Metal industry is characterized as very dynamic since continuous advancements are taking place in the field of materials and process technologies. The manufacturing companies need to be responsive to cater to the evolving needs of customers. Productivity, asset performance, energy management, inventory management, quality and regulatory compliance are some of the challenges faced by manufacturing plants. Sensys open, scalable, and simplified architecture lays strong foundation for companies to achieve operational excellence.

We provide steel specific solutions in all domains including HMI/SCADA, Plant Information Management System, Overall Equipment Effectiveness, MES and Business Application Integration thus enabling the companies to achieve their manufacturing goals by maximizing the true potential of real-time information.


Operator Level/ Centralized HMI

Sensys provides state of the art customized high resolution representation of plant floor and processes for Ferrous (Iron/Steel), Aluminum, and Non-Ferrous metals to ensure visibility and traceability of the entire operations in a plant and enabling the management to perform monitoring and control on real-time basis. We have expertise in providing customized dashboards for different operations and processes including Steel Manufacturing, Casting, Smelting, Reduction, Rolling, and Finishing etc. We offer operator level console as well as act as a centralized platform in case of multiple facilities thus catering to entire needs of the company.

Plant Information Management System

Sensys offers state of the art Plant Information Management System with advanced historian capabilities that allows data collection, data storage, data archiving and instant data retrieval upon user request. Manufacturing companies such as Steel comprise several processes which lead to a large number of parameters and KPIs to be calculated and controlled. IntelliMAX enables clients to centralize data from various data sources and provides a central platform to access historical data. User can perform advanced trending and charting analysis on critical parameters such as No. of heats produced, Tap to Tap Time, Exhaust Emissions, Scrap production, Steam Generation, and Energy Consumption etc. Reports can be generated on KPIs such as Production in Tons/day, DRI/Ton, m3 of Ar/Ton, m3 of CO2/Ton, Scrap Tons/Ton etc. This data can be used to perform in-depth analysis on both processes and operations to get better insights and improve productivity and efficiency.

Production Planning and Scheduling

Production Planning and scheduling is that critical phase from where the process of production at the shopfloor starts. Careful planning of production according to the orders and then its scheduling in order for smooth execution are critical for any steel plant. IntelliMAX facilitates the planning and scheduling of metal products and then tracks its execution in light of the original plan and schedule. A full module is available to select and assign products for the shop floor. the execution takes place according to the selections made by the planners in the exact directed sequence. This tight integration between planning and executions keeps all the stake holders in loop while the manufacturing on shop floor is in progress. At any point in time, the users can find out whether the production is going according to the plan or not. Automatic notifications are sent to the relevant stakeholders whenever the production deficit beyond a user defined threshold occurs between the planned and actual execution. Whenever there is any occurence of an un scheduled event, IntelliMAX automatically adjusts the plan for the remaining days and gives the projection of possible production according to the remaining scheduled days. Reasons for all those events that affect the production are recorded and also reported back to the ERP system.

Energy Management

Rising energy costs and availability have become critical considerations for manufacturing industries to ensure uninterrupted and profitable operations. Sensys provides Metal Industries with specific Energy dashboards in order to enable users take necessary measures to optimize energy. IntellIMAX EMI provides visibility to system by providing real-time monitoring and control of energy parameters such as KWH/Ton, MJ/Ton etc.  for both supply and demand. It has the capability to provide in-depth analysis via advanced trending, charting and reporting on Energy Consumption by source be it Water, Gas, Steam or Electricity. By having an accurate data about energy consumption, user can better estimate patterns and perform in-depth analysis to optimize the supply and demand for energy. We offer load balancing and optimization taking into account the demand in real-time. This results in secure and reliable energy availability, improved energy efficiency and better profitability.

Recipe & Batch Management

Sensys comes up with a highly efficient, customizable Recipe Management system for manufacturing companies such as steel, aluminum etc. which enable them to develop/formulate recipes as per requirements, act as a standardized database for storage of recipes, logically categorize recipes and also integrate with other business applications like ERP etc.  In addition, it enables users to adjust recipes as per actual scenarios and also provides traceability for all batches, products and their ingredients.  IntelliMAX EMI also completely supports the ISA-88 batch management standard.

Condition Based Maintenance

Condition based maintenance is a maintenance strategy used to improve the effectiveness of maintenance programs and reduce the life cycle costs of assets. It plays a key role in the capital extensive metal Industry where the goal is to maximize the performance of different assets such as pumps, compressors, etc. IntelliMAX caters to Condition based maintenance utilizing the real-time data associated with the asset such as Running hours, temperature, pressure, vibration, speed, flow-rate, voltage, current, stress, etc. and analyzing these to determine the state of assets. These parameters are regularly monitored on real-time basis and the values of the mentioned parameters are compared against their set points to see deviations. Trends can be plotted to analyze the behavior and thus predict the maintenance.

Overall Equipment Effectiveness

SENSYS’s IntelliMAX EMI solution provides a comprehensive way to monitor and improve the overall efficiency of production processes in Metal industry through its OEE module. IntelliMAX EMI tracks key metrics contributing to OEE i.e. availability, performance and quality and provides users contextual analysis at equipment, assembly, facility and plant level. IntelliMAX EMI’s OEE dashboard enables users to analyze Planned vs Actual OEE, Visibility of key reasons causing downtime, Knowledge of reasons attributing to performance loss and causes contributing to poor quality. It provides management with key information at plant level such as Breakdowns per day, Scrap Tons/Ton, Quality Loss, Speed Loss, etc. This results in better utilization of the assets and production lines which improves productivity and profitability.

Scrap Management

Scrap from manufacturing process is an important area from management’s perspective. IntelliMAX provides complete scrap information in terms of weight, length, width and other parameters and also logs this for comprehensive reporting. Operator can trace scrap to its parent input and keep complete track of scrap from production to inventory. Scrap can be categorized and reasons can be logged against each scrap item. In addition, IntelliMAX provides comprehensive reporting based upon the logged information. Furthermore, integration with ERP enables this information to be used across the enterprise for faster decision making.