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Real-Time Error Tracking and Handling in JSW's Manufacturing Plants with 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
The 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.
The Customer
JSW Steel Ltd
About The 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.
The 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.
Operational Impact
Quantitative Benefit
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