This is just a small glimpse of how we can apply IOT in a steel plant(eg. SAIL) For more in depth analysis and application consultancy ping me at paragjyotiborah1993@gmail.com

1. Business Discussion Proposal
19-06-2018

2. SAIL Business: Our Understanding
• Largest steel making company in India owned and operated by the Government of India and 24th largest steel
manufacturer in the world.
• SAIL operates and owns 5 integrated steel plants at Bhilai, Rourkela, Durgapur, Bokaro and Burnpur (Asansol) and
3 special steel plants at Salem, Durgapur and Bhadravathi.
• Complete solutions provider in terms of Flat products (tin plates, coils, sheets) and Long products (crane rails,
wire rods).
• Wheels ,axles, wheel sets
• Pig iron and Fertilizers such as Calcium Ammonium Nitrate ("Sona"), Ammonium Sulphate ("Raja") and Coal
Chemicals like Benzene, Toluene, Xylene etc.
• In-house design, engineering & consultancy unit of SAIL provides the complete range of services from concept to
successful commissioning of projects in the complete value chain of integrated steel plant and its mines
• Development process includes design, development, diagnosing, testing, manufacturing, delivery and
aftermarket sale service for a wide range of technology-intensive steel component products

3. SAIL Strategy – Key Elements: Our Understanding
• To be a respected world-class corporation and the leader in Indian steel
business in quality, producibility, profitability and customer satisfaction
• Continuously improve the products, the research on them and their design
capabilities
• To scale up the products and tap the rural market
• To continuously improve the exports and tap the market
• Expanding manufacturing capabilities as well as the distribution network
• Leverage their brand equity into other scalable products of steel.

4. Focus on increasing the operational efficiencies so
as to improve returns
• Reduce inventory holding cost
• Reduce semi finished products
• Increasing the manpower productivity against their cost
• Proper energy consumption audit
• Proper safety audit

5. Modernizing the technology of IoT through
innovation thus addressing the challenges of
achieving real-time data in various Industries
Such as Food, Oil & Gas, Dairy, Industrial and
Agriculture among others.
Building strategy for enterprises and
organizations to redefine their products by
understanding the accomplishment of a
product to Drive Efficiency and Enhance
Customer Experience.
Winjit: Capabilities
Internet of Things
Product Engineering
Applying various data and schematic models in
wide range of business process for Big Data
Over Cloud to the Smaller Dataset On the Edge
Level and incorporate on device machine
learning
There has been a paradigm shift when we talk
about finance today. With digitalization and
innovation on the forefront, technology has
completely taken over finance emanating a
New Emerging Sector Called Fintech.
Artificial Intelligence & ML
Blockchain and Fintech
“Engineering ideas with technology”

6. Currently used systems and methods
• ERP systems to monitor the work right from procurement ,sales and distribution, production, finance etc.
• CRM and SRM systems and IT driven automation to an extent.
 High man power cost and low productivity.
 25% of the products are in the semi finished state
 Increased inventory holding cost
 Employee Grievances
 No proper usage of the consolidated data.
 Confidence level in the demand – supply is low.
 No manual intervention for triggers
 No proper prediction on breakdown of machines.

7. Advanced full-scale IoT Platform, which enables connecting Modern as
well Legacy Protocol sensors, on the edge & cloud, securely.
IoTSense provides real-time analytics, rule-based actions & M2M
communication, to make it more comprehensive.
Using features like edge level Machine Learning & APIs for 3rd party
integration, comprehensive IoT solution can be developed for your
custom needs.

