On a sweltering August day, the POSCO steel mill in Pohang buzzes with activity, showcasing a remarkable transformation in industrial operations. Artificial intelligence is now taking on some of the most challenging and hazardous tasks within this sprawling complex. This integration of technology signifies a shift towards smarter, safer, and more efficient steel production processes, demonstrating how industry leaders like POSCO are embracing innovation to enhance their operations.
At a product inspection area located about 15 minutes from the main gate, a fleet of smart CCTV cameras springs into action as a large trailer truck carrying 14 coils of wire rod arrives. These AI-powered cameras, implemented in collaboration with POSCO Group’s IT subsidiary, POSCO DX, meticulously scan barcodes and labels affixed to each coil. This automated process, which went live after a six-month testing period, verifies that the production information in the manufacturing execution system aligns with the actual products being shipped to customers, both domestically and internationally.
Previously, inspectors had to manually check approximately 3,000 wire rod labels against MES records daily, a task fraught with potential errors and safety risks. Inspectors often had to climb onto vehicles to view labels on the opposite side of the load, exposing them to dangerous situations. The introduction of the new AI system has eliminated these risks and inaccuracies, significantly improving both efficiency and safety in the inspection process.
The reach of AI at POSCO extends far beyond product verification. In the continuous casting plant, where molten iron is solidified into semi-finished slabs, AI serves as a vigilant guardian against potentially catastrophic accidents. Smart CCTV systems monitor the movement of 35-metric ton slabs heated to 1,000°C along conveyor belts. If a slab begins to misalign, a situation known as “snaking,” the AI can alert operators and autonomously halt the production line to prevent accidents. Since the introduction of this smart system in 2021, there have been no incidents of slab misalignment, freeing staff from the monotonous task of constant monitoring and significantly enhancing workplace safety.
Moreover, even the massive 1,000-metric ton locomotives transporting molten iron throughout the complex are now under AI supervision. POSCO DX has developed an AI solution that analyzes CCTV footage around railroad crossings, alerting train operators to potential hazards such as workers or vehicles in the vicinity. This proactive approach not only enhances safety but also streamlines operations by minimizing the risk of accidents.
To tackle challenges posed by frequent coastal fog, POSCO DX has partnered with Pohang University of Science and Technology to develop technology that removes fog and dust from CCTV images. This ensures clear visuals for AI analysis, even in adverse weather conditions, further enhancing the reliability of the surveillance systems in place.
Yoon Il-yong, head of POSCO DX’s AI Technology Center, emphasizes the importance of industrial AI in addressing quality inconsistencies that arise from variations in worker skill levels. By focusing on replacing tasks that do not necessarily require human involvement and eliminating hazardous on-site work, POSCO aims to transform its steel mills into intelligent factories. This shift not only promotes safety but also fosters a more efficient production environment, ultimately leading to higher quality steel products.
