Country: Austria

Solution

qontrol steelmaking

Short Desription

In this project, qoncept started the implementation of its qontrol maps software in a foundry. The introduction began as an off-line solution for charge optimization and was gradually expanded with coupling to SAP and the full integration of the scrap yard. The cost-optimized charge calculation generated measurable savings, which supported the further rollout of the software integration.

Building on this foundation, the system was extended to cover the EAF, two induction furnaces (IF), an AOD, and the casting shop. With seamless integration into the IT landscape, the solution combines office applications for product definitions, order planning, charge preparation, production overview, and reporting with shop floor applications for real-time process monitoring and operator interaction.

At the process control level, the software ensures process data acquisition, heat and material tracking, real-time monitoring of metallurgical operations, and dynamic setpoint control. By linking advanced metallurgical models with practical operator guidance, the system standardizes process know-how, ensures secure material supply, and improves resource efficiency across the foundry’s value chain.

Solution

qontrol customized

Short Desription

In this project, qoncept implemented a software system to seamlessly integrate the final processing of flat steel into the customer’s IT landscape. The system, based on the qontrol framework, covers the complete workflow from order preparation to pallet handling and ensures reliable monitoring and control of all production steps.

At Level 2, the solution provides real-time process monitoring and control. It records and processes cyclical data and events, transmits setpoints to Level 1.5 systems, and observes production steps through an integrated camera system. Downtime and error tracking are managed in real time, while live production status updates provide operators with full transparency across all units.

At the MES level, the software enables structured production management and data integration. Functions include master data management of products, materials, storage locations, equipment, and manufacturing specifications. Orders received from the ERP system are prepared, sequenced, and released for production through fine planning. Product and material tracking, combined with reporting interfaces for external systems, ensures end-to-end traceability and operational efficiency.

With its modular design and deep IT integration, the solution establishes a digital backbone for the final processing of flat steel, supporting optimized workflows, consistent data flows, and improved production reliability.

Solution

qontrol MES

Short Description

At a leading Austrian steel producer, qoncept implemented a new software system to replace paper-based workflows in the finishing area. Building on a comprehensive requirement specification previously defined by qoncept, the system digitally maps and controls all processes from order intake to final delivery.

The solution integrates both Level 2 and MES functionalities. At process level, it captures and processes real-time data, provides online system monitoring, and enables direct process control. At the MES level, it manages master data, production planning and sequencing, material and product tracking, as well as quality assurance and reporting. Advanced analytics, KPI monitoring, and downtime tracking support continuous improvement and greater operational transparency.

With its modular architecture and seamless integration into the existing IT landscape, the system ensures full product traceability, higher efficiency, and a solid digital foundation for future expansions in the finishing area.

Solution

qurve

Short Desription

In this project, qoncept delivered a fully integrated and automated solution for tracking and optimizing the scrap handling and charging process in an electric arc furnace (EAF) steel plant. Together with our customer, we implemented a system that captures all material movements from the arrival of scrap at the plant to its final charging into the EAF.

At the core of this solution is qurve: our intelligent sensor/camera system purpose-built for steel plant environments. It integrates high-performance imaging, embedded software for real-time analysis, and robust mechanical design including cooling and protective housing to ensure reliable operation under extreme conditions. Multiple qurve units were strategically installed at key points in the process to achieve the following objectives:

  • Detection of the number and position of incoming scrap railway wagons
  • Precise localization of both scrap charging cranes using a unique camera-based positioning method

By integrating data from all qurve sensors with additional signals from the scrap charging cranes and scrap bucket transfer cars, we enabled complete tracking and real-time reporting of all scrap charging operations.

This fully automated solution allowed the customer to (1) gain full transparency into the scrap handling process, (2) optimize the performance and control of the EAF and (3) improve scrap logistics and supply chain management.

Focus Area

  • Strategic Metallurgy & Process Development

Short Description

For this project, qoncept provided strategic and technical consulting to support the production of ferrovanadium from vanadium-rich steelmaking slag. Since the raw material must meet strict chemical requirements, the project focused on developing the metallurgical and operational know-how required to identify and qualify suitable slag sources. In addition to technical expertise, qoncept supported the client in research activities, supplier engagement, and the preparation of technically sound business plans. The work included direct discussions with potential steel producers to evaluate collaboration opportunities and ensure supply chain feasibility.

Focus Area

  • Strategic Metallurgy & Process Development 

Short Description

In this study, qoncept conducted an on-site assessment of the ladle management practices at a steel foundry, with a specific focus on the ladle preheating process. The scope included recording and analyzing the current condition during production and jointly defining the desired state in collaboration with plant personnel. Based on these findings, the energy consumption and associated costs for ladle preheating were quantified and evaluated in relation to their impact on liquid steel temperature control. Potential areas for technological improvement were identified, and the resulting energy savings were estimated. The study concluded with an ROI-based analysis to support decision-making regarding possible upgrades or replacement of the current preheating technology.

Focus Area

  • Requirements Engineering and Management 

Short Description

This project focused on defining the functional requirements for a tailored software solution to support and manage complex melting and casting operations in a foundry setting. The scope included multi-route production with induction furnaces, coordinated partial tapping, ladle tracking, and alloy-specific treatment logic. In addition to process management, the specification addressed production planning, recipe handling, material and equipment tracking, and real-time integration with MES and ERP systems. The result is a modular, scalable specification designed to improve production transparency, consistency, and metallurgical control across the entire casting workflow.

Focus Area

  • Validation, Testing and Quality Assurance

Short Description

This project focused on supporting the test planning and functional evaluation of software systems in a highly automated ingot casting environment. The aim was to validate the integration between various Level 2 systems involved in logistics, casting, and upstream meltshop coordination. qoncept proposed a structured testing strategy including the definition of test scenarios and test cases, execution of functional tests, and documentation of results. By comparing implemented features with the original specifications, the goal was to assess the system’s readiness for commissioning and ensure stable operation in one of the most complex digital casting environments in the industry.

Focus Area

  • Digitalization Strategy and Roadmapping

Short Description

In this project, qoncept developed a structured digitalization roadmap for a specialized manufacturing company as part of the Green Tech TopRunner Program. Over eight on-site workshops, the team assessed the current state of both office and shop floor processes and identified potential for digital transformation. Two strategic approaches were evaluated in detail: a modular open-source ERP system combined with track-and-trace solutions, and a fully integrated single-source software system. Based on these scenarios, concrete functional requirements were derived, including planning, dispatching, material tracking, equipment management, downtime recording, and digital work instructions. The resulting roadmap supports a step-by-step transformation aligned with the company’s agile and customer-driven operations model.

Focus Area

  • Requirements Engineering and Management
  • Wireframing and UI/UX Concepts

Short Description

In this project, qoncept supported the development of a comprehensive requirements specification for a modular software system aimed at optimizing the production of FeNiMo, FeV, and Calumet® for a European alloy producer. Based on several on-site workshops, the focus was placed on the most time- and energy-intensive stage of the smelting process: Stage 1 of the smelting operation. The scope included defining functional and non-functional requirements for process monitoring, control, and optimization in detail. This included metallurgical modeling, campaign planning, traceability, and advanced reporting. The system was designed to seamlessly integrate with existing Level 1 and ERP systems, providing a future-ready platform for scaling to subsequent process stages.