Zyfra Heat Treatment – ENG

What does it do?

Zyfra Heat Treatment AI assists with and improves planning, technical optimization, real-time operations and analytics. The focus is pipe production for lines with a capacity of 30 000 tons a year and more. 

  • Increases Production Volume
  • Reduces Costs
  • Customer Satisfaction
  • Provides Automation

Advanced Planning & Scheduling

This module provides optimal shift planning, taking into account all current, logged orders, their dates, priority and margin — transition times, supply limitations and delivery logistic limitations.

Instant Re-Scheduling

This provides fully automatic scheduling, data integration, less than 1-minute ‘new plan’ gene- ration and the best new schedule while limiting the number of changes to a minimum.

Real-Time Decision Support System

This system monitors temperatures in the furnaces and sprayer/tub. It can apply suggested furnace section temperature changes and ensure that all pipes in the batch maintain quality despite changes in the furnace state. This means overall quality is improved, both in random tests and in actual product to client

Technology Intelligence

We had equipment fluctuations, how did this affect production? We used new AI-suggested modes, how did it help? A batch failed quality control, how is it different from other batches? We produced 1000 tons more, but what is our margin?

Zyfra Artificial Lift – ENG

What is this for

Zyfra Artificial Lift provides optimal control for ESP via daily recommendations prioritizing the changes to reduce operational costs.

  • Oil production increase
  • Optimal control provides increased oil production while not damaging the field long term
  • Tracking
  • Well shutdown prevention
  • Automatic oil flow calculation and operating mode control
  • Reducing well shutdown risk by optimal & safe control

Features

  • Well true flow rate calculation
  • ESP historical and current mode auto-detection
  • Automatic data cleaning and augmentation
  • Economic effect calculations
  • Optimal ESP controls

Zyfra Production Scheduling – ENG

What is Zyfra Production Scheduling

A set of brand-new IT tools aimed at controlling and improving all relevant production procedures and processes – that means better production problem solving and better production management power for your enterprise.

  • Modelling production processes and resources to solve specific production problems
  • Transforming production data into information relevant to all specialists and managers involved in production
  • End-to-end production chain tracking of the finished product
  • Improving efficiency for technical equipment usage, energy, material, and other production resources

Benefits and Results

In today’s production world it’s all about producing more, faster and cheaper while cutting losses and maintaining quality standards. Zyfra Production Scheduling can help your enterprise with all that and put more control over your operation into your hands and the hands of your specialists, managers and engineers.

It’s all about improving efficiency, constant monitoring and identifying potential problems, before they can interrupt production. Production Scheduling is unique in that it provides a company with various applied solutions, which meet modern business requirements, in a short time and at minimal cost.

  • Reduced equipment downtime by an average of 15%
  • Reduced ‘work in progress’ by 15%
  • Increased service life of fixed assets by an average of 10%
  • Identification of production bottlenecks
  • Reduced costs associated with resource support of production planning processes
  • Increased working capital turnover
  • Reduced production cycle time
  • Improved work culture, motivation, and productivity
  • Increased efficiency and soundness of managerial decision making

Zyfra Mass&Energy Balance – ENG

What is Zyfra Mass&Energy Balance?

A tool which constructs models of the production process based on the movement of materials and energy. These models are used by operating personnel (economist, technologist, power engineer, metrologist) to comply with the production plan and ensure its operational adjustment.

  • Operational control of the choice of technological mode, taking into account the maximum output of target products
  • Timely adjustment of energy consumption to comply with the technological regime (Energy Balance)
  • Data preparation for end-to-end production accounting
  • Status monitoring of the measuring system of production accounting

Why Zyfra Mass&Energy Balance?

This software product combines the functions of a monitoring and measuring system and a mathematical solver, which allows you to control both countable (measurable) flows and calculated ones, taking into account all instrument cluster errors.

