The company’s record results stem from Industry 4.0 digitalisation and an AI-powered Predictive Maintenance Platform, which has cut downtime by over 25,000 hours across 10 plants.
(Source: prhandout)
“AI enablers are not just technological upgrades; they are strategic enablers that position us to lead with agility and innovation,” says Jayant Acharya, Joint Managing Director and CEO, JSW Steel, in a recent company filing. The company, in FY 2024–25, bagged 100 product/grade approvals. Moreover, the steel major’s Centre of Excellence (CoE) executed 565 projects, with 345 delivering direct business benefits.
According to the company report, “JSW Steel has been steadily growing in India and is now the country’s largest steelmaker with a domestic capacity of 34.2 MTPA. We are well-placed to pursue value-accretive growth and are targeting a domestic capacity of 50 MTPA by FY 2030–31.” As per the company’s financial results, it registered the highest-ever crude steel production of 27.791 million tonnes, with revenue from operations of ₹1,68,824 crores in FY25.
At the heart of this…
Among other factors, JSW Steel attributed the record performance to the massive digitalisation drive in the company. “By embracing Industry 4.0 technologies across manufacturing, supply chain, sales, safety, and sustainability, we are setting new benchmarks in performance and stakeholder value,” says Acharya, further adding, “At the heart of this transformation is our AI-powered Predictive Maintenance Platform, now live across 10 plants and over 2,900 critical assets. This system has helped us avoid over 25,000 hours of unplanned downtime and maintenance costs by enabling real-time, condition-based monitoring through 13,500 smart sensors.”
However it’s important to note, “JSW Steel reported consolidated Crude Steel production for the first quarter of FY 2025-26 at 7.26 million tonnes. The Crude Steel production was higher by 14% YoY. However, it was lower by 5% Q-o-Q primarily due to planned maintenance shutdowns of blast furnaces during the quarter,” says the company’s Q1 FY26 financial results.
Employees from across hierarchies at JSW Steel have taken 5,000+ hours of digital training, and about 12+ flagship digital projects are underway in the company, says the filing.
Coupled with digital twin
The AI-powered platform is enabled by real-time condition-based monitoring. It has given a major fillip to asset reliability, energy efficiency, and the availability of manufacturing operations. The predictive maintenance platform is complemented by the deployment of Digital Twins—a virtual reproduction of key factory assets, integrating IoT sensor data with AI diagnostics. These interventions are reshaping asset performance and ROI, with up to 12% downtime reduction and maintenance cost savings. They have also resulted in a 10% increase in asset lifespan through early detection and optimised maintenance.
Digitisation reduces logistics costs
The entire spectrum of the material handling value chain has also been digitised, resulting in considerable savings in time taken and costs incurred in material management.
JSW Steel introduced a digital IMS (Internal Material Shifting) tracking system across its mines in Odisha. Hitherto, the process was plagued with mismanagement and errors because it was reliant on manual logs. Geofencing at loading, unloading, and weighbridge points, coupled with Global Positioning System (GPS) devices, has enabled real-time trip monitoring and weight verification. Since implementation, over 80,000 weighments have been digitally processed. The time required for management information calculations has dropped dramatically—from 45 minutes to just 3 seconds.
In addition to IMS, the company has also launched Project SAMPARK in the area of logistics. It is a unified, end-to-end digital platform that enhances efficiency, transparency, and sustainability at the Vijayanagar and Dolvi plants. SAMPARK replaces outdated processes with automation and smart tracking, tackling key challenges such as lack of real-time visibility, manual dependencies, and suboptimal resource use.
Reduction in CO₂ emissions
Project SAMPARK ensures safety, reduces delays, and cuts emissions, saving around 5,000 tonnes of CO₂ annually. The programme has digitalised over 10 million transactions, dispatching goods worth ₹160 crore daily and saving 2 million man-hours each year. The initiative is equipping over 500 employees with digital skills.
“Looking ahead, we are committed to deepening our digital and AI-led transformation to build a fully connected, agile, and resilient enterprise,” says Sajjan Jindal, CMD.
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