MES Implementation for Integrated Steel Manufacturing

Client Overview

Tata Steel Long Products Limited (TSLPL), a Tata Steel company, operates an integrated steel manufacturing facility at Gamharia, Jamshedpur. The operations span Blast Furnace, Steel Melting Shop, and Mills, requiring seamless coordination between production, quality, and inventory processes to deliver consistent throughput and quality.

Business Challenges

Prior to MES adoption, TSLPL faced:

• Delayed Coordination between operations and stakeholders, impacting schedules.

• Manual & Paper Based Workflows leading to errors and slower decisions.

• Limited Real Time Visibility into production performance and downtime.

• Material Traceability Gaps from raw material input to finished goods.

• Difficulty Capturing Losses to drive performance improvements.

  
  

Project Objectives

• Implement a Manufacturing Execution System (MES) to digitize and streamline operations.

• Provide real-time visibility of production and key process parameters.

• Deliver end-to-end material traceability for quality and compliance.

• Integrate MES with plant systems and enterprise applications to enable connected manufacturing data.

• Empower stakeholders with dashboards and analytics for better decision-making.

Solution Highlights

A robust MES solution was deployed to:

• Standardize and digitalize order scheduling, job execution, and tracking.

• Capture production, quality, and inventory data in real time.

• Provide live material genealogy from raw material to finished goods.

• Integrate with existing automation and business systems to ensure a single source of truth.

• Deliver role-based dashboards and on-demand reports for operations and management teams.

  
  

Expected Benefits (Initial Rollout – WRM)

The go-live at Wire Rod Mill (WRM) has laid the foundation for plant-wide MES adoption and is expected to deliver:

• Improved Real Time Visibility of production performance and losses.

• Enhanced Material Traceability for compliance and quality assurance.

• Yield and Energy Efficiency Gains anticipated as full rollout progresses.

• Reduction in Internal Rejections through proactive quality monitoring.

• Faster & Data Driven Decision-Making with digital dashboards replacing paper processes.

• Scalable, Future Ready Platform for extending MES across other plant areas.

Conclusion

The MES implementation at TSLPL Gamharia is a major step toward smart and connected manufacturing. By integrating MES with plant and enterprise systems, TSLPL is building a single digital thread across operations improving transparency, reducing inefficiencies, and aligning with its long-term Industry 4.0 vision.