01Late holds
Every hold with its options, cost and history.
- Re-treat or regrade, priced against the order it affects
- Similar past heats show what worked
Decisions in minutes, not meetings
EnterpriseSteel Twin · integrated steel plant digital twin
Every heat, traceable. From raw material to dispatch.
For plant heads and shift controllers in integrated steel plants. One live view of the physical flow — blast furnace, converter, ladle, caster and mills — with every heat linked to its grade, sales order, chemistry and product, and one ranked queue of what needs a decision.
- Heat genealogy end to end
- One action queue ranked by cost
- Shift replay for every review
WhySound familiar?
Three things we hear in every first conversation.
From plant heads, shift controllers and quality heads in integrated steel plants. Composite quotes from discovery calls — the problems are real; the names are left out.
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“The hold was found at the gate, after the slab was cast.”
Chemistry, process and order data live in different systems, so a problem heat is discovered late.
Quality headHolds found too late
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“Every shop optimises its own number.”
The converter hits its tap-to-tap while the caster breaks sequence and an order slips.
Plant headMargin lost between shops
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“We learn about energy overruns the next day.”
Power, oxygen and gas against norm arrive in a morning report, after the shift has gone home.
Shift controllerNo chance to correct in the shift
HowWhat changes with Steel Twin
The same three problems, on the screens that solve them.
Product screens with illustrative data. In a briefing we trace one week of your heats.
02Shops in silos
Every heat traced from charge to coil.
- Grade, sales order, route, chemistry and stage on one queue
- heat_id joins MES, LIMS, ERP and the historian
One plant, one record
03Next-day reports
Alerts reach the shift while it can still act.
- Holds, sequence risks and energy variances pushed to the controller
- One tap logs the decision to the genealogy
Corrected in the shift
FieldSteel Twin in the field
The people, the phone, the place.
The workplace it runs in, the person who uses it on a phone, the team at the desk and the detail it reads.
Photographs are illustrative — real customer sites are not shown.
- heat_idOne keyacross MES, LIMS, ERP and historian
- 7Systems joinedPLC · historian · MES · LIMS · ERP · EAM · energy
- ₹ at riskOn every holdcost of each decision shown
- LiveEnergy vs normby unit and shift
- PredictiveAsset healthbefore the sequence breaks
- ReplayAny shiftwith sources
01The screens
From the blast furnace to the coil that ships.
The control room, the heat queue, quality gates and shift alerts.
autowhat · Steel Twin / Plant control room
Illustrative data
The physical flow from raw material to dispatch, and the ranked action queue.
Product screens with illustrative data — every name, place and figure is a placeholder.
02Before and after
Margin leaks between systems, in silence.
Process, quality, orders and energy are already measured — in seven systems that do not share a clock.
| Area | Today | With Steel Twin |
|---|---|---|
| Heats | Tracked in the unit’s own system | One genealogy from charge to coil |
| Holds | Found at the gate, decided by phone | Options, cost and history on the hold |
| Energy | Reported next day | Against norm, by unit and shift |
| Assets | Fixed after the break | Health exceptions before the sequence breaks |
| Review | Shift log and memory | Replay with every event and source |
03One plant record
Eight steps, from sensor tag to shift decision.
heat_id is the correlation key; every event keeps its source timestamp and quality flag, so stale data is never hidden.
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01
Sense
PLC · SCADA
Temperatures, flows, speeds and equipment states stream from Level 1.
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02
Record
Historian
Process tags kept as time series for replay.
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03
Trace
MES
Heat, ladle, sequence, slab and coil genealogy joined on heat_id.
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04
Test
LIMS · QMS
Chemistry, mechanical tests, defects and holds attached to each heat.
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05
Plan
ERP
Grade demand, orders and dispatch linked to what is being made.
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06
Maintain
EAM
Asset health, work orders and spares beside the process.
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07
Rank
Action queue
Holds, constraints and variances ranked by cost and urgency.
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08
Replay
Shift review
Every shift replayed with the decisions taken and why.
04The platform
Flow, quality, energy and assets on one twin.
Start with steelmaking and casting; iron-making and mills join on the same record.
Flow twin · 4
- Raw material to dispatch
- Heat queue
- Sequence planner
- Shift replay
Quality · 4
- Quality gates
- Holds & disposition
- Defect Pareto
- Heat genealogy
Operate · 4
- Energy & utilities
- Asset health
- Action queue
- Order adherence
Data hub · 4
- PLC / SCADA
- Historian
- MES · LIMS
- ERP · EAM
05How we deliver
Steelmaking first, then the whole plant.
Built with metallurgists and software engineers around your units and your systems.
- Months 1–2 · ConnectMES, LIMS and historian joined on heat_id for one shop.
- Months 2–3 · OperateHeat queue, quality gates and the action queue in daily use.
- Months 3–5 · ExtendEnergy, asset health and iron-making joined.
- Then · ScaleMills and dispatch; shift replay for every review.
FAQQuestions we get about Steel Twin
Straight answers, before the call.
Steel Twin is a digital-twin control room for integrated steel plants: raw material to dispatch on one live flow, every heat linked to grade, sales order, route and chemistry, quality gates priced, energy against norm and one ranked action queue. Short, factual answers for buyers, procurement and the assistants people ask first.
In short. Steel Twin is a digital-twin control room for integrated steel plants: raw material to dispatch on one live flow, every heat linked to grade, sales order, route and chemistry, quality gates priced, energy against norm and one ranked action queue. It is built for plant heads, shift controllers and quality heads in steel. It exists to remove the problems those teams describe in almost every first conversation: holds discovered at the gate, after casting; and each shop optimising its own number. With Steel Twin, teams get a heat genealogy joined on heat_id across MES, LIMS, ERP and historian, and every hold with options, cost and history. It connects to PLC / SCADA & historian, MES · LIMS, ERP · EAM and Energy management, is used by Plant head · shift controllers · QA, and runs on web + mobile. Like every Autowhat AI product, Steel Twin goes live on one site, lane or process first, usually within weeks, on managed cloud, in your own VPC or on-premises, and shares one operational record with the other products, so the second deployment reuses the data and integrations of the first.
Who is Steel Twin for?
Plant heads, shift controllers and quality heads in steel. A digital-twin control room for integrated steel plants: raw material to dispatch on one live flow, every heat linked to grade, sales order, route and chemistry, quality gates priced, energy against norm and one ranked action queue.
What problems does Steel Twin remove?
holds discovered at the gate, after casting; each shop optimising its own number; energy overruns reported the next day.
What do we get with Steel Twin?
a heat genealogy joined on heat_id across MES, LIMS, ERP and historian; every hold with options, cost and history; shift alerts with one-tap decisions and a replay.
What does Steel Twin connect to, and who uses it?
It connects to PLC / SCADA & historian, MES · LIMS, ERP · EAM, Energy management. Users: Plant head · shift controllers · QA. Channel: Web + mobile.
How do we start with Steel Twin?
With a 30-minute working session on your own data — an engineer from the relevant sector, not a sales queue. The first wave is scoped in that call; most products go live on one site, lane or process within weeks and then scale.
Where does Steel Twin run, and who owns the data?
On managed cloud, in your own VPC (AWS, Azure or GCP) or on-premises, with your keys. SOC 2 Type II and ISO 27001 controls, India data residency when required, and local or open-weight models when policy demands it. The data stays yours.
06Briefing
Bring one week of heat records. We’ll show you where the margin leaked.
A working session: your heats traced end to end, holds priced, and the first action queue built.