How a complete steel melt shop unified production across Furnace, AOD, and CCM with real-time visibility, AI-powered safety, and live equipment data—transforming a reactive plant into a proactive operation.
Large steel operations run on the principle of modular production: raw material enters the Furnace, transitions to AOD for refining, and flows into CCM for casting. Each stage is critical, but before SmeltSync, each stage operated in isolation. Furnace operators recorded temperatures and timings on paper logsheets. The AOD station kept its own separate records. CCM tracked final outcomes in Excel. When shift supervisors needed to understand a heat's journey—why it took longer, what contributed to scrap rates, where safety margins were thin—they faced hours of manual consolidation. By then, the data was old, and the opportunity to learn or correct course had passed.
Safety monitoring at most plants is reactive: cameras roll all day, but footage is reviewed only after something goes wrong. At Rattan Ispat, a worker entering a high-heat zone without proper PPE would be caught on video—after the heat had already been tapped, after the risk had passed. The safety team could document the breach, but prevention remained impossible. Production decisions suffered similarly. Managers made choices based on partial information, yesterday's data, or gut instinct rather than real-time truth. Equipment failures were discovered during shift handovers, not before they cascaded into downtime.
SmeltSync unified Rattan Ispat's operations with three core components. First, digital logsheets for Furnace, AOD, and CCM replaced paper and Excel, capturing every heat's journey in real time. A single heat number links all three stages—operators at any station can see the complete history of that heat in seconds. Second, AI Vision monitors the plant floor in real time. When a worker approaches a hazardous zone without proper gear, or PPE compliance drifts, the system alerts the safety team immediately—not after the shift ends. Third, SCADA integration pulls live data directly from equipment: furnace temperatures, AOD pressure, CCM casting speed, all flowing into SmeltSync's unified dashboard. No manual transcription. No delays.
With every heat linked across all three stages, production supervisors now see heat outcomes the moment they happen. If a heat shows unusual properties coming out of CCM, they can trace it backward—furnace temperature profile, AOD timing, refining parameters—without hunting through logbooks. Yield improvements come fast. When a heat quality trend emerges, it's visible mid-shift, not discovered in month-end reconciliation. Equipment anomalies surface instantly: a furnace running hot, a pump losing pressure, a casting machine drifting out of spec. The team intervenes before scrap accumulates.
AI Vision safety monitoring at Rattan Ispat has fundamentally shifted the safety culture. The system isn't watching for violations to punish them; it's watching to prevent them. When a breach is detected, the safety team is notified in real time, allowing them to coach the worker before a heat reaches a dangerous stage. Over weeks, workers internalize the safety zones and PPE requirements because they're no longer reactive consequences—they're real-time guidance. Near-misses that cameras would have only caught in retrospect are now prevented entirely. The plant has moved from responding to incidents to building a system that actively protects everyone, every shift.
"Real-time plant control isn't about watching more carefully—it's about connecting every station so the whole operation sees and reacts as one."
30-day pilot. No disruption to your current process.