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Combinatorial optimization of steel galvanizing
Client
NDA
industry
Metallurgical production
Business process
Feeding of steel billets into a continuous hot-dip galvanizing unit

Estimation of optimal sequence of feeding steel coils to the continuous hot-dip galvanizing machine. This case demonstrates that quantum algorithms work successfully even without quantum computers.

Main Problem

The coils to be fed into the galvanizer have different geometry and the finished product has to have different coating thickness and a variety of other parameters, depending on the batch and each individual customer. As a result, reconfiguration of the machine is often required during the transition from one coil to another, and sometimes so-called «transitional» coils from the stock storage are used to achieve a smooth transition from one coil to another. The more such operations occur, the less efficient the line is.

 

Additional Factors and Limitations

 

 

The output has different coating thickness and other parameters that are tuned for each customer individually;

 

Incoming coils have different geometry;

 

During one shift one machine can process from 30 up to 100 coils. 

 

Search algorithm

To solve this case QuSolve used the Hamiltonian path quantum algorithm simulated on a classical computer. This algorithm can be used for a wide range of manufacturing and business tasks: optimal path search, vehicle loading schemes, job shop scheduling.

 

graph reflecting the costs of transitions between all shift rolls
graph of the optimal sequence of rolls with transition costs (36 rolls per shift)
the optimal solution was found in 20,000 iterations
Software Implementation

This solution doesn't require any special computing equipment, therefore, takes a short time to implement. 

 

The outcome

Two-fold reduction of coil transition costs compared to the Ant colony algorithm, which in turn is 4-5 times more effective than a conventional greedy algorithm. Also the computing time was reduced by almost a hundred times – just around 1 second for a batch of 40 coils on a desktop computer.

 

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Optimization of Railway logistics of a Steel Mill
Client
Steel Mill
industry
Metallurgical production
Business process
Loading of slabs into wagons for railway transportation

Optimal slabs loading system that reduces the number of railway carriages required for transportation.

Main problem

Minimize the cost of freight, taking into account the difference in freight rates for various carriage types and destinations, batch discounts and business limitations. 

 

Additional factors and limitations

Сarrying capacity, geometry, serviceability and availability of carriages for each destination;

Forwarder’s technical conditions that take into account absolute and relative weight constraints, geometry, mutual placement of slabs and centering limitations which results in 174 available loading schemes.

 

Party FormationModeling the State SpaceInitial ApproximationFinding the Optimal Solution

(state = acceptable combination of slabs in a certain type of wagon)

Software implementation

Software is integrated into the customer's ERP system, has an intuitive web interface for loading scheme visualization. Implementation time estimate starts at 7 days.

 

Software testing

 

 

Testing period: 15.03.21 – 16.03.22

 

Batches: 6 964

 

Carriages: 93 695

 

Outcome

 

 

Annual savings on freight – 5,1%

 

Transportation cost was cut for 87% of batches

 

NPV - 2,4 billion rubles.

 

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