Optimizing Steel Manufacturing with AI
Root Cause Analysis for Operational Efficiency
Challenge
A leading European steel manufacturer faced persistent challenges in their sand casting process for large, custom steel pieces. The high precision required by clients often led to excess material usage, extensive grinding, and increased production costs. The foundry needed a strategic approach to reduce errors, minimize grind time, and enhance overall operational efficiency
Solution
We developed and executed a comprehensive strategy that integrated AI-driven innovation, strategic problem-solving, user experience design, and stakeholder communication to optimize the casting process:
- Reduced Wastage
- Increased Productivity
- Enhanced Operational Efficiency
- Innovation Leadership
1. Root Cause Analysis & Strategic Problem Solving
Conducted in-depth investigations, including stakeholder interviews with foundry personnel, to identify the root causes of errors in the casting process.
The analysis revealed that dimensional inaccuracies were introduced by a combination of environmental factors, process deviations, and design flaws.
We devised targeted interventions to address these issues, focusing on critical areas such as pattern design, sand composition, and environmental conditions.
2. AI & Emerging Technology Innovation
Mapped out the entire casting process ecosystem and identified critical points for AI integration.
We collaborated with the client's internal AI team and an external AI services provider to develop a deep learning solution that could monitor and optimize the casting process in real-time.
This solution involved training a neural network to recognize and correct deviations from the ideal casting conditions, taking into account factors such as temperature, humidity, and material properties.
The approach was supported by the development of a patented system for error reduction in materials casting.
3. UX Strategy for Products & Platforms
Designed an intuitive, user-centric interface for the AI-driven platform, enabling foundry operators to interact seamlessly with the system.
The interface included advanced data visualization tools that allowed operators to quickly interpret complex casting data and make informed decisions.
This design ensured that the technology was accessible and actionable for the operators, facilitating better process control and reducing the likelihood of errors.
4. Stakeholder Communication & Collaboration:
Facilitated workshops and communication sessions with foundry experts, AI scientists, and management to ensure alignment with project goals.
These sessions were essential in securing buy-in from all stakeholders and ensuring that the solution met both practical and strategic needs.
The collaborative approach also included detailed documentation and ongoing training to support the successful adoption of the AI solution.
Impact
Our strategic guidance and AI-driven solutions led to significant improvements in the casting process:
Reduced Wastage
Optimized casting pattern designs and AI-driven adjustments resulted in a substantial reduction in material wastage.
Increased Productivity
The user-centric design of the AI interface empowered foundry operators, leading to enhanced productivity and reduced grind time.
Enhanced Operational Efficiency
The integration of advanced data analytics and AI streamlined foundry operations, improving efficiency and cost-effectiveness.
Innovation Leadership
The successful development and implementation of the deep learning solution positioned the client as a leader in AI-driven manufacturing innovation, supported by a patent for the deep learning application.
How We Can Help
At Industriant, we specialize in strategic planning, AI innovation, and user experience design for complex industrial processes.
Our expertise can help your organization:
- Identify Strategic Opportunities for AI integration in your manufacturing processes.
- Develop Comprehensive UX Strategies for complex industrial systems, including data visualization.
- Facilitate Stakeholder Communication & Collaboration to ensure project alignment and successful adoption.
- Guide the Development of Innovative Solutions that drive productivity and reduce costs.
Client Experiences
Under intense time pressures and often incomplete briefs, they consistently deliver polished results. Visual communication skills ensure a high-quality finished product.
Game Designer at Ubisoft Toronto
Industriant consistently delivered comprehensive designs in both website and interactive visualizations for industrial and mechanical concepts.
Industrial / Product Designer at Reliably Creative
I really enjoyed working with them. Forward-thinking UI experts - an asset to interdisciplinary teams.
Senior Developer, Microsoft Research
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