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April 10, 2019


Fourth Industrial revolution is expected to provide exponential growth by transforming the ways, manufacturing is set-up today, by redefining the modes in which workers deliver their work and will guide industries to define new business models including how, what, why and where to produce.

In today’s world of cutting edge technology, only keeping the manufacturing plant running is not enough, they also need to invest in the next generation IT systems that can help them create value to their business.

This blog is relevant for metals industry experts looking for ways to achieve digital transformation in metals industry as per Industry 4.0 concepts. Industry 4.0 in steel industry will impact in areas of processes, technology platforms, people, organization structures, attitude to risk and operating models & eco systems.

Factors which are expected to disrupt above areas are:

  • Automation & time compression
  • Personalization
  • Miniaturization & Virtualization
  • Greening the world
  • Agile & flexible manufacturing

Metals manufacturers have been facing issues of high cost of investment, price volatility and comparatively low returns. This industry has huge unutilized capital investment due to uncertainties in the market. Therefore this sector is not able to focus on innovations, infrastructure upgrades.  Value engineering initiatives supported by IT enablement will help them to overcome these challenges.

“MADE 4M” a digital transformation framework for Metals Industry, provides solutions for all the functions on shop floor to ensure that they are integrated and synchronized, bring in real time visibility, timely actions and process optimization through continuous feedback.

MADE 4M covers 4 major areas: Manufacturing Operations, Asset management, Data & Analytics and Energy & Utilities Management. MADE 4M template provides structured approach, tools to prioritize areas which can give exponential growth, guidance on implementation of right solutions, on-time deliveries and on-time ROI.

Figure 1

1)      Manufacturing for Metals:

This offering focuses on transformation & standardization of manufacturing operations & IT through integration, enhancement or replacement of existing manufacturing IT systems. This also provide solutions for IT-OT integration and OT security. Additionally it has components of business process improvement by implementing lean manufacturing concepts and through manufacturing intelligence.

Following are the typical use cases implemented by our customers:

  • Achieve operational efficiencies & reduce costs
  • Manage repeatability and predictability of product quality
  • Reduce the WIP inventory and free the working capital
  • Manage overly complex MOM and decision support systems?
  • How to manage the security of OT systems

2)      Asset for Metals:

This offering focuses on maintenance transformation through implementation of Enterprise Asset management systems and IoT based asset management. Associated predictive and prescriptive analytics framework also supports reduction of maintenance cost and improve availability. Next generation solutions like AR/VR, drones, image analytics further helps to improve and optimize operator efficiencies.

Following are the typical use cases implemented by our customers:

  • Improve the asset reliability and availability
  • How to move from reactive maintenance to predictive and prescriptive maintenance?
  • Augmented reality for maintenance optimization
  • Spend analytics and reduction in spares cost


3)       Data & Analytics for Metals:  

This offering covers solutions like digital twin, digital threads and dynamic recipe control, which facilitates faster new product development, process optimization and continuous improvement. R&D as service helps to analyze the historical data for continuous improvements.

Following are the typical use cases implemented by our customers:

  • Faster & cost effective  NPD
  • Process Optimization & cost reduction
  • Accelerate insights to improve efficiency
  • Efficient resolution of chronic issues

4)      Energy for Metals:

Energy & utilities cost is a considerable component of overall manufacturing cost in metals industry. Therefore, objective of this pillar is to provide central platform to manage, control & optimize WAGES (Water, Air, Gas, Energy and Steam) across operations. Also there are solutions to manage carbon footprint.

Following are the typical Energy & Utilities 4M use cases implemented by our customers:

  • Maximize energy utilization and reduce energy costs
  • Manage demand and supply of WAGES
  • Reduce wastages and improve utilization of WAGES
  • Management and control of carbon emission
  • Improvement in per ton consumptions of WAGES

Manufacturing Transformation Success Story

TCS is leading multiple transformation and improvement programs at Tata Steel, Europe, including a manufacturing IT transformation program: SMART (Sustainable Manufacturing Accounts for Reliable Throughput) Steel Factory program.  The objective of this large MES transformation program is to implement integrated way of working in the area of planning & scheduling, production execution, quality management and warehouse management to reduce production cost, improve visibility and enable new product development. “Template Solution” based on the first pillar of the MADE framework i.e. the manufacturing pillar is designed, which is getting implemented across multiple lines with minimum customization. Multiple streams and cross functional teams such as MES, ERP, Process Control, Interface, and Business Intelligence are involved in integrated requirement gathering, solution & design, development, testing and deployment phases.

Right prioritization of improvement areas and deployment of right tools, technology & processes with engagement of right resources will help Metals industry to overcome challenges and sustain growth.

Manish Lunge is the Segment Head for the Metals unit in TCS. TCS has delivered multiple transformation programs under his leadership. He has a rich experience of more than 20 years and has successfully managed cross-functional and cross-cultural team/s to deliver multiple global programs. He is an Industrial Engineer and a certified Six Sigma Black Belt.


Vidula Joshi is working as a Project Manager for Rolling and Finishing area in one of the global steel major’s large transformation program, ‘Smart Steel factory’. She is a Power Electronic Engineer with 16+ years of rich experience in Instrumentation & Process Control, MES and Business Intelligence.


Venkatesh Patil heads the Engineering and Industry Solutions (EIS) group for Energy, Utilities, Resources and Government domains. He has done Masters in Engineering and has 25+ years of rich experience in IT. He has been supporting global customers of TCS to improve and optimize their operations in the areas such as plant solutions, asset management, control systems, and plant information management.



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