MANUFACTURING (METAL CASTING + GALVANIZING) CASE STUDY
Cut energy use by 20% for a high-volume metal foundry
Delivered an AI vision + IIoT furnace health monitoring layer integrated with MES and SCADA for real-time decisions.
20% less energy
15% less scrap
12% higher OEE
Manufacturing (Metal casting + galvanizing) Case Study
THE CHALLENGE
What was holding them back
Operational pain
Inconsistent furnace performance triggered frequent production halts.
Business risk
Rising scrap and energy costs, plus delivery slippage.
Why tools failed
Manual monitoring had no real-time insight or fast root-cause visibility.
CLIENT SNAPSHOT
About the client
Industry
Manufacturing (Metal casting + galvanizing)
Geography
India
Service
AI & Automation
Existing Tools
MES + SCADA + manual checks (spread across shifts)
THE SOLUTION
Our Manufacturing (Metal casting + galvanizing) Solution
AI Vision Furnace Health Monitoring
- Continuous visual detection of abnormal furnace states.
- Early warnings tied to operator actions and shift context.
IIoT Sensor Fusion (Temperature + Vibration)
- Real-time sensor streams for stability and drift tracking.
- Pattern signals to spot degradation before shutdowns.
Edge Processing for Low-Latency Analytics
- On-site processing to reduce alert delay and noise.
- Resilient monitoring even during network fluctuations.
MES + SCADA Integration with Shift KPIs
- Unified view: furnace signals mapped to production events.
- Shift-level KPIs for supervisors to act faster.
Alerts + On-Floor Adoption Workflow
- Role-based alert routing for operators and maintenance.
- Simple, actionable thresholds aligned to shop-floor reality.
THE IMPACT
Measurable Results
20%
Energy
less consumption per melt cycle
15%
Scrap
lower scrap from furnace instability
11%
Stops
fewer unplanned production halts
12%
OEE
higher overall equipment effectiveness
8%
Waste
less material and rework waste
6
weeks Time-to-value
to live dashboards
TECH STACK
Technologies Used
AI Vision
MES
SCADA
IIoT
Edge Processing
