SmeltSync at Rattan Ispat Ltd — Steel Plant Digitalization Case Study

From fragmented plant monitoring to a connected, real-time ecosystem.

Rattan Ispat Ltd operates a complete steel melt shop—Furnace → AOD → CCM production line. Before SmeltSync, production data lived in silos: individual logsheets at each station, no real-time heat traceability, and limited visibility into process outcomes. SmeltSync unified the entire operation with digital logsheets, AI Vision safety monitoring, and SCADA integration—turning reactive plant management into proactive control.

Plant

Rattan Ispat Ltd, West Bengal

Process

Furnace → AOD → CCM

Problem

Fragmented monitoring across stations, no real-time visibility, manual consolidation delays

Solution

SmeltSync: Digital logsheets + AI Vision + SCADA integration

PROJECT OVERVIEW Video demonstration

BEFORE / AFTER Production visibility and control

BeforeData scattered across three stations—Furnace operators recorded on paper, AOD used separate logsheets, CCM tracked outcomes in Excel. No real-time heat linking. Safety monitoring was post-incident only. Production delays waiting for shift-end consolidation.

AfterUnified digital logsheets track every heat from Furnace through AOD to CCM. AI Vision monitors safety compliance in real-time—alerts trigger before hazards occur. SCADA integration provides live plant data. Heat-wise traceability instant. Decision-making moves from reactive to proactive.

RESULTS What changed

Real-time heat traceability across all three production stages
AI Vision safety monitoring catches PPE violations and proximity breaches before incidents
SCADA integration provides live equipment status and process data
Shift supervisors no longer spend hours consolidating data—it's live and accurate
Production decision-making accelerated: outcomes visible immediately, not month-end
Safety culture shift: from post-incident investigations to real-time interventions

From fragmented plant monitoring to a connected, real-time ecosystem.

See it on your own heats before you decide anything.

From fragmented plant monitoring to a connected, real-time ecosystem.

Steel melt shop software

AI Vision for safety

SCADA & PLC integration

See it on your own heats before you decide anything.