PlantOS™ Case Study · JSW Steel
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• Steel Manufacturing
• JSW Steel
• Data as of Jan 2026
PLANT RELIABILITY.
Equipment Faults + Process Anomalies
JSW Steel — a global leader in integrated and downstream steel operations — didn’t just digitize its plants. It closed the loop: from raw sensor signal to prescribed action to user-validated production outcome. And in one breakthrough year, it doubled its results. Here’s what enterprise-wide prescriptive reliability looks like across 139 plants and two continents.
Read the Full Transformation
Thank you for your interest in
PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.
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0
Hrs Downtime
EliminatedDoubled in 12 months.
User-validated.
0
Prescriptions Executed At 89.61% implementation rate
0
%
Prediction Accuracy Across 490 areas,
3,815 critical assets
0
Hrs MTBF 139 plants.
Across India and the Americas.
All figures validated by JSW Steel’s Reliability & Operations teams via PlantOS™ Prescription Engine
What’s inside
FROM NOISE
TO OUTCOMES.
Mechanical Faults
Vibration, wear &
bearing degradation
Physics + AI models detect bearing defects, gearbox anomalies, and lubrication failure across Ball Mills, Hot Strip Mills, and Coke Oven Pumps before they cascade into unplanned downtime.
Electrical Faults
Motor overheating &
drive anomalies
Temperature and vibration trend analysis at motor DE and NDE bearings surfaces inadequate lubrication conditions and load imbalances before they trip Blast Furnace Blowers or Electric Arc Furnace drives.
Process Induced Faults
Parameter drift &
production deviation
Continuous 24×7 monitoring across Sinter Plant Blowers, Continuous Casting, and Cold Rolling Mill sections detects process shifts before they impact yield — and before they reach the next stage.
01
490 areas. 3,815 assets. One Single Source of Truth.
How JSW Steel unified 139 plants — from India to the Americas — across Pellet Plants, Electric Arc Furnaces, Blast Furnaces, Steel Melting Shops, and Hot Strip & Cold Rolling Mills into a single contextualized source of truth.
02
Physics + AI: precision that predictions can’t match
PlantOS™ doesn’t flag anomalies. It traces root cause — across mechanical, electrical, and process domains — with 99.75% accuracy. Co-innovated solutions for cranes, steam fans, ROT roll monitoring, and gearbox reliability that no off-the-shelf tool could deliver.
03
Diagnostic → Recommendation → Action
6,047 prescriptions executed. Digital work orders and automated prescriptions improved shop floor execution discipline — not dashboards, not alerts. Work orders that close.
04
Outcomes the plant’s own engineers signed off on
36,108 hours recovered. 6,917 hrs MTBF. Utilization rate raised 2.5% in mills section. All figures validated by JSW Steel’s own Reliability & Operations teams.
Prediction
≠
Outcomes.
Most AI deployments stop at the alert. They predict. They visualize. They dashboard. But prediction without a closed loop is just a more expensive alarm bell.
JSW Steel’s deployment with PlantOS™ proves the gap isn’t in the model — it’s in the mile between insight and action. The 99% Trust Loop™ is what bridges it. And at JSW scale — 139 plants, 3,815 assets, two continents — the results don’t just compound. They double.
18,367 hours saved in Jan 2025. 36,108 hours by Jan 2026. Single Source of Truth. Earned trust.
The 99% Trust Loop™ — how outcomes are guaranteed
1.
Contextualize equipment + process
490 areas, 3,815 assets, 139 plants — One Prescriptive AI platform
2.
Detect with physics-based precision
Mechanical, electrical, and process anomalies — not noise
3.
Prescribe exact corrective action
6,047 prescriptions. 89.61% execution rate. Diagnostic → Recommendation → Action
4.
Validate outcomes. Close the loop.
Engineers validate results in PlantOS™ Digital Reporting
Reliability
Throughput
Process Efficiency
3 Guaranteed Outcomes. 0 Guesswork.
We needed a partner willing to co-innovate on our most difficult problems. With Infinite Uptime, we’re not monitoring equipment anymore — we’re enabling AI-assisted decision-making from work order creation through execution.
Mr. Alec Glenn,
Vice President of Reliability, JSW Steel
Full Transformation Story
GET THE COMPLETE PICTURE.
The numbers above are the headline. The full story reveals the real challenges JSW Steel faced — building trust for prescriptive AI across complex multi-plant operations, scaling from India to the Americas, and co-innovating solutions for problems no generic tool could solve — and exactly how PlantOS™ flipped the script, doubling unplanned downtime savings in a single year.
✔
Real PlantOS™ Diagnostic Reports from live JSW Steel deployments
✔
Equipment-level fault detection across mechanical, electrical & process domains
✔
The 99% Trust Loop™ framework — step by step
✔
User-validated outcome data, confirmed by JSW Steel’s Production & Reliability team.
Download the Full Transformation Story
Infinite Uptime · 946 plants · 26 countries · Production Outcomes. Delivered.
Thank you for your interest in
PlantOS™ Prescriptive AI.
Enter your official work email to unlock specs delivering
3 outcomes in 1 prescription — zero guesswork.
[contact-form-7 id=”e0d679c” title=”landing page of JSW Steel pdf downlaod”]