If your company suffers from material and energy wastage and you’re having trouble identifying exactly when and where these losses are occurring, Zyfra Mass&Energy Balance is a solution you’re going to want to know more about. Not only can it help you identify your problematic areas, but it can also help solve these issues and reduce losses by up to 60% in the first 3 years. Sounds like something your business can benefit from?

Zyfra Quality Assurance – ENG

Features

A single tool for quality control, at every stage of production. Zyfra Quality Assurance was created using a stack of modern technologies, and so complies with the modern requirements for LIMS class system.

  • Creating a reliable source of data regarding quality at the production site.
  • Improving the integrity and management of laboratory data.
  • Automating of internal laboratory business processes.
  • Improving quality and efficiency of the testing laboratory.
  • Improving the reliability of enterprise data on quality.
  • Integrating of quality related data into a single information space

up to 50% increase in laboratory efficiency

  • Improving quality of laboratory tests
  • Accelerating the receipt of quality related data for the operation
  • Eliminating the “human factor” when working with laboratory data and equipment
  • Simplifying the laboratory accreditation process
  • Improving the efficiency of resources usage (equipment, supplies and personnel).
  • Standardizing and unifying internal laboratory processes
  • Automating the process of generating output documentation (magazines, reports, protocol, passport, etc.)

Zyfra MDCplus – ENG

What is Zyfra MDCplus?

Zyfra MDCplus designed to track equipment, operations, and personnel performance remotely, sending you real-time customizable and downloadable notifications and reports, to evaluate and increase OEE as well as cut down on costs. MDCplus is the ultimate production management upgrade.

Features

  • Real-time machine monitoring
  • Production control
  • Video monitoring
  • Power consumption monitoring
  • API connection
  • Vibration, monitoring and diagnostics
  • DNC communication & NC program management
  • Computerized maintenance

20% increase in your production efficiency

Machine Tool Compatibility

With its automated wireless control, MDCplus is programmed to perform independently of hardware. All it requires is inserting a network cable and selecting one’s settings. Our engineers are constantly developing new and improved communication protocols for industrial monitoring equipment, with the aim resultingin a single information environment, linking CNC machines and robots alike.

Zyfra Industrial IoT Platform – ENG

What is Zyfra IIoT Platform?

A tool built to combine the digital elements of the industrial production process as well as business processes. It provides the possibility for basic automation of technology based processes in support of uninterrupted, continuous production, the creation of applied applications and data preparation for machine learning and artificial intelligence.

  • Creating a single digital layer within the production
  • Combining dissimilar information and automated systems into units
  • Monitoring the technical process as well as notifications of personnel events
  • Creating digital copies and predictive models using AI
  • The collection, storage and analysis of both production and technical data

6% COST REDUCTION MORE THAN 421 BILLION USD* — THE ANNUAL BENEFIT OF COST OPTIMIZATION AND INCREASED EFFICIENCY DUE TO THE TRANSITION TO INDUSTRY

Who is Zyfra IIoT Platform for?

  • IT integrators
  • Technical plant operators
  • Technical engineers
  • Dispatchers
  • Heads of Production Units
  • IT departments

Zyfra Precision Drill – ENG

Key Benefits

  • Increased drill rig productivity through reduced downtime
  • Reduced drilling and blasting costs
  • Increased excavator and mill productivity
  • Elimination of human impact
  • Reduced re-drilling volumes
  • Increased drill rig availability and utilization

Features and Functionality

High Precision Navigation

  • Transmission of drilling project from most vendors’ drill planning system.
  • 10 cm accuracy guidance and targeting assistance of the drill rig to holes without the use of physical control points.
  • Leveling assistance and actual depth calculation according to the bottom line.
  • Automatic data collection regarding the coordinates of actual wells.
  • Compliance with the drilling grid for precise blasting design.

Collecting Drilling Parameters

  • Drilling depth
  • Drilling speed (linear)
  • Axial pressure on the tool
  • Rotation speed of the drilling tool
  • Angle of the drill string
  • Currents and voltages
  • Oil pressure / air pressure
  • Drilling time

Production KPI’s Calculation

  • Monitoring of production operations and downtime.
  • Monitoring of drill rig fuel consumption.
  • Calculation of drill rig and operator performance.

