Real-time production intelligence across your entire steelmaking journey — from Meltshop through Hot Strip, Cold Mills, and Galvanising — in a single configurable platform. 20 integrated modules. One unified data model.
Validated against pilot deployments. Numbers are benchmarks observed within twelve months of go-live.
DigiPlantMES is organised as a suite of tightly integrated modules — production, quality, planning, intelligence, governance, and engagement — all sharing one live data backbone.
Executes and records every stage of steelmaking — from scrap charging through continuous casting. 9 sub-modules covering furnace operations, secondary metallurgy, chemistry/LIMS integration, ladle refractory life, and emissions per heat. 38 production models.
The operational core. Process → Operation → Line → WorkCenter → Equipment. Flexible 1:1, 1:N, N:1, N:M schedule patterns. Operation Screen framework — zero-code customisation of input, info, output, actions. HistoricalRecords on every model.
Every heat, slab, coil, billet, plate as a TrnMat record. Parent-child genealogy with spatial cut coordinates. Soft → firm allocation lifecycle. ERP outbound triggers GOODS_MOVEMENT to SAP automatically.
3D coordinate-based location for every steel object. LYMN automated placement from cranes and stackers. Yard layout designer with zone-painted floor plans. Three.js 3D pile viewer with floor-plan overlays.
3-level defect catalog (Category → Type → DefectCode). 10 disposition decisions with approval chain. Customer tolerance rules. Defect inheritance across split/cut/recoil. Ingests from surface cameras, gauges, and NDT systems.
From test catalog and sampling rules through planned tests to EN 10204 Type 3.1/3.2 certificate issuance. Lot-genealogy support for heat-level inheritance. Calibration tracking with overdue alerts. Multi-standard spec libraries.
Complete lifecycle of work, backup, and intermediate rolls. Immutable event log — corrections via reference, never edits. Roll campaigns, paired-set validation, 9-point diameter profiles. Two-level scrap approval workflow.
CO₂ per heat, coil, batch, and shift across every process stage. Versioned emission factors with immutable factors snapshot per record. Compliance periods: OPEN → CLOSED → SUBMITTED → VERIFIED. Auto-computed CO₂ intensity (kg/ton) per production unit.
From emission measurement to commercial outcome. EU ETS allowance management. CBAM declarations with embedded emissions per CN code. Carbon credit ledger. Customer carbon disclosure per shipment. Supports ResponsibleSteel, ScopeX, IRMA frameworks.
6 PO statuses: DRAFT → RELEASED → IN_PROCESS → COMPLETE. Auto-numbered with tenant-configurable format. 4-level attribute hierarchy. Heat and coil allocation to customer order lines.
Multi-tenant BOM with semantic versioning. Status workflow DRAFT → PENDING → APPROVED → ACTIVE. Multi-level explosion, where-used, cost roll-up. Run types REGENERATIVE, NET_CHANGE, SELECTIVE. Circular reference detection.
Shift patterns, calendar generation, crew/roster. Employee availability, leave, maintenance windows. Handover templates with checklists. Embedded Kanban: boards, columns, cards, history. Shift context auto-tagged on every production record.
Plant engineers, QC inspectors, planners ask natural-language questions about material status, NCRs, shift summaries, MRP exceptions, and grade specs — and get structured, cited answers from live MES data. 7 query intents routed to 5 DB fetchers. SSE streaming. Hindi, Tamil, Japanese, Chinese, Arabic, Turkish, German, Dutch, more.
The enterprise bus. Verified at 10,000 messages per hour. 15 endpoint types, 7 authentication types, 10 system types. Signal-driven outbound triggers — config-driven, no code. Idempotency keys, Dead Letter Queue, pipeline stages with enrichment hooks.
BA-manageable. 5 evaluator languages. Fires synchronously on every registered model save. 7 action types including SET_FIELD, BLOCK, WARNING, NOTIFY. Steel checkpoints: TAC, LCC, ALC, MCC, QGC.
Cross-module full-text search with relevance ranking. Auto-indexing via signals — zero-code registration. Voice command routing for hands-free navigation in PPE. Per-user search history with selection tracking.
Configurable reports with zero custom code. 3 report types, 2 data sources (validated SQL, dynamic ORM). Dashboards with CSS-grid widget composition. Tenant auto-injection — cannot be overridden.
Role and permission management with cache invalidation. Field-level overrides per user or role. Audit trail for every RBAC change. Security audit reports: high-risk perms, unused roles, inactive users. Bulk operations.
Telemetry that scales with the plant. Error deduplication via SHA-256 fingerprinting. Alert rules with cooldown and in-app notification bell. Append-only system event and user activity logs. Hourly/daily email digests.
Engagement that drives adoption. Personal avatars, themes, and shift-aware greetings. Achievement badges: first heat, streaks, zero-NCR week. Zero-coupling design — cannot break production. Per-user preferences and per-tenant message customisation.
Responsive UI across desktop, tablet, mobile. Role-based screens designed for plant-floor workflows. Mill certificates, dispatch notes, and audit packs out of the box. SSO. Public REST APIs for every entity and event. Voice search for operators in PPE on the floor.
Generic MES platforms force steel mills to retrofit their workflows. DigiPlantMES does the opposite — the core entities, KPIs, and workflows are built around how steel actually flows through a plant.
Power periods, sub-lance readings, blow events, charge plan vs. actual — captured per heat, not approximated from spreadsheets.
LF, VD, AOD (with blow steps), VOD treatments. Heat samples, chemistry results, CEV calculation, aim chemistry.
Strands, tundish, sequence, cast products. Ladle line campaigns, refractory life tracking, heat disposition.
Campaign planning, roll wear tracking, immutable event log. Roll Sets with paired validation — diameter match, material match.
Coating line zinc bath chemistry, weight, and strip tension. Cold mill pass schedules, pickling acid concentration, annealing.
EN 10204 mill certificates and CoA generation per order line. Audit-grade test trail. Multi-standard spec libraries — ASTM, EN, JIS, customer-specific.
A live, second-by-second picture of the meltshop — heats in flight, OEE, scrap, active orders. Built for the people who actually run it.
A different kind of MES for steel production.
EAF/BOF, CCM, rolling, galvanising, and cold mill workflows live in the data model — not bolted on. Generic MES platforms force steel mills to retrofit. We don't.
Start where it hurts most. Add the rest at your own cadence. No big-bang programme required. One unified data model, whether you run one module or all twenty.
Operation Screen, Business Rule Engine, reporting, integration — all configured by BAs, not engineers. Zero-code customisation, every installation.
ISA-95 aligned. OPC-UA, MQTT, Kafka, REST. Every entity and event is API-accessible. Integration bus verified at 10,000 messages per hour.
FerroGPT lets anyone interrogate live plant data in 20+ languages — no SQL required. Cited answers, traceable to source records. Tenant-isolated by design.
Run on-premise for air-gapped networks, in your private cloud, or fully managed. The platform doesn't care — and neither will your IT department.
We're partnering with a small number of forward-looking steel operations to shape the platform's roadmap. Differentiated pricing. Direct roadmap influence. First-mover advantage. Limited slots — by application.
Apply to the programme →We work with steel producers to configure, deploy, and go-live fast. Bring your production data — we'll show you what your plant looks like inside DigiPlantMES.