MillFlow

Plant-aware quoting for steel mills.

Before a quote becomes a promise, MillFlow shows the real margin, line fit, ship-date risk, and energy cost behind it.

Real margin x line fit x ship-date risk x energy cost

Baseline Week 21 screenshot showing scenario workspace, schedule consequences, grouped intake, and quarter impact
Problem

The quote goes out before the real margin is known.

Steel mills already have ERP, planning tools, spreadsheets, and experienced operators. The problem is not missing data. The problem is that order acceptance still gets assembled across disconnected systems and judgment calls. By the time line reality, ship-date risk, and energy cost are visible, the commercial promise has often already been made.

Status quo

ERP export. Quote spreadsheet. Planner gut check. Line-manager call. Energy priced too late.

The current stack can store the data, but it does not give the commercial leader one trusted answer on whether the mill should commit right now.

  • CommercialCommits before route, queue, and contribution margin are priced together.
  • PlanningInherits schedule damage after the quote has become a customer promise.
  • OperationsSees constraints move faster than the commercial desk.
  • CEO / CFOHas to explain margin movement after the quarter is already exposed.
Three-factor model

Compute trade-offs using real-world data.

Every quote is a trade-off between revenue, line reality, promise risk, and energy timing. MillFlow scores that trade-off before the commercial answer leaves the desk.

Factor 01

Commercial value

Price, order value, customer priority, delivery penalties, and product mix.

Factor 02

Plant feasibility

Route fit, bottlenecks, setup families, queue reality, maintenance state, and yield.

Factor 03

Energy cost

Time-of-use electricity, process load, energy intensity, and cost exposure by route.

Campaign Planner screenshot showing a ranked energy-aware line plan and 10-factor route evidence
First wedge

Start where the money is: quote-to-margin and constraint-aware scheduling.

MillFlow begins where commercial leaders lose control: what to quote, what to accept, when to run it, and what margin remains after setup, yield, delay, disruption risk, and energy are priced in.

01 / Ingest

MillFlow captures live plant realities from ERP, MES, historians, maintenance, and energy systems into a computable plant context.

02 / Compute

The model prices the trade-off between commercial value, plant feasibility, and energy cost against the real queue and route options.

03 / Recommend

The team gets a defensible answer on whether to take the order, how to group it, what to charge, and what to promise.

Product features

One model, three places decisions actually happen.

The same margin calculation follows the team from quote intake, to plant reality, to energy timing.

Quote Desk screenshot showing RFQ split, sub-orders, raw-material lots, and quote controls
Quote desk

Split the RFQ before the promise goes out.

The quote desk keeps client order, sub-order, lot, line, and ship-date context in one operating surface.

Plant Ontology screenshot showing line assets, route connections, and Galv Line 2 context
Plant ontology

The plant model is visible, editable, and accountable.

Line capability, upstream and downstream dependencies, child assets, queues, risk, and uptime stay attached to the decision.

Smart metre screenshot showing tariff levels, measured consumption bars, peak exposure, and Temper Mill energy cost
Smart metre

Energy becomes a timed planning input.

Tariff dots and measured consumption bars give the planner the same horizon, clock, and cost exposure.

Dashboards

See and control where margin leaks.

The commercial wedge is tight: Quote Desk, Campaign Planner, and Executive View keep every commitment tied to the same plant-aware margin calculation.

Precision steel components arranged on a brushed metal surface
Quote desk Order split / promise
Dashboard 01 / Quote desk

Stop accepting orders before contribution margin is real.

Decide whether to take the order, how to split or group it, what to charge, and what lead time is credible before the quote becomes a promise.

  • Check route fit before the customer answer leaves the desk.
  • Expose margin, setup, yield, risk, and protected ship date together.
Circular machined steel assembly photographed from above
Campaign planner Group / simulate
Dashboard 02 / Campaign planner

Choose the campaign that protects ship dates and margin.

Compare contribution, setup loss, line fit, and energy spend before the schedule absorbs the cost.

  • Bundle inbound work into line-ready simulations.
  • Rank alternatives by contribution, disruption, setup, and energy drag.
Stack of machined steel blocks and cylindrical parts on a dark surface
Executive view Margin / risk
Dashboard 03 / Executive view

Show leadership which commitments are creating risk.

Roll up new commitments against current constraints so CEOs and CFOs can see margin and delivery risk before it compounds.

  • Show the money at risk before the week hardens.
  • Connect every intervention to the record that explains it.
Why MillFlow

Smart decision layer over existing systems.

Commercial control

The commercial leader sees margin and plant consequence before saying yes.

Leadership traceability

When leadership asks why margin moved, the answer traces back to the order, line, campaign, tariff window, and promise date.

Practical

MillFlow sits above ERP, MES, APS, historian, quality, and maintenance systems rather than asking the plant to rip them out first.

Contact

Talk to MillFlow.

If commercial commitments are moving faster than plant truth in your mill, let's talk. MillFlow starts where order acceptance meets line constraints, energy cost, and real operating margin.

First pilot One mill. One order family. One campaign horizon.

Use existing ERP and MES exports, then produce decision recommendations within weeks.