What is IoT??
and its
Application in
Steel Plants in
India
Leveraging IoT for Smart
Manufacturing and Operational
Efficiency
Introduction to IoT
Key Components of IoT
IoT in Manufacturing and Steel
Plants
Conten Benefits of IoT in Steel Plants
t: Case Study 1: IoT in Tata Steel
Case Study 2: IoT in JSW Steel
Challenges and Future Trends
Introduction to
IoT
• Definition of IoT: A network of
interconnected devices that collect
and exchange data.
• Key characteristics: Sensors,
connectivity, data processing, and
automation.
• Examples: Smart homes, wearables,
industrial IoT (IIoT).
Key Components
of IoT
• Sensors and Devices: Collect data from
the environment.
• Connectivity: Transmit data via Wi-Fi,
Bluetooth, or 5G.
• Data Processing: Analyze data using
cloud or edge computing.
• User Interface: Visualize data for
decision-making.
Sensors
Definition
• A sensor detects (senses) changes in the
ambient conditions or in the state of another
device or a system, and forwards or processes
this information in a certain manner .
• “A device which detects or measures a physical
property and records, indicates, or otherwise
responds to it” -Oxford Dictionary
Sensors
•They perform some input functions by
sensing or feeling the physical changes
in characteristics of a system in
response to a stimuli.
•For example heat is converted to
electrical signals in a temperature
sensor, or atmospheric pressure is
converted to electrical signals in a
barometer.
Transduce
rs
§Transducers convert or transduce
energy of one kind into another.
§For example, in a sound system, a
microphone (input device) converts
sound waves into electrical signals for
an amplifier to amplify (a process),
and a loudspeaker (output device)
converts these electrical signals back
into sound waves.
§The word “Transducer” is the
collective term used for both
Sensor Sensors which can be used to
sense a wide range of different
vs. energy forms such as
movement, electrical signals,
Transduce radiant energy, thermal or
magnetic energy etc., and
r Actuators which can be used to
switch voltages or currents .
Sensor
Types
SENSOR
S
EXAMPL
ES
IoT in
Manufacturing
and Steel
Plants
• Predictive
maintenance
• Energy management
• Quality control
• Supply chain
optimization
Benefits of IoT in Steel Plants
05
01 02 03 04
Operational Cost Safety: Enhanc Sustainability Supply Chain
Efficiency: Rea Reduction: Pre ed worker : Energy Optimization:
l-time dictive safety through optimization Tracking raw
monitoring and maintenance remote and reduced materials and
automation. reduces monitoring. waste. finished goods.
downtime.
Challenges in IoT
Implementation
• High initial investment.
• Data security and privacy
concerns.
• Integration with legacy systems.
• Skilled workforce requirement.
Future Trends in
IoT for Steel Plants
• AI and machine learning
integration.
• Expansion of 5G networks.
• Increased adoption of edge
computing.
• Focus on sustainability and green
manufacturing.
JSW Steel’s IoT Journey
JSW Steel is also using IoT and sensor technologies in its "Smart Steel Factories"
initiative, focusing on creating digitally connected operations
smart Iron Zone: JSW Steel uses IoT along with
artificial intelligence and drone technology to manage
raw materials. This includes creating an integrated
model for raw material selection and optimizing costs
across various processes.
Smart Steel Zone: JSW Steel is deploying IoT
and machine learning to enhance
throughput, minimize defects, and increase
machine availability.
Smart Mill Zone: JSW Steel is using predictive
technologies, computer vision, and IoT to
enhance the throughput of its steel mills and
ensure higher asset utilization.
Tata Steel’s IoT
Journey
Tata Steel is implementing several IoT and
sensor-based technologies to optimize its
operations. These include:
Real-time locating systems
Advanced industrial IoT for
(RTLS) for key manufacturing
process optimization
components
IoT real-time energy data
Sensor-based data collection
aggregation and reporting
for energy management
dashboards
Conclusion
To summarize, IoT is a game-changer for steel
plants, enabling smarter, more efficient, and
sustainable operations. Through predictive
maintenance, energy management, and real-
time monitoring, IoT delivers significant
benefits. The case studies of Tata Steel and
JSW Steel illustrate its transformative potential.
Thank you for your attention. I’ll now open the
floor for questions."
Different IOT initiatives
undertaken in SAIL/DSP
Reducing Specific Water
Consumption in DSP
PLANTWISE CONDITION MONITORING THROUGH 350
IOT SENSORS in DSP
ONLINE GPS BASED MONITORING in DSP
Thank YOU
