days each month to complete.

Outcomes

To address this, manufacturers have turned to mathematical optimization models, solving constraints using tools like Gurobi. These models have helped streamline the production process, leading to significant time savings—reducing a process that once took days to mere minutes. In one case, this optimization resulted in annual savings of approximately $1.5 million.

Insights

The adoption of data analytics in manufacturing is gaining traction, but many companies struggle to know where to begin. With a variety of technologies available, finding the right approach can be daunting. Analytics consultants and optimization tools play a crucial role in guiding companies through this transformation, helping them maximize the value of their data and technology investments.

By integrating optimization solutions, even small- and medium-sized businesses can address specific needs without the need for extensive infrastructure, like data warehouses or predictive models. This approach has been particularly beneficial for companies seeking more efficient operations and better decision-making.

Simplifying Complex Workflows

Manufacturers that blend raw materials often rely on complex systems that are not widely understood by staff. This creates a need for simpler, more user-friendly solutions. Optimization models allow companies to automate and streamline processes, making them easier to manage and more accessible to a broader team.

Spreading the Benefits of Optimization

Optimization is often seen as a tool reserved for large corporations with advanced technical infrastructures. However, many smaller companies can benefit from optimization without needing all the advanced tools in place. By focusing on practical, real-world problems, optimization solutions can help businesses of all sizes improve their processes and save valuable time and resources.

Saving Time with Optimization

With the use of optimization tools, companies have significantly reduced the time spent on creating production models. What once took days can now be completed in minutes, resulting in both time and cost savings. In some cases, this has led to financial benefits of $1.5 million annually.

The adoption of these user-friendly solutions has made it easier for companies to incorporate optimization into their operations, even for employees without technical expertise.

Continuous Improvement

The benefits of mathematical optimization extend beyond immediate cost and time savings. Continuous improvements and support from tool providers ensure that companies can stay ahead in their optimization journey, solving increasingly complex challenges and driving value across their operations.