Projects

STEELOPT
Optimization-Based Production and Logistics Planning for an Integrated Steelworks
Start: 01/2012
End: 12/2026

As part of their research collaboration, AG der Dillinger Hüttenwerke (Dillinger) and FZI are developing mathematical models and algorithms to optimize production and logistics processes in the steel industry. The aim is to enable better decision-making in complex planning environments, make efficient use of available resources, and take an integrated view of interdependencies across the production chain.
Crane and Stack Planning
Plates, mother plates, and slabs are transported by crane and stacked between production stages. Intelligent stack formation is essential to avoid unnecessary reshuffling, waiting times, and resource conflicts. Tree-search methods are therefore investigated to jointly optimize stack configurations and crane movements.

Mother Plate Cutting Optimization
Cutting optimization involves assigning products to suitable mother plates and determining the corresponding cutting layouts. This requires a wide range of constraints to be considered, including order specifications, the technical capabilities of the cutting line, the available input material, and restrictions imposed by upstream furnaces. Column-generation methods are developed to solve the resulting large-scale combinatorial problems.

Capacity, Routing, and Scheduling
Suitable production routes and time windows are determined for each product. The planning process accounts for available plant capacity, technological requirements, planned and unplanned equipment downtime, temporal dependencies across the production chain, and customer-requested delivery windows. These planning problems are primarily modeled and solved using mixed-integer programming.

Role of the FZI
The collaboration combines applied operations research with real-world challenges in production planning and technical logistics. Its primary focus is on advanced mathematical optimization models and solution methods, complemented by modern AI techniques and discrete-event simulation. These additional methods are used, for example, to represent dynamic production processes and evaluate planning outcomes.

The resulting approaches provide transparency into complex interdependencies, enable the systematic comparison of planning alternatives, and support well-informed decision-making. Key objectives include reducing material waste and unnecessary reshuffling, improving capacity utilization, and generating robust and transparent planning recommendations.

Contact person
Department Manager
Division: Information Process Engineering
Headquarters Karlsruhe

Research focus
Mobility and Logistics

Autonomous shuttles, intelligent logistics, and software-defined vehicles: We use IT to create the connected, safe, and sustainable mobility and logistics solutions of tomorrow.

Energy and Sustainability

Sustainability and practical relevance are key: We develop IT innovations for companies that contribute to a climate-friendly and resource-efficient economy.

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