Client Profile

• Client: Confidential – One of India’s Top 5 Integrated Steel Producers
• Sector: Heavy Manufacturing – Steel
• Location: Eastern India
• Engagement Duration: 15 months
• Annual Plant Revenue (Start): ₹9,300 Cr
• Annual Plant Revenue (Post): ₹11,200 Cr
• Total ROI on DCS Engagement: 9.8x

Background

Our client, a top-tier Indian steel manufacturer, operates a legacy steel plant with 6 million tonnes annual production capacity. Despite its size and experience, the company faced operational limitations threatening scalability and profitability in the modern era, including:

• Unpredictable equipment failures and unplanned downtime
• Inefficient manual data capture across SCADA, MES, and ERP layers
• High rework and rejection rates due to poor inline quality control
• Energy inefficiencies across furnace and rolling operations
• No real-time insights across units or data standardization

The management’s vision was clear:

"We want this plant to become a world-class Smart Factory with predictive intelligence, automation, and real-time control — not just for performance but for global competitiveness."

Why DCS Was Chosen

Dodong Consulting Services (DCS) was selected after a multi-round evaluation over global system integrators and consultants, for one key reason:

We not only deploy technology — we engineer measurable transformation across people, process, and platforms.

DCS Transformation Strategy: “SMART-FAB” Framework

DCS deployed its proprietary 5-stage SMART-FAB framework to transform the plant into a Smart Industry 4.0 Lighthouse Factory:

• S – Sensorization & IoT Infrastructure:
  • Installed 2,000+ IIoT-grade sensors across blast furnaces, continuous casting, rolling, and packing lines
  • Integrated with legacy PLCs via MQTT & OPC UA protocols
  • Established real-time data lake with 98.6% asset visibility
  • Impact: Full digital footprint of core plant processes captured within 8 weeks
• M – Machine Learning & Predictive Intelligence:
  • Built live anomaly detection models (bearing wear, furnace drift, motor vibration)
  • Developed predictive maintenance triggers reducing MTTR and false alarms
  • Used ML to predict quality deviations, minimizing rejects during hot-rolling
  • Impact:
    • Unplanned downtime reduced by 41%
    • Bearing-related failure incidents cut from 21/year to 8/year
    • Inline product quality success rate improved to 98.3%
• A – Automation, Robotics & AR:
  • Introduced robotic coil handling and automated slag removal arms
  • Enabled AR-guided maintenance for field teams using smart glasses
  • Launched AGVs (automated guided vehicles) for billet transport inside the plant
  • Impact:
    • Operator productivity improved by 29%
    • Manual fatigue and error incidents dropped by 44%
    • Maintenance resolution time reduced by 34%
• R – Real-Time KPI Dashboards:
  • Rolled out CommandOps™ Visual Cockpit Dashboards across plant heads
  • Unified metrics: OEE, scrap %, energy per ton, predictive downtime alerts
  • Enabled shift-wise performance benchmarking & deviation alerts
  • Impact:
    • First-pass yield improved from 91% to 98.3%
    • Energy wastage reduced by 21%
    • Decision latency (average issue-to-action time) dropped by 48%
• T – Total Systems Integration:
  • Integrated SCADA, MES, ERP, and legacy data historians into a single digital layer
  • Built APIs to sync with procurement, inventory, and distribution
  • Developed a Digital Twin model for real-time scenario simulation and planning
  • Impact:
    • Seamless visibility across production, supply chain, and maintenance
    • Faster monthly closing and real-time operational reconciliation
    • Roadmap built to replicate the model at two other national plants

Simulated Plant Performance Impact

Client Speaks

"DCS did what no one else could — they embedded intelligence into the plant itself. From day-to-day…"