Tata Steel Nederland, Remote Industrial Operations and Senseye
Predictive Maintenance
Operational continuity, efficiency, security
and environmental protection
Tata Steel Nederland, Remote Industrial Operations and Senseye
Predictive Maintenance
Operational continuity, efficiency, security
and environmental protection
Metals
TATA Steel Netherlands
JZ Velsen-Noord
Tata Steel Nederland runs their Hot Strip Mill and Hot Dip Galvanizing Line on the Siemens Industrial Automation DataCenter. They required support with maintaining and securing this critical IT/OT infrastructure due to resource constraints and the need for specialized expertise. At another production site - the Coldmill Annealing Bay - Tata Steel Nederland was seeking increased continuity, efficiency, and sustainability in its production operations. A shortage of skilled workers and complex automated systems and processes could lead to high downtime costs.
To address these challenges, Tata Steel Nederland decided on a Siemens
approach made up of two solutions.
Remote Industrial Operations Services for expert
maintenance and security:
At the Hot Strip Mill and the Hot Dip
Galvanizing Line they implemented the Siemens Managed IT/OT Infrastructure with
Remote Industrial Operations Services for continuous monitoring, maintenance,
management and cyber protection of close to 300 systems of their Industrial
Automation DataCenter.
System availability is optimized
through various services such as continuous monitoring for early detection of
issues, incident management for quick restoration to normal operations,
disaster recovery support in case of a shutdown, as well as regular reporting
for transparency and accountability.
The system is protected through
various security measures such as patching, traffic monitoring and
vulnerability management.
The maintenance of the infrastructure
includes update services, preventive and periodic maintenance, backup and
restore, configuration and change management as well as asset management.
Siemens provides remote support and
expert assistance as well as technical product and hardware support for the
Industrial Automation DataCenter.
Senseye Predictive Maintenance for intelligent
and data-driven asset management:
With Senseye Predictive Maintenance,
Tata Steel Nederland took the Coldmill Annealing Bay to the next level of
digitalization.
The predictive maintenance
application leverages shopfloor data and AI-driven algorithms to create models
that alert maintenance teams to emerging issues to prevent possible failures
instead of correcting them after they occur.
One example of this is a case where
the Senseye application detected a reduction in airflow caused by a clogging
filter in the exhaust air cleaning unit. The system identified a mismatch
between increasing fan speed and decreasing flow rate - an early sign of filter
blockage. This insight allowed the maintenance team to intervene before a full
blockage occurred, replacing the filter, updating control parameters,
increasing inspection frequency and also preventing the release of harmful
fumes into the environment.
Senseye Predictive Maintenance’s
built-in Generative AI Copilot also helped to bridge the knowledge gap within
maintenance teams and gives technicians more guidance on occurring problems.
As a trusted partner, Siemens delivers integrated, scalable services that enable Tata Steel Nederland to achieve operational continuity and enhance efficiency, compliance and cybersecurity across different production lines. Together, we are paving a clear path toward scalable, secure, and future-ready industrial operations.
Through continuous proactive monitoring as well as regular maintenance, several shutdowns of main and utility systems were prevented, reducing downtime and costs
During initial implementation, Siemens service experts resolved around 25% of update and backup issues, ensuring proper system backups
Additionally, the Managed Services support Tata Steel Nederland to fulfill cybersecurity compliance requirements such as NIS 2
By entrusting Siemens with the 24/7 remote management and support of their IT/OT infrastructure, Tata Steel Nederland can redirect valuable resources toward their core business operations
Predictive maintenance reduced equipment breakdowns by 67%. The early detection of several issues prevented production losses.
With continuous monitoring in place, the need for manual inspections and measurements is reduced and asset degradation is now proactively managed. This allows Tata Steel Nederland to lower the number of on-site maintenance staff and reduce travel-related costs through remote support.
A successful use case involving filter clogging prevention led to scaling the solution across other factories within six months.
Tata Steel is
one of the largest steel manufacturers in the world, with an annual crude steel
capacity of 35 million tons and more than 77,000 employees worldwide.
Related Links
Please note that some of the links may be only available in Intranet.
Catalyst for steel transformation
Watch the video and read how digital transformation is supporting Tata Steel Nederland’s efforts to improve operational efficiency.
