The metals industry is currently squeezed between deteriorating raw material grades and the uncompromising precision required by global supply chains. Success now depends on the ability to bridge the gap between the high-heat "Liquid Zone" and precision finishing mills through real-time, closed-loop control.
Stabilize Process Quality & Yield: Detect deviations early across furnaces, casting, and rolling to reduce off‑spec heats, material downgrade, and throughput losses.
Improve Asset Reliability & Energy Efficiency: Identify early wear in high‑heat equipment and monitor power consumption to reduce downtime and control energy costs.
Syncing upstream and downstream data for peak throughput
IT-OT Integration
Connecting data from varied DCS and PLC systems across Furnaces, Hot Rolling, Cold Rolling, and Color Coating lines to drive real-time KPI visibility and process analytics.
Integrated LIMS Platform
Digitize quality data of Spectrometers, UTM and other testing machines. Perform SPC, Golden Batch chemistry analytics. Integrate with MES and ERP for realtime actions.
Customized Digital Twins for Furnaces
Be spoke High-fidelity virtual modeling for critical assets like Blast Furnace, DRI, EAFs, Induction Furnace, BOF, Annealing, Secondary furnaces to optimize product quality and cost of operations.
Coil Surface Defect Detection
Automated computer vision based AI detection of scratches, pinholes, and edge cracks specifically for high speed color-coated production lines to reduce the wastages.
Coke Oven Efficiency Analytics
Integrated use case to analyse the carbonisation in coke oven battery. Detection of green coke and embers post quenching process using computer vision to ensure effficiency of blast furnace.
Cell House Efficiency Tracking (Zinc)
Monitoring electrolyte temperature, electrode current and weight of zinc deposition at electrode level to track and control the efficiency.
Energy & Utilities
Driving down Net Heat Rates and Specific Energy Consumption
AI based for Power Plant NHR Reduction
AI-driven optimization for captive thermal Power Plants specifically designed to reduce Net Heat Rate (NHR). Providing automated problem identification, root cause and recommendations to improve KPIs across boilers, turbine, condensors & auxilary power equipments.
AI agents for SPC reduction
Highly customized process or asset specific solution to provide diagnostic and prescriptive analytics for increase in specific energy consumption. The solution analyses sub equipments, proces parameters, idle time to augment user quickly narrow down the issue.
Energy Management
Classic but effective tools to map and monitor the plant wide energy meters. Providing alerts on power quality, high demand, over equipment consumption, high motor current, low PF etc.
Intelligent Maintenance
Transitioning from reactive repairs to pro-active reliability
Vibration based Condition Montioring
Advanced vibration sensors and automated diagnostics of critical rotating assets including Main Drive Motors, Gearboxes, Cooling Tower Fans, and Exhausters. Identification if issues like structural looseness, misalignment, unbalance, bearing issue etc.
Substation & Power Monitoring
Comprehensive health tracking for Energy meters, Transformers, Relays, Breakers, Bus Bar temperature, ambient temperature, VFDs, and UPS systems to prevent electrical downtime.
Conveyor Health Monitoring
Computer vision based defect detection in Belt, Tray, and Shuttle conveyors to detect structural wear, misalignment, tearing etc.
Foreign Particle Detection
Vision systems trained to identify tramp iron, wood debris, or oversized stones before they enter crushers or rollers.
Green Coke and Hot Ember Detection
Computer vision based detection of green coke and hot embers on coke wharf to ensure coke purity and safety in blast furnace.
Operational Safety & Compliance
24/7 automated vigilance for a zero-harm workplace
PPE Compliance Monitoring
Real-time detection of helmets, high-visibility vests, and safety harnesses in high-risk zones.
Vehicle Overspeeding
Vision-based speed tracking for forklifts and material handling vehicles in crowded bays.
Red-Zone Intrusion
Instant alerts when personnel enter hazardous areas around the Continuous Caster or automated cranes.
Ladle & Hot Metal Safety
Monitoring for splashing or overflow risks during molten metal transport and pouring.
Fall & Ergonomics Detection
Identifying slips, trips, or falls in utility areas and monitoring for safe lifting postures in warehouses.
Discover how Faclon delivers measurable value to every role from strategy to operations, maintenance, and the shop floor.
Vivek Singh
Solution Expert
Focused on delivering predictive analysis to anticipate performance trends, enabling predictive maintenance to minimize downtime, and applying anomaly detection to identify risks before they disrupt operations.
Expert in creating digital logbooks for seamless data capture, applying statistical process control for quality assurance, and using time series forecasting to optimize planning and operations.
Specializes in managing water systems with digital intelligence, delivering accurate renewable energy forecasting, and providing deep RHT insights to improve efficiency, reliability, and sustainable industrial operations.
Expert in optimizing machine health with predictive insights, bridging IT-OT systems for seamless operations, and forecasting energy demand to ensure efficiency, reliability, and smarter decision-making at scale.
Focused on driving energy visibility across plants, improving utilities efficiency with actionable insights, and ensuring reliable operations through advanced OEE monitoring and performance tracking.
Expert in optimizing HVAC chillers and standalone units for peak efficiency while enabling advanced solar monitoring to ensure energy reliability, sustainability, and smarter performance across industrial operations.
Specializes in delivering OEE insights for productivity improvement, enabling seamless PLC control for automated processes, and streamlining CMMS workflows to enhance maintenance efficiency and reduce downtime.
Specializes in building digital twin solutions that accurately mirror real-world operations, while enabling end-to-end traceability to improve quality, compliance, efficiency, and transparency across complex industrial processes.