OpenLegacy Case Studies Real-Time Error Tracking and Handling in JSW's Manufacturing Plants with OpenLegacy

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	Real-Time Error Tracking and Handling in JSW's Manufacturing Plants with OpenLegacy OpenLegacy

Real-Time Error Tracking and Handling in JSW's Manufacturing Plants with OpenLegacy

OpenLegacy

Technology Category	Application Infrastructure & Middleware - Database Management & Storage Infrastructure as a Service (IaaS) - Cloud Databases
Applicable Industries	Cement Equipment & Machinery
Applicable Functions	Maintenance Product Research & Development
Use Cases	Additive Manufacturing Root Cause Analysis & Diagnosis
Services	System Integration Training
Challenge	JSW, a multi-billion dollar company, is a key player in India’s steel, energy, cement, and infrastructure industries. The company's steel manufacturing is spread across multiple plants, each housing dozens of machines with numerous sensors tracking multiple data points and supplying event data every 2-3 seconds. This data includes field maintenance, material consumption, and machine usage. Although the data is saved in each machine’s database and transferred to the central Oracle databases, the process had significant issues. Each machine used its own data protocols, making the data transfer processes 'closed' and lacking a standard way of reporting errors. As a result, some errors went unnoticed for a long time, leading to financial losses. For instance, the production of metal with incorrect dimensions could go unnoticed, resulting in significant waste and financial loss. Read More
About Customer	JSW is a multi-billion dollar company that has played a significant role in India’s growth in the steel, energy, cement, and infrastructure industries. The company prides itself on its differentiated product mix, state-of-the-art technology, excellence in execution, and focus on sustainability. JSW's steel manufacturing is spread across multiple plants, each housing a variety of machines equipped with numerous sensors tracking multiple data points. These machines generate a vast amount of data, including field maintenance, material consumption, and machine usage, which is then transferred to central Oracle databases. Read More
Customer Name	JSW Steel Ltd Read More
Solution	JSW implemented OpenLegacy’s platform to generate microservice-based APIs that encapsulated the processes of transferring data between the machines and the central Oracle database. OpenLegacy generates standard Java code that is easily extended in any development environment, giving JSW's developers full flexibility to handle exceptions and errors with any level of granularity. They could, for example, send an email to a team when detecting one type of error, or simply log an error message for a less critical error type. Furthermore, JSW wanted to programmatically surface errors from the shop floor in their SAP ECC Quality Control module. OpenLegacy enabled this integration quickly and easily by supporting seamless data transfer from the sensors to the Oracle databases and to SAP. Read More Log in to view content
Contents

Technology Category

Application Infrastructure & Middleware - Database Management & Storage

Infrastructure as a Service (IaaS) - Cloud Databases

Applicable Industries

Cement

Equipment & Machinery

Applicable Functions

Maintenance

Product Research & Development

Use Cases

Additive Manufacturing

Root Cause Analysis & Diagnosis

Services

System Integration

Training

Challenge

JSW, a multi-billion dollar company, is a key player in India’s steel, energy, cement, and infrastructure industries. The company's steel manufacturing is spread across multiple plants, each housing dozens of machines with numerous sensors tracking multiple data points and supplying event data every 2-3 seconds. This data includes field maintenance, material consumption, and machine usage. Although the data is saved in each machine’s database and transferred to the central Oracle databases, the process had significant issues. Each machine used its own data protocols, making the data transfer processes 'closed' and lacking a standard way of reporting errors. As a result, some errors went unnoticed for a long time, leading to financial losses. For instance, the production of metal with incorrect dimensions could go unnoticed, resulting in significant waste and financial loss.

About Customer

JSW is a multi-billion dollar company that has played a significant role in India’s growth in the steel, energy, cement, and infrastructure industries. The company prides itself on its differentiated product mix, state-of-the-art technology, excellence in execution, and focus on sustainability. JSW's steel manufacturing is spread across multiple plants, each housing a variety of machines equipped with numerous sensors tracking multiple data points. These machines generate a vast amount of data, including field maintenance, material consumption, and machine usage, which is then transferred to central Oracle databases.

Customer Name

JSW Steel Ltd

Solution

JSW implemented OpenLegacy’s platform to generate microservice-based APIs that encapsulated the processes of transferring data between the machines and the central Oracle database. OpenLegacy generates standard Java code that is easily extended in any development environment, giving JSW's developers full flexibility to handle exceptions and errors with any level of granularity. They could, for example, send an email to a team when detecting one type of error, or simply log an error message for a less critical error type. Furthermore, JSW wanted to programmatically surface errors from the shop floor in their SAP ECC Quality Control module. OpenLegacy enabled this integration quickly and easily by supporting seamless data transfer from the sensors to the Oracle databases and to SAP.

Impact #1	The implementation of OpenLegacy's platform has revolutionized JSW's error detection and handling process. Errors are now detected in real-time, leading to improved performance, less waste, and substantial savings. The platform has also ensured the timely availability of authenticated data, handling an impressive service level agreement (SLA) of 300 records per second. Furthermore, OpenLegacy uses standard technologies, eliminating the need for JSW to hire external development resources or invest in training on multiple proprietary protocols. This has led to cost savings, faster implementation, and better usage of existing teams, enhancing the overall operational efficiency of JSW's manufacturing plants.

Impact #1

The implementation of OpenLegacy's platform has revolutionized JSW's error detection and handling process. Errors are now detected in real-time, leading to improved performance, less waste, and substantial savings. The platform has also ensured the timely availability of authenticated data, handling an impressive service level agreement (SLA) of 300 records per second. Furthermore, OpenLegacy uses standard technologies, eliminating the need for JSW to hire external development resources or invest in training on multiple proprietary protocols. This has led to cost savings, faster implementation, and better usage of existing teams, enhancing the overall operational efficiency of JSW's manufacturing plants.

Benefit #1	Real-time error detection leading to improved performance and substantial cost savings
Benefit #2	Timely availability of authenticated data, handling an SLA of 300 records per second
Benefit #3	Cost savings and faster implementation by relying on in-house developers and standard, open technologies

Benefit #1

Real-time error detection leading to improved performance and substantial cost savings

Benefit #2

Timely availability of authenticated data, handling an SLA of 300 records per second

Benefit #3

Cost savings and faster implementation by relying on in-house developers and standard, open technologies

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Overview

Real-Time Error Tracking and Handling in JSW's Manufacturing Plants with OpenLegacy

Operational Impact

Quantitative Benefit