Video Analytic Solutions for process safetyObjective:
To ensure process/industrial safety measurements
Social Distance
Mask Detection
PPE Detection
No Man Area Zones
Hand Rail Holding Detection
Fire Detection
Feature & Benefits:
Ensure Safety compliance at all levels inside the plant
Social distancing, Mask detection etc through video analytics improves containment & prevention of epidemic spread like COVID
Critical safety hazards are eliminated at process industry floors through PPE Detection, No man area zone & Hand rail holding detection
Fire Detection solutions contribute a major factor in zero harm for all personnel & property
Explosive Detection SystemObjective:
Detect explosives mixed with scrap on the conveyor to the shredder and alarm accordingly to ensure safety
Feature & Benefits:
Automatic detection of explosives in material yards/scrap yards that could be hazardous
Added safety with enhanced vision over a bulk of materials
Zero Human intervention required thus reducing personnel harm
Hook VisionObjective:
Provide real-time visualization of crane hook engagement with ladle trunnion without any intervention from the crane operator
Feature & Benefits:
Ban human signaling near the vicinity of hot metal
Multi-streamed latency-free auto-switched video transmission in both cranes & ground (like Dish TV Communication)
Minimum electronics & maintenance on crane side
Easy to use & hassle-free software design
Change in inherent work culture
Implemented in all steel melting shops of TSJ, TSK & TSM
Remote Machines1) RRC in Locomotives of Hot Metal LogisticsObjective: To improve safety standards and productivity in the Movement of Hot Metal Torpedoes
Features & Benefits:
24×7 seamless RRC Control for critical assets
Increase in productivity by reduction of Time of travel and increased availability of Locos
2) Video Wall in Bof Converter HandlingObjective: To ensure safety at BOF Control Room by using video wall instead of glass wall
Features & Benefits:
24×7 latency-free real-time video streaming for critical application
Prevention of loss of life inside the control room during the worst case of BOF Converter’s explosion
3) Manless Cranes in Scrap Management.Objective: To eliminate Human-machine interface in the operation of cranes inside Steel Melting shop
Features & Benefits:
Safe, ergonomic and productive operation of cranes
Easy to operate & enables maneuverability of critical crane operator resources inside steel melting shops
Remote Sprinkler for Stock YardsObjective: To eliminate human presence for operating sprinklers in stockyards
Issues & Concerns:
It is unsafe to use raw material storage yard to operate sprinklers
Waste of manpower resources for a simple job
Sprinklers working is necessary for environmental hygiene
Benefits:
Remote operation of sprinklers (No line of sight required)
Enhanced safety and productivity
Compliance with statutory environmental rules and regulations
Plume Dispersion SystemObjective: Estimation and visualization of pollutants deposition (PM, SOx, NOx) in real time to demonstrate the environmental impact
Solution:
Developed a real-time process model using Gaussian distribution methodology for estimation of plume dispersion and deposition
Benefits:
Results are displayed on an HMI screen which is overlaid with Google map
Displays the deposition profile of each stack for the last 24 hours
Early intervention in case of emergency
Predictive maintenance
Ashiyana – manufacturing or other industries in general
1. Digital Negotiation FactoryProblems Addressed:
Real time tracking of all negotiations
Availability of structured data in a single platform
Enable negotiation decisions based on past data (historical vendor data) ,current data (clean sheet) and future data (forecast for materials)
Supplier’s competitiveness will increase
Error free and faster executions
Maintain a digital repository of past negotiations
Impact
Negotiations are now more objective backed by readily availability of data
Digital visibility will prevent cartelization
Help in achieving ~5% savings during negotiations
2. Catalogue Management SystemProblems Addressed
High transaction workload for category managers
High PR — PO time for MRO Items with multiple interactions between users and category managers
Competitive and Negotiated rate contracts availability through keyword search under ARC/Hosted Catalogue
Increased visibility of procured material by providing pictorial representation of item selected
Impact
Rate reduction by 10%-15% across MRO categories due to increased vendor competition (Punchout/Hosted catalogs); increased vendor sale efficiency (annual rate contracts)
Base P2P system leveraged with E-Catalog integrated to minimize change management for users
ARC coverage increased by 20%
3. Life Cycle Tracking SystemProblems Addressed
Visibility of combined data from multiple systems involved in entire process (8-9 systems across entire cycle)
Frequent queries on status update by multiple stakeholders
Correspondence with the person responsible for the present stage of request
Impact
Improvement in payment cycle time by ~20% Smooth Delivery of Materials as per schedule during Covid -19
Improvement in PR-PO cycle time by 20%
4. DigiWheelsProblems Addressed
Uitilzation Tracking of the vehicles
Ensuring optimal usage of vehicles
Manual record-keeping necessary to track vehicle distances/usage for fuel reimbursements and other payments
Impact
Reduction in size of fleet. Increase in utilization figures from (20-40%) to (75-90%)
Real time monitoring of entire fleet to ensure 100% availability. ~25% savings on contracted vehicles
Objective:
Smart solution for identification & tracking of manpower deployed inside plants
The Solution has 4 critical components – Lora Wan, BLE Beacons, Android / IOS Mobile App & Cloud application
1. LoRaWAN Network – LoRa Network to be installed depending on the Plant/office coverage and reach [only if the solution is used in collaboration with SafePass Cards]
