Steel

More good tonnes from every heat.

In a steel plant the margin sits in melt-shop yield and power per tonne, in getting each heat's chemistry right the first time, and in rolling through a shift without cobbles or quality rejects.

Book a site survey See how it works

Our first deployments are with auto-component makers. In this industry we start the same way, with a site survey on your floor and a written read-out of where we would begin.

Where efficiency is lost

Four places a steel plant loses efficiency.

Stamped builds models of your plant from the data it already records, finds where efficiency is lost across process, quality, planning and maintenance, and improves it with actions your team can take.

01 · Process and controlLearn more »
Run every heat better than your best.
Tap-to-tap time and power per tonne swing with the charge mix, how full the furnace runs, delays between heats and how much superheat each crew carries. Stamped models how each grade and charge mix behaves in your furnaces and recommends charging, power or temperature practice that improves on your best heats, for the melt-shop in-charge to accept, adjust or turn down.
EnergySuperheat, delays and part-full heats show up directly in power per tonne.
02 · Quality and lot checksLearn more »
Know which heat or bar is at risk before it ships.
Chemistry misses, surface defects and dimensional rejects usually trace back to the scrap mix, the time a billet spent in the reheating furnace or a stand set slightly off. Stamped links melt, casting and rolling data to each heat and bundle and alerts the in-charge while there is still time to act, for example when a billet has overstayed in the reheating furnace. Heats that look like past rejects are flagged while they can still be checked, and each heat's record is ready when a customer asks.
EnergyA rejected bar has already been melted, cast, reheated and rolled.
03 · Planning and schedulingLearn more »
Keep the melt shop and the mill in step.
When the furnace runs late or the mill stops, billets wait, cool down and need more fuel to reheat, and the rolling programme slips. Stamped keeps track of the whole plant, from furnace and caster status to billet temperatures and the rolling programme, and proposes the sequence that works best across melt shop, caster and mill, showing what each option does to output, reheating fuel and delivery.
EnergyKeeping hot charging going through a delay saves reheating fuel and scale.
04 · MaintenanceLearn more »
Prescribe the fix that saves the most tonnes.
Cobbles, guide and roll problems, lining wear and crane delays each cost tonnes in different ways. Stamped ranks stops by the output and yield they cost, watches specific energy consumption and other slow drift, such as power per tonne creeping up on the same charge or a stand drawing more load for the same section, and prescribes the fix and a window that fits the rolling programme.
EnergyRising power for the same charge is often the first sign of lining or electrical wear.

In this plant

Melt shop, casting and reheating, rolling and utilities.

Most of the data that explains a poor heat or a cobble is already recorded somewhere between the furnace logs, the lab, the mill and the electrical system.

Induction and arc furnaces
In the melt shop the questions are about power per tonne, tap-to-tap time, metallic yield and chemistry hit rate, and Stamped compares each heat with the best ones on the same grade and charge mix, shows which practice made the difference and where it can be improved further.
Casting and reheating
Billets that sit too long in the reheating furnace lose metal to scale and burn extra fuel, so Stamped follows residence time and zone temperatures against what the mill actually needs, especially during delays.
Rolling mill
Crop, cobbles and dimensional rejects decide mill yield, and Stamped links each of them to the stand setup, guide changes and billet temperature that came before them, so the mill team knows which problem to fix first.
Cooling water, fume extraction and compressed air
Pumps, fans and compressors often run at the same duty whatever the furnace and mill are doing, and Stamped points out where they can follow production and where their power draw is drifting.

Example actions

What the people who own the problem receive

Each action goes to the person best placed to act, with what to do, by when, and the reasoning behind it.

Process

Melt shop, for the melt-shop in-charge

Heats on Furnace 1 this week tapped about [N]°C hotter than the grade needs, compared with the best crew's practice, so a lower tap-temperature aim is ready for your review.

Quality

Melt shop, for the quality in-charge

Heat [N] was charged with a scrap mix similar to the heats behind last month's residual copper misses, so a chemistry check before casting is worth doing.

Planning

Rolling, for the mill planner

The mill is expected to stop for about [N] minutes, so holding the next billets at the caster and rolling the angle order first keeps hot charging going for most of the shift.

Energy

Reheating, for the furnace operator

Billets sat in the furnace about [N] minutes longer than the mill needed during last week's delays, so lowering zone setpoints during long delays is ready for review.

Maintenance

Rolling, for the mill maintenance lead

Stand 6 has had [N] cobbles this month on the same section, mostly soon after a guide change, so the guide setup is the first thing to check.

Maintenance

Melt shop, for the electrical lead

Power per tonne on Furnace 2 has crept up on the same charge mix for several weeks, so the lining and the power connections are worth checking at the next relining window.

These are examples, and numbers in [brackets] are placeholders. Your pilot writes the real ones from your own plant data.

Impact

What changes in the plant.

The first finding usually comes within about two weeks. Results are measured against your own baseline and published only with your permission.

Fewer rejections reach the customer

Because lots at risk are caught in real time, while they can still be saved.

More output from the same lines

With bottlenecks, idle time and restarts found and fixed, and control improved beyond your best runs.

Fewer surprise breakdowns

Since slow drift shows up in data you already collect.

Less energy for every good part

Once idle heat, reheats and scrap are counted and brought down.

Before you book

What owners usually ask us first.

Book a site survey

What does it cost?: Only the pilot price is agreed at the survey. The pilot is paid and priced on its own, and the annual price comes after, based on the pilot's results.
What do we need to install?: Nothing new to start. Stamped connects to the machines, meters, ERP and registers you already have, and the survey tells you plainly if that is enough.
How much of my team's time?: Some hours with your plant head and your quality and maintenance leads during the survey, planned around production. In the pilot, actions reach the people who already own that work.
Is our data safe?: We sign an NDA before the survey. Stamped runs on a zero-trust architecture with encryption, your data is stored on cloud servers in India, and we work only with the data your team agrees to share.

Book a site survey

FAQ

Common questions

Has Stamped worked with steel plants?

Our first deployments are with auto-component makers, including forging and heat treatment, which share a lot with a melt shop and a rolling mill. In steel we start the same way, with a site survey on your floor and a written read-out of where we would begin.

Does it work for induction furnace plants as well as arc furnaces?

The approach is the same for both, because it learns from your own heats. The site survey tells us which furnace, lab and mill records you already have and where the first finding is most likely to come from.

Do we need new hardware, or another system next to MES, ERP and SCADA?

No hardware retrofit is needed to get started, because Stamped is software that works with the systems you already run. It is not another MES or CMMS: your MES, ERP and SCADA are where the data comes from, and Stamped works alongside them. Stamped brings their data onto one timeline, so they finally work as one picture of the plant.

How do we start?

We start with a site survey, which means a few days on your floor and a written read-out of where efficiency is being lost and what we would change first. If it makes sense, that is followed by a paid pilot on one line for eight to twelve weeks, and the first finding usually comes within about two weeks.

More good tonnes from every heat.

Four places a steel plant loses efficiency.

Run every heat better than your best.

Know which heat or bar is at risk before it ships.

Keep the melt shop and the mill in step.

Prescribe the fix that saves the most tonnes.