8. IOT sense: Approach to
implementation
Better prediction for breakdown
• IOT create a network of machines , advanced analytics, supply chain and people.
• Perform root cause analysis
• The blast furnace is temperature intensive and it is critical that the temperature is
maintained consistently gradually down the blast furnace.
• Amount of slag produced and heat lost in the blast furnace.
• Differential temperature Sensors can be mounted on such machines across all the
production plants, which can further be connected to the IoT Sense.
• This data will be cleansed at Edge level and will be then sent to the IoT Sense Dashboard,
where it will be represented in Custom Charts & Graphs
• The admin can Monitor and Compare the Deflection in temperature of the machines
deployed at different plants
• Moreover, Triggers Can Be Set to notify the admin if the temperature drops below the
Tolerance Level, so that preventive measures can be taken

9.  IOT sense: Impact
• Who is responsible for mixing the components in the blast furnace.
• Monitor the health of the blast furnace depending upon its output
• Machine Vision (vision sense)
• Monitor the accuracy of cutting by the shaper tool
• In the cold milling process to monitor thickness
• The % of default product reached to the QA team is reduced
• Immediate action real time
• Checklist operation for safety by bringing in mobility
• The data generated can be stored both on premise as well as cloud and can be used to predict at what point
of the time do temperature fluctuates the most.
• Better monitoring of the inventory holding and proper prediction(predict sense) of the demand supply when
integrated with their SAP system

10.  IoT Sense: Key Features
• Full-scale IoT Platform
• Bi-directional Connectivity
• Device management
• Data processing & action management
• Data visualization & analytics
• External Interfaces
• Aggregate data from legacy or new type of sensors
• Supports wide range of industry protocols
• MQTT, AMQP, REST, OPC, SNMP, COAP, ModBus, CANBus etc.
• Edge as well as Cloud offerings
• Open API’s & 3rd party easy integration
• Edge level machine learning

11. An automated machine learning platform built on an open API structure
using efficient algorithms.
It helps you to solve complex real-time business problems with its high-
power algorithms in a very less amount of operational time.
It builds predictive models which in turn helps you take precise and
optimum business decisions.

12. PredictSense: our approach to SAIL
The data accumulated can not only be used for analysis and monitoring but can
also be used for predicting.
• The temperature sensor barometric pressure sensor and radar probe will act as a
source of data.
• The sensors will provide Predict sense with data on- furnace temperature ,
burden level, flow rate, temperature, composition, and pressure.
• By analyzing such critical data coming from different machines, various
unforeseen disasters and anomalies can be predicted using Predict Sense

13. PredictSense- Impact
• It helps you to solve complex real-time business problems with its high-power algorithms in a very
less amount of operational time.
• It builds predictive models which in turn helps you take precise and optimum business decisions.
• Design of an analytic model to predict a sustainability performance especially power
consumption, using the big data infrastructure.
• Consumer product demand sensing based upon the trends in the previous cycle
• Fina a cause effect relationship
• Macro level planning-assign yield, manufactured products (design and material differences) and
their machine tool allocation.
• Micro level planning: establishes a specific micro plan for each product, based on the macro plan.
The design and material differences influence operation sequences and process parameter sets

14. Machine vision in assembly line automation: Automate the process of
inspection and verification on manufacturing assembly line. Based on the
output object detection, the solution will either move the product further in
the assembly line: alerts are set based on the rules set for object or product
to be examined with closed box lighting conditions.

15. Requirements and features
Image formation
• - Camera
• - Lens & optics
• - Lighting
Image acquisition & Analysis
• - Computer & its peripheral
• - Software
• - Algorithms
Result interpretation
• - Measurement
• - Alignment
• - OCR

16. VisionSense- Impact
Vision sense will give a real time monitoring of the operations like
Production
Planning
Depending upon the
number of defaults
Production can be
planned or stopped
Production and Process
Guidance
• Monitoring while
cutting
• Monitor the angles
of cutting
Quality
Inspection
Applications such as
meeting the
standards of the
product by capturing
image.
Security
• People Tracking
• Batch ,Product
number reading
Data Input /
Capturing
Read Shipment
Labels and capture
data in logistics,
supply chain
management
Object
Counting
Package Counting,
People Counting for
foot fall in crowded
spaces