Drilling Tool Usage Accounting (CONSUMABLES)

  • Cone consumption accounting corresponding to the particular drilling site and number of drilled wells.
  • Correlation between the consumption of cones and the rock density / quality of the operator’s work.

Zyfra Safety- ENG

Key Benefits

  • Reduced injury frequency rate
  • Reduced number of recurring violations
  • Improved quality of operational management
  • Reduced inspection related costs and penalties

Features and Functionality

Shift Management Automation (Up To 100% Compliance With Compulsory Procedures)

  • Control of arrival at work
  • Medical inspection
  • Competence control
  • Formation, approval of tasks, admissions — including contractors
  • Qualification control, training
  • Automatic formation of teams for complex or dangerous work, taking into account the rating / competence of personnel
  • Risk evaluation
  • Task assignment
  • Control of work performance, registration of violations, implementation of restrictions, operational changes of tasks when necessary
  • Shift acceptance
  • Report creation, including shift-day reports
  • Safe completion of shift

Deep Analytics

  • Real-time data monitoring by personnel.
  • Mapping – a map display of places with existing violations and a survey of workers in these zones.
  • Monitoring of personnel productivity.
  • Detailed analysis and risk assessment.
  • Automated reporting related to industrial safety, including the generation of xml files for government agencies.

Deep Integration

  • Integration with business processes of the enterprise (planning, accounting, etc.).
  • Integration with the existing IT environment of the enterprise (AUTOMATED SYSTEMS SUCH AS FMS, ERP, MES).

Mobile Solution

  • Mobile application for employees – instantaneous display of security risks in the system.

Electronic Digital Signature

  • Eliminates paper routine task load
  • Transparency of task assignment

Zyfra Undergound – ENG

Key Benefits

  • Increase of productivity
  • Reduction of expenses
  • Reduce adverse human impact
  • Increase of safety
  • Improve decision making

Onboard Equipment

A complete set of onboard equipment and sensors to improve safety of your underground mine and reduce the human factor’s impact. Ready for integration with any installed geological & mining informational systems

Features and functionality

Integration With Any Installed Geological & Mining Informational System (ERP, EAM)

Collecting data regarding:

  • Shift plan and plan corrections
  • Ore flow guidelines
  • Map of the mine
  • Geological information

Provide:

  • Production statistics
  • KPI of the mine, equipment and employees

Real-Time Production Statistics and Reporting

  • Transfer of task assignment to the on-board computer (tonnage, number of rock mass buckets, loading and unloading locations) and assignment execution control.
  • Automatic calculation of mining equipment cycles and idles.
  • Control and management of mining processes and transportation based on automatically collected KPIs (plan&fact ratio, idles, productivity, etc.).
  • Equipment operation analysis for different reporting periods.
  • Cumulative statistics on the quantity and quality of transported rock mass, with the possibility of aggregation by operator, unit of equipment, production and/or ore discharge.

Ore Flow Control

  • Visualization of ore movement (volume and quality) from active face to mill.
  • Accounting of ore reserves in active faces and chutes.
  • Includes transportation operations by LHD, underground trucks, skip hoists and conveyors.
  • Can include weight, volume and quality measure systems.

Analysis of Operator Performance

  • Operator performance analysis based on different criteria set together with Customers.
  • Providing each operator’s performance results to the Customer’s HR department for further training programs.

Dynamic Optimization

  • Allows for the distribution of LHD and underground trucks along routes in an open cycle, in accordance with the multi-criteria optimization approach.
  • Optimization of changes, lunches and refueling.

Tire Management

  • Monitoring technical characteristics (pressure and temperature) of installed tires.
  • Accounting of mileage and technical condition of tires.
  • Accounting of installation, reinstallation, removal and disposal of tires.
  • Operation control of units and assemblies; the use of tires.