Product or Service: Digitalization

Focus Area

  • Requirements Engineering and Management
  • Scrap Yard Management and Charge Design
  • Strategic Metallurgy & Process Development

Short Description

As part of this feasibility study, we analyze the existing production and quality data of the aluminium melting operation at the client with the aim of evaluating the potential for data-driven raw material optimization. The study includes in particular:

  • an on-site visit to assess the local production conditions;
  • an evaluation of the data basis with regard to completeness, consistency, and suitability for model development;
  • an analysis of historical production data (e.g. scrap quantities, melting parameters, chemical analyses) in order to identify relevant correlations between scrap usage and melt quality;
  • the development of a concept to determine whether, and in what form, a raw material optimization software solution (or a customer-specific adapted version) can be applied to this process;
  • an assessment of the economic potential, for example through the reduction of impurities, minimization of primary aluminium usage, and optimized scrap planning.

Special attention is given to the possibility of retrospectively evaluating scrap qualities on the basis of the available process and analysis data, in order to enable a more targeted use of critical scrap grades in the future. With the objective of reducing the existing production complexity (multiple parallel production lines, melting furnaces, holding furnaces), this study is focused on only one production line, consisting of one shredder plant and one melting furnace, in order to assess the general feasibility.

The result of the feasibility study is a final report containing an evaluation of the technical and economic feasibility of implementing an individual raw material optimization software solution for the operation at the customer.

Focus Area

  • Requirements Engineering and Management
  • Conceptual Software Engineering
  • Digitalization Strategy and Roadmapping

Short Description

The client plans to increase the level of digitisation in its operations, requiring full transparency and traceability across all relevant business and production processes. In order to define all requirements of a suitable software system, an assessment of the current production processes and IT infrastructure together with the key stakeholders of the client was performed. Based on the resulting requirement specification document, the client is able to make educated desicions on how to proceed in terms of relevant software solutions and implementation strategies. 

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.

Focus Area

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

Short Description

In this requirement engineering project, qoncept developed a mockup-driven concept for software-based production control in copper electrolysis. Through on-site workshops with plant stakeholders, the team analyzed core process requirements and translated them into interactive interface prototypes. The solution was designed to support digital tracking of cell-level parameters, electrolyte composition, material usage, and batch-specific treatment steps. The resulting mockups illustrated how a future software system could structure production planning, resource management, and process monitoring directly at the shop floor, while enabling knowledge-based process standardization and improved operational transparency.

Focus Area

  • Requirements Engineering and Management
  • Conceptual Software Engineering

Short Description

As part of a strategic digitalization initiative at a leading Austrian steel producer, qoncept was tasked with defining a comprehensive set of functional and non-functional requirements for a new software system. The system aims to digitally map and control all processes within the finishing area, from order intake to final delivery. The project focused on building a detailed requirement specification covering all aspects of production tracking, planning, equipment monitoring, and quality assurance. In addition, qoncept structured the logic for product-level traceability, system interfaces, and real-time data capture. The result was a future-proof requirement specification that enables modular development and seamless integration into the plant’s IT architecture.

Focus Area

  • Requirements Engineering and Management
  • Conceptual Software Engineering

Short Description

As part of a strategic modernization initiative, qoncept developed a detailed requirements specification for a Level 2/3 software system to digitalize and optimize melting and casting operations in a foundry environment. The specification was the result of several on-site workshops and defined all functional and non-functional requirements related to charge tracking, process parameter recording, quality data management, energy and raw material consumption monitoring, and casting documentation. A modular architecture was proposed to ensure seamless integration with existing ERP systems and to support long-term scalability. This foundational document enabled structured vendor engagement and served as a blueprint for digital transformation.

Focus Area

  • Digitalization Strategy and Roadmapping

Short Description

As part of an international workshop with participants from multiple countries, qoncept delivered a keynote impulse on the strategic and technological dimensions of industrial digitalization. The session addressed the shift from knowledge to capability-based value creation and explored how modern manufacturing environments benefit from hybrid modeling approaches combining physics-based and data-driven elements. Using examples from the steel industry, the presentation illustrated the role of digital twins, real-time process modeling, and intelligent systems in enabling traceability, optimization, and competitive advantage. The impulse sparked discussion on how companies can actively shape their role within Industry 4.0 ecosystems.