Predicting Power Requirement In Steel Manufacturing (EAF) Problem In the steel manufacturing industry, Electric Arc Furnace (EAF) and Ladle Refining Furnace (LRF) processes require substantial electrical power, supplied by captive power plants (CPPs). Striking a balance between power supply and the manufacturing demand is a complex task due to the variable nature of manufacturing processes and environmental factors. This often leads to surplus power generation, also […]
Real-Time Visual Inspection of Ingot Defects for the World’s Second Largest Integrated Zinc-Lead Producer Problem The world’s second-largest integrated zinc-lead producer faced significant challenges with its ingot production process. With a high production rate of 600 ingots per hour, manual quality control (QC) became impractical and hazardous for workers. The company needed a solution to […]
Streamlining Manufacturing Efficiency – Autonomous Production Planning & Scheduling Problem Many manufacturing companies face challenges with their manual production scheduling processes, leading to limited capabilities in handling complex multi-layer constraints and resulting in inefficiencies and suboptimal productivity. Static schedules often fail to accommodate changes in demand, machine breakdowns, or material availability, causing wasted resources and […]
Smart Production Scheduling to Minimize Planning Losses and Material Losses Problem The production scheduling process is critical for optimizing resources, minimizing planning losses, and reducing material losses in manufacturing operations. However, traditional production scheduling methods may lack real-time visibility and flexibility, leading to inefficiencies, missed opportunities for optimization, and increased material wastage. The challenges faced […]
Real-Time Optimization of Refinery FCC Problem Optimizing plant performance is crucial to maximize output and achieve optimum profit, yield, production, and energy consumption without significant capital investments. However, many plants operate based on outdated design conditions and set points, leading to suboptimal performance. Additionally, the implementation of Advanced Process Control (APC) does not always result […]
Remote Plant Performance Monitoring for Ethylene Plant Problem Ensuring overall plant performance and individual system and equipment performances are crucial for achieving production targets, yield optimization, energy efficiency, and profitability in an ethylene plant. However, existing plant monitoring practices, predominantly based on Distributed Control Systems (DCS), lack real-time insights from the massive data generated. Many […]
Product Quality Prediction in Textiles Manufacturing Problem In textiles manufacturing, detecting defects on Work-in-Progress (WIP) and finished goods is critical for ensuring product quality. Early detection of defects enables operators to take corrective actions promptly, reducing wastage and improving shop floor margins. The challenges faced in textiles manufacturing include: Approach To address the challenges and […]
Polypropylene Quality Prediction for a Petrochemical Company Problem A leading petrochemical company faced challenges in increasing the production of Polypropylene due to lump formation during the complex polymeric reaction process. The operator’s dependence on delayed lab-based quality estimation hindered their ability to address the issue promptly. The lump formation led to increased downtime, operational expenses, […]
Heat Exchangers Fouling Prediction and Cleaning Schedule Optimization Problem The refining and chemical industries face a significant challenge with heat exchanger fouling, where deposits of impurities accumulate on heat exchanger surfaces over time. This fouling reduces heat transfer efficiency, leading to several issues: Approach To address the challenges of heat exchanger fouling and optimize the […]
EOR Optimization and Polymer Injection Reduction for Upstream Oil & Gas Operator Problem The upstream oil and gas operator uses Polymer Enhanced Oil Recovery (EOR) to improve the sweep efficiency of existing water flood systems. Polymer injection involves increasing the viscosity of injected water with polymers to improve sweep efficiency. However, maintaining the right viscosity […]