Steel Manufacturing Industry

Enhance Process Efficiency through AI algorithms


Introduction

Jindal Steel & Power Limited used our Lucrys Analytics Platform to connect their machines, track and improve the deviations in the manufacturing process on real time basis.

JSPL is an industrial powerhouse with a dominant presence in steel, power, mining and infrastructure sectors. Part of the US $ 22 billion OP Jindal Group, the Company is continuously scaling its capacity utilisations and efficiencies to capture opportunities for Building A Nation of Our Dreams.


Their Objective

JSPL was unable to track and locate deviations in the manufacturing process accurately. This inability could potentially mean the loss of essential and high-value clients and market reputation.

Their deviation management process had many standard components. Collecting data manually isn’t optimal as such information isn’t always reliable. It can be a nightmare to manually track and monitor every step in a complex manufacturing process, such as theirs.

JSPL approached us to introduce industrial automation and digitization in their manufacturing process. This transformation would help them closely monitor critical manufacturing details and parameters in real-time.

Our Solution

We began installing our integrated industrial gateways on their assets and connected it to our Lucrys Analytics system.

During the steel manufacturing process, once the molten steel strands come out on the rollers, it’s almost impossible to verify the raw-material composition of the end product manually. Additionally, manually differentiating between strands of different heat numbers and sequence numbers can be frustrating.

Our algorithm tracked every minute detail of their production process from start to finish. This precise tracking enabled real-time identification of deviations at any point throughout the process. Additionally, the users could also monitor whether all parameters are always within acceptable limits.

Once our AI platform identifies anomalies in the process, the system relays any changes in these values to the operators. They then immediately intervene and alter the process parameters in real-time to ensure agreed quality and proper production of the steel.

Additionally, such an automated and reliable system allows JSPL always to substantiate and prove their dedication to quality and customer obligation.

Additionally, such an automated and reliable system allows JSPL always to substantiate and prove their dedication to quality and customer obligation.

Results

This accurate prediction allowed Chemicals Ltd to prevent downtime of 12 hours.

And that's not all. When they compared the amount invested in our products and their savings in downtime costs, they found the ROI to be 10 times their investment in Machstatz!

This way we noit only accurately predicted what component caused the recuring shutdowns, but we also identified why the component failed frequently. We removed costly guesswork and replaced it with an intelligent system that consistently warns them about immient issues.

Products Used

Integratred Industrial Gateway

Lucrys Analytics


Solution Used

Acute



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