Cogniplant project to increase plant efficiency through advanced hierarchical monitoring and supervisory control

Alongside 3 other SPIRE (Sustainable Process Industry through Resource and Energy Efficiency) companies Aceralava will act as a demo plant for the application of advanced analytics and cognitive reasoning to improve industrial processes. The initiative sets out the following general goals:

  • Increase operational performance, by up to 68%
  • 65% greater efficiency in Quality Control processes
  • 70% reduction in response time to uncontrolled incidents
  • CO2 reduction of up to 20%

Data from the plant’s sensory equipment will be collected and consolidated to form a digital overview of energy and resource use. The subsequent data analysis will allow the proposal of optimized operating plans, which can be tested and compared with normal operations using a Digital Twin model and a real-time reactive scheduling tool.

The conclusions of the project will then be transformed into a training program, to share outcomes and solutions with other SPIRE members.

The Cogniplant consortium is made up of 15 organizations, including universities, research centers, and software and data specialists.

As part of the kick-off activities a team of project members from Technische Universität München, Savvy Data Systems and IDEKO visited the plant in January to view the facilities and establish KPIs. Specific goals for the for the Aceralava plant, expected 5 years after beginning the project, include a 25% reduction in energy consumption and an 18% reduction in CO2 emissions.

TUBACEX, Recognition for this Efforts in Training Young People

The team of instructors from TTI, ACERÁLAVA ,TTA and Tubacex Innovation, all of which are companies and areas within the TUBACEX Group located in Basque Country/Spain, has been recognised by Basque Business Confederation (Confebask) for its efforts in the training of young people.

In the public act held last November, the work of TUBACEX was highlighted and more specifically that of
the team of instructors for its active participation in the implementation of placement processes, collaborating effectively in the education of Vocational Training students. In this way,at the suggestion of
the Vocational Training centers participating in the TUBACEX programs (Zaraobe and Llodio) and thanks to
decision of SEA entrepreneurs of Alava ,Tubacex commitment to quality training has been recognized, whereby this training is in line with the company´s values and adapted to its needs in this stage of transformation, increasing its competitiveness as well as professional and occupational development of these young people.

The Tubacex instructors participate actively in the training of 55 students who are on the dual training
programs promoted by the company worldwide. More specifically, on the “Preventive Maintenance “and the “Extrusion, Rolling and Forging” programs, which were launched in 2016 and 2017 respectively .They are four-year academic programs in which 75% takes place at work centers and which include a year of international experience at any of the Tubacex plants as a differential aspect. These programs have been promoted through the Tubacex Foundation, whose lines of work include fostering training though dual training programs in collaboration with public institutions, national grant programs and international grants to be developed at the Tubacex plants in USA, Italy Austria or Thailand.

Aceralava and Tubacex Catalogs

For additional information and an in-depth view of Aceralava and our parent company, Tubacex, please review our company catalog.

ACERALAVA is a wholly owned subsidiary of TUBACEX GROUP, one of the leading producers of seamless stainless steel tubing products in the world. This offers the benefits of a well-respected and solid international corporation with sales offices throughout the world, as well as an integrated source for materials from start to finish.

Download Aceralava’s entire company catalog here.