Raw materials and production cost optimization for Metals industry

Reduce your raw material costs by up to 4%.*

Make your decision process more responsive. Optimize your model with new conditions in a few seconds.

Customized model for each production unit.

Optimize global objective by integrating decisions between departments.

*Data based on the average result of previous projects.

Data and Mathematical Model

The process is represented by a customized mathematical model made by theoretical equations and empirical relations based on historical production data. The model integrates thermal, chemical and mass balances, physical quality of materials, and environmental restrictions in all production processes.

All costs are considered and will be balanced across the whole production chain. In that way, trade-offs between cheap materials and increase of production cost due to their quality will be optimized, aiming to the minimum production cost of the final products.

Payback in a few months

One of the fastest payback in the software industry. Based on previous projects,
we estimate recurrent savings of up to 4% of material cost.

Optimize your value chain

A lower-cost final product does not always result from lower-cost products throughout its production. Determine the right quality for your intermediate products

Determine the value in use of your materials

Buy raw material at the ideal price to be paid. This price varies with the quality of the material and the impact it has on the cost of production.

Optimize your material consumption

Raw materials' purchase constitutes an important part of the total production cost. Any related decision is hence very strategic. Select your suppliers and determine the right quantity to buy considering the price, the quality and the logistics costs.

Determine production levels

Set production goals that minimize your total cost based on the marginal cost of production for each intermediate product. Take into account different scenarios such as the availability of materials and market conditions.

Evaluate your investments

Evaluate the return on investments in productive capacity through editable parameters according to the sizing and characteristics of the plants.

Applies to all processes

Companies of the metals industry (steel, iron, copper...) set to face similar challenges, from the acquisition of raw materials, or their processing, to the decision of the portfolio of products sold. See some examples of the application of our solution.

Integrated Steel Plants

Optimize your purchase of coal, use the necessary pellet, determine the best desulfurization and dephosphorization strategy, optimize your energy matrix.

Direct Reduction

Choose pellets considering their impacts on metallization, carburization, and productivity. Integrate and optimize the decisions between reduction and melt shop, such as the amount of sponge iron in the charge of the electric furnace.

Stainless steel

Optimize the purchase of carbon and stainless steel scrap together with ferroalloy consumption. Integrate material and process decisions (chromium recovery, build-up, etc.) for an even lower production cost.

Charcoal-reduced steel processes

Optimize the purchase and use of ores of different qualities, impacting the bio-reducers' consumption and the pig iron production capacity.

Minimills

Optimize the purchase of scrap from several suppliers considering the chemical and physical aspects, impacting the power-on time and then cost and production of the steel.

Foundry

Optimize the use of the returns generated at the mill and the purchase of scrap from the market by type of alloy produced, choosing the best production route according to energy consumption (coke or electricity), yield and production pace.

Your Process

We will create the perfect model to support you in making strategic decisions for your plant/factory.

Features

Compare the optimized results in different scenarios.

Analyze data and select the best regression that represents the reality of the process.

Perform advanced analysis in just a few clicks:

Marginal cost/profit curve by the production level
Custo Marginal by quality
The marginal value of the use of raw materials
Attraction and profitability of two products by quality

Import data from other systems in an automated and secure way.

Compare the optimized results in different scenarios.

Analyze data and select the best regression that represents the reality of the process.

Perform advanced analysis in just a few clicks:

Marginal cost/profit curve by the production level
Custo Marginal by quality
The marginal value of the use of raw materials
Attraction and profitability of two products by quality

Import data from other systems in an automated and secure way.

More information about Quandec

Testimonials

Guilherme Liziero Ironmaking Technical Consultant - GERDAU

“We have implemented Cassotis' model customized for our integrated steel plant at Ouro Branco. The model based on our production data and the features of Quandec improved and speeded up our decision-making process. We now optimize our purchases and quantify any decision with a global vision.”

Usiminas Industrial Engineering

“The project we carried out integrated the productive areas of Ipatinga's plant. In addition to their expertise, one of the highlights of working with Cassotis is the customer service and availability of the consultants. And this, from the implementation process to the post-project support.”

Vinícius Ricardo Lima de Deus Industry 4.0 - Gerdau

“A few months after concluding the project with Cassotis, we could already achieve higher planning accuracy and improvement in our results. We observed a significant cost reduction compared to the spreadsheet we were using to make monthly decisions for the procurement of the raw material used in the furnaces.”

Join the best client team

Know our cases

About us

The project to implement these solutions is led by a team of Cassotis consultants who work in close collaboration with the experts of each industrial process. All developments are made with a critical eye on each decision and are delivered in different versions of the solution throughout the project. Thus, the final solution, which consolidates all the company's knowledge, is made available to qualified and trained users, responsible for decision-making processes. These will be supported by the same team of consultants in order to guarantee the maximization of the expected results.