Industry
From melt to coil, one honest version of the plant.
We build the historian, quality and yield software that ties a metals plant together, from the melt shop through casting and rolling, so every tonne is traceable and every loss is visible while there is still time to act.
Overview
An integrated metals plant is really a chain of processes that each keep their own truth. The melt shop has its Level-2 system, the caster and the mills have theirs, the labs have LIMS, maintenance has its CMMS, and the historian holds millions of tags that almost nobody queries directly. The data exists in abundance. What is missing is a single, coil-level thread that follows a heat from ladle to finished product, so that yield, quality and energy can be judged against the same batch rather than three different views of it.
We were built by people who worked in heavy industry before they consulted, so we know what a genuine yield number costs to assemble and why a metallurgist distrusts a report that cannot show its lineage. We start by advising honestly on where the real gaps sit, usually at the seams between Level-2 systems, the historian and the lab, then build the integration that stitches heat, cast, coil and test result into one traceable record. When yield and quality read from the same source, the morning meeting stops arguing about numbers and starts fixing the process behind them.
The questions we help answer are the ones that move margin: where prime yield is really lost between casting and finishing, which defects recur on which grades and lines, how energy intensity moves with product mix, and which heavy assets are quietly eroding availability before they stop a line. Reheat furnaces, casters and rolling mills are unforgiving and expensive to run idle, so downtime by genuine cause and reliability trends over time become visible enough to plan around instead of react to.
Metals plants are hot, continuous and hard on software. Signals come fast, shutdowns are costly and the people who need the answer are on the floor, not at a desk. We design for that: robust historian and Level-2 integration, screens that hold up in the control pulpit, and analytics honest enough to trust on a night shift. We advise, we build and we can run the platform afterwards, so it keeps pace as grades, lines and the product mix change.
The reality
What we hear from metals & steel teams.
Yield and quality numbers that never reconcile across melt shop, caster, mills and lab
No single traceable thread from heat and cast through to finished coil
Historian and Level-2 data that is abundant but rarely turned into decisions
Recurring defects and downgrades whose root cause stays buried in separate systems
Energy intensity that shifts with product mix but is hard to attribute or control
Heavy assets like furnaces, casters and mills losing availability to unseen faults
How we help
Software and data, built for metals & steel.
Historian & Level-2 integration
We connect historians, Level-2 systems, LIMS and maintenance into one consistent data layer, so process, quality and reliability can finally be read side by side instead of in isolation.
Yield analytics
Clear, reconciled views of prime yield and losses by heat, line and grade, so the whole plant works from one honest figure and can target where metal is really lost.
Material traceability
A genealogy that follows a heat from ladle through cast, coil and finishing, tying every test result and process condition to the product, ready for audits and customer claims.
Quality & defect insight
Defects and downgrades linked back to grade, line and process conditions, so recurring problems become patterns you can act on rather than one-off surprises.
Energy & intensity tracking
Energy consumption tied to product mix and process, making intensity per tonne visible enough to manage as grades and campaigns change.
Reliability & maintenance
Continuous visibility of heavy asset health with honest downtime by cause, so maintenance and operations plan interventions before a fault stops a line.
How we work
People who have worked your world, not just read about it.
Advise
We spend time from the melt shop to the finishing line, trace where your yield and quality numbers really come from and agree the shortest path to a traceable, trusted picture.
Build
We deliver in working increments, integrating your historian, Level-2 and lab systems first, then layering yield, quality and reliability analytics so value shows up early.
Run
We can operate and support the platform, adapting it as grades, lines and product mix change so it stays accurate rather than drifting out of date.
- +1-3% typical
- Prime yield recovered once losses are seen by heat and line
- Coil-level
- Traceability from heat and cast to finished product
- One number
- Yield and quality agreed across operations, quality and finance
FAQ
Questions we hear a lot.
How do you integrate Level-2 and historian data without disrupting the plant?
We integrate around your existing systems rather than replacing them. We read from historians, Level-2 automation, LIMS and maintenance systems into a single data layer, working from the seams where the systems meet so nothing on the process side is touched. The plant keeps running as it is, while yield, quality and reliability finally become readable from one consistent source.
What does material traceability give a steel plant in practice?
It gives you a genealogy that follows each heat from the ladle through casting, rolling and finishing, with every test result and key process condition tied to the product. When a customer raises a claim or an auditor asks, you can show the full lineage of a coil in minutes rather than reconstructing it from separate logs. It also makes recurring quality problems far easier to trace to their real source.
Can you help us understand where prime yield is actually lost?
Yes, this is one of the most common reasons plants come to us. We reconcile yield across the melt shop, caster and mills so losses can be seen by heat, line and grade rather than as one plant-level figure. Once the losses are visible in context, the improvement work has a target, and even a small recovery in prime yield is worth a great deal at plant scale.
Do you cover energy intensity as well as production?
We do. Energy is a major cost in metals and it moves with product mix, campaign length and process conditions. We tie energy consumption back to the product and process so intensity per tonne becomes visible and attributable. That turns energy from a monthly total into something operations can actually manage as grades and schedules change.
Working in Metals & Steel? Let's talk.
Tell us what you are trying to fix. We will tell you how we would approach it, and whether software is even the right answer.