Services
Consulting for rolling plants and mill builders
I work with plants to raise quality, yield and throughput, and with OEMs to set up and prove out mill control and process strategies.
Areas
Strip profile and flatness
Crown, wedge and flatness targets met through better use of bending, shifting, roll grinding and thermal camber.
- Actuator strategy and set-up review
- Offline flatness control strategies
- Root cause of buckles, quarter waves and edge defects
Gauge and mill control
Built on 15 years designing and tuning rolling mill control systems.
- Model-based mill set-up and pass schedules
- Feed-forward, cascade and Smith predictor control
- Control loop tuning and performance audits
Strip measurement
Getting reliable measurements of the things that matter for downstream customers.
- Surface quality inspection and control
- Strip temperature measurement and control
- Camber measurement and correction
Quality, yield and productivity
Structured improvement work that pays for itself in tonnes and recovery.
- Statistical process control and data analysis
- Speed and uptime improvement projects
- Quality systems, including IATF 16949
Mill mechanics and modelling
Physics-based analysis of the roll stack and roll bite to answer questions the plant data cannot.
- Roll stack deflection and contact pressure
- Hertzian flattening and roll gap crown
- Bite mechanics, forward slip and neutral point
Support for OEMs
Independent process expertise for mill builders during design, commissioning and acceptance.
- Process input to control system design
- Commissioning and performance testing
- Customer training at hand-over