2. BLE Beacon – BLE Beacons to be installed across the plant/office demarking various Zones.
The BLE beacons will be configured as either:
» Entry Beacon – Demarking and indicating to the Mobile App that the worker is entering the plant/office
» Exit Beacon – Demarking and indicating to the Mobile App that the worker is exiting the plant/office
» Hazardous Beacon – Demarking a Hazardous area within the Plant / Office
» Safe Beacon – Demarking normal working zones within the plant / Office
3. Mobile App via Bluetooth capable of detecting the various beacons, collecting beacon information, and sending data, alerts via the internet as well generating user alerts via buzzer/vibration
4. Application to generate additional reports and alertsTata Steel Digital JourneyOur Industrial 4.0 Architecture
Insight Platform: Visualization, Artificial Intelligence, User Apps
Data Platform: Data & Analytics
Infra Platform: Enterprise Applications, Sensors, Level I & II, Network, Cyber Security, Cloud
Key Business Outcomes
Safety
Productivity
Yield, Throughput
Energy
Quality
Asset Performance
Knowledge Management
Data Privacy
Cyber Risk mitigation
Technology Obscelence
Goals
Intelligent Enterprise
Digital Enterprise
Agile Enterprise
LaurelsA Look Back at 2022 AccomplishmentsDigital ConsultancyIndustry 4.0 lighthouse visit
Tata Steel was quick to board the Industry 4.0 wave and had dedicated efforts to building organization wide enthusiasm for digital adoption since 2015. As the early wins started coming in, adoption picked up pace in and sizeable bottom-line impact and employee experience
enhancement has been consistently achieved. Given this early adoption and hot pursuit of business goals through digitalization, Tata Steel currently has established an early lead in Industry 4.0 maturity.
Today, Tata Steel holds the unique distinction of having three of its sites recognised as Industry 4.0 lighthouses. Its oldest and newest site in India – Jamshedpur and Kalinganagar have both been bestowed with this recognition.
A visit to Tata Steel aimed at building an appreciation of the impact that digital transformation can achieve would involve interactions with the important stakeholders to the digital transformation process, witnessing digital technologies in action and correlating the same with real world business impact brought about by adopting Industry 4.0 technologies in Tata Steel.
TSIC organizes customized Industry Visits to Tata Steel units enabling the participants to witness first-hand the impact of Industry 4.0 in a real-world setting. Participants also interact with the different stakeholders within the organization that deliver the change including line functions, Automation, IT Infrastructure and Business Process Enhancement.
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and more recently with desktop publishing software like Aldus PageMaker including versions of Lorem Ipsum.
Lorem Ipsum is simply dummy text of the printing and typesetting industry. Lorem Ipsum has been the industry’s
standard dummy text ever since the 1500s, when an unknown printer took a galley of type and scrambled it to make a
type specimen book. It has survived not only five centuries, but also the leap into electronic typesetting, remaining
essentially unchanged. It was popularised in the 1960s with the release of Letraset sheets containing Lorem Ipsum passages,
and more recently with desktop publishing software like Aldus PageMaker including versions of Lorem Ipsum.