PLANT RELIABILITY.
Equipment Faults + Process Anomalies
JSW Steel — a global leader in integrated and downstream steel operations — didn’t just digitize its plants. It closed the loop: from raw sensor signal to prescribed action to user-validated production outcome. And in one breakthrough year, it doubled its results. Here’s what enterprise-wide prescriptive reliability looks like across 139 plants and two continents.
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PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.
Eliminated
User-validated.
3,815 critical assets
Across India and the Americas.
FROM NOISE
TO OUTCOMES.
Mechanical Faults
Vibration, wear &
bearing degradation
Physics + AI models detect bearing defects, gearbox anomalies, and lubrication failure across Ball Mills, Hot Strip Mills, and Coke Oven Pumps before they cascade into unplanned downtime.
Electrical Faults
Motor overheating &
drive anomalies
Temperature and vibration trend analysis at motor DE and NDE bearings surfaces inadequate lubrication conditions and load imbalances before they trip Blast Furnace Blowers or Electric Arc Furnace drives.
Process Induced Faults
Parameter drift &
production deviation
Continuous 24×7 monitoring across Sinter Plant Blowers, Continuous Casting, and Cold Rolling Mill sections detects process shifts before they impact yield — and before they reach the next stage.
490 areas. 3,815 assets. One Single Source of Truth.
How JSW Steel unified 139 plants — from India to the Americas — across Pellet Plants, Electric Arc Furnaces, Blast Furnaces, Steel Melting Shops, and Hot Strip & Cold Rolling Mills into a single contextualized source of truth.
Contextualization layerPhysics + AI: precision that predictions can't match
PlantOS™ doesn't flag anomalies. It traces root cause — across mechanical, electrical, and process domains — with 99.75% accuracy. Co-innovated solutions for cranes, steam fans, ROT roll monitoring, and gearbox reliability that no off-the-shelf tool could deliver.
Intelligence layerDiagnostic → Recommendation → Action
6,047 prescriptions executed. Digital work orders and automated prescriptions improved shop floor execution discipline — not dashboards, not alerts. Work orders that close.
Prescriptive engineOutcomes the plant's own engineers signed off on
36,108 hours recovered. 6,917 hrs MTBF. Utilization rate raised 2.5% in mills section. All figures validated by JSW Steel's own Reliability & Operations teams.
Validated outcomesPrediction
≠
Outcomes.
Most AI deployments stop at the alert. They predict. They visualize. They dashboard. But prediction without a closed loop is just a more expensive alarm bell.
JSW Steel’s deployment with PlantOS™ proves the gap isn’t in the model — it’s in the mile between insight and action. The 99% Trust Loop™ is what bridges it. And at JSW scale — 139 plants, 3,815 assets, two continents — the results don’t just compound. They double.
18,367 hours saved in Jan 2025. 36,108 hours by Jan 2026. Single Source of Truth. Earned trust.
Mr. Alec Glenn,
Vice President of Reliability, JSW Steel
GET THE COMPLETE PICTURE.
Real PlantOS™ Diagnostic Reports from live JSW Steel deployments
Equipment-level fault detection across mechanical, electrical & process domains
The 99% Trust Loop™ framework — step by step
User-validated outcome data, confirmed by JSW Steel's Production & Reliability team.
Thank you for your interest in
PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.
A PlantOS™ Transformation Story · Production Outcomes. Delivered.
