Platform Premiere Prompts Pivotal Production Progress

At the Global Steel Dynamics Forum in New York on June 18, Infinite Uptime unveiled PlantOS™, an advanced manufacturing intelligence platform, and its POaaS model. Designed for heavy industries such as steel, cement, and chemicals, PlantOS™ uses AI and device-agnostic sensors to enable near-perfect equipment availability and operational efficiency, setting a new benchmark for industrial reliability.

AI‑Augmented Availability Achieves Almost Absolute Uptime

PlantOS™ delivers 99.97% equipment availability by capturing live data from vibration, acoustic, and thermal sensors, including piezoelectric & MEMS devices, in extreme environments (up to 150 °C or 2 rpm). These real-time insights enable predictive maintenance and rapid interventions, effectively reducing unplanned breakdowns and maintaining production continuity.

Energy‑Efficiency Edge Enshrined Through Embedded Reduction

Beyond uptime enhancement, PlantOS™ also drives tangible energy savings. Infinite Uptime estimates that clients can reduce energy use per unit produced by up to 2%. This reliability-to-sustainability synergy benefits both bottom-line margins and ESG goals, as industrial firms increasingly seek to decarbonise operations while cutting costs.

Modular Mastery Makes Scalable Steel Solutions

PlantOS™ is built around five core modules: Sense & Ingest, Administer & Configure, Diagnose & Analyze, Act & Resolve, and Collaborate & Integrate. This structure enables clients to deploy the platform in incremental phases, starting with basic monitoring and advancing to AI-powered analytics and human expert collaboration, fully tailored to each facility’s maturity level.

Proven Performance Powers Partnering Partnerships

The platform has been validated across more than 53,000 installations, with JSW Steel standing out as a signature success story. JSW’s use of PlantOS™ added 25,842 hours of production uptime across its plants, enhancing throughput, cutting costs, boosting sustainability, and delivering multi-million‑dollar ROI within 6–12 months.

Diagnostic Deployment Drives Data‑Led Decision Dominance

PlantOS™ was rolled out across key sub-plant areas: from the sinter plant and coke oven to wire rod and cold rolling mills. Device-agnostic sensors were installed across equipment in over a dozen divisions, each feeding data to an AI-native platform built to detect failure precursors. Piezoelectric and MEMS sensors operated under harsh conditions, and every dataset, from vibrations to RPM fluctuations, fed into live dashboards accessible to both plant engineers and executives.

Outcome Orientation Orchestrates Operational Overhaul

Results followed fast. JSW recorded a cumulative 25,842 additional production hours across its steel plants. Fault prediction rates climbed above 99.97%, leading to preemptive maintenance cycles and dramatically reduced breakdowns. Energy efficiency improved by up to 2% per unit of output. Beyond productivity, man-machine interfaces were streamlined, safety protocols enhanced, and plant-wide decision-making became deeply data-centric.

Co‑Innovation Catalyses Customised Condition Monitoring

JSW and Infinite Uptime didn’t stop at standardisation, they co-developed bespoke predictive models for sector-specific problems. Solutions included:

• Crane system optimisation across yards

• Predictive analytics for steam fan failure in energy zones

• Real-time monitoring of ROT (Run Out Table) rolls in hot strip mills

• Gearbox reliability frameworks for long product mills

Each innovation addressed known bottlenecks with tailored tech and validated impact, setting benchmarks for the global steel industry.

Structured Staging Streamlines Scaling Success

The partnership followed a structured deployment methodology:Discovery & Feasibility involved workshops, site surveys, application scoping, and risk assessments.Delivery & Commissioning included full system installation, trial runs, and user sign-off.Customer Success ensured onboarding, system adoption, value realisation, and performance tracking.Outcomes Delivered included improved reliability, reduced downtime, data-informed decisions, and optimised throughput across all measured plants.

Digital Discipline Delivers Durable Downtime Decline

By applying PlantOS™’s vertical-specific AI and cross-layer integration of human insight and algorithmic automation, JSW turned its plants into smart environments. Engineers received actionable alerts; finance heads monitored ROI in real time. Asset health dashboards became as crucial as yield reports. Every decision, from when to lubricate to when to schedule overhauls, was backed by granular equipment intelligence.

Validation Vindicates Value Beyond Vendor Speak

JSW’s success has become an industry benchmark. The partnership model not only enabled uptime and energy gains, it redefined how Indian manufacturing can marry scale with digital discipline. With 84 million metric tons of steel monitored globally through Infinite Uptime’s systems, JSW remains one of its most advanced clients, demonstrating the scalability of PlantOS™ across subcontinent-sized operations.

Forward Focus Frames Future Fabrication Philosophy

The collaboration continues. Infinite Uptime and JSW are now exploring AI-driven risk models, enhanced EHS analytics, and newer integrations with plant ERP and MES systems. As both companies move beyond diagnostics into decision automation, they aim to shape the global discourse on what “smart manufacturing” truly means, pragmatic, productive, predictive, and proven.

Key Takeaways:

• Infinite Uptime introduced PlantOS™ & POaaS at the Global Steel Dynamics Forum, delivering 99.97% equipment availability & up to 2% energy savings per unit produced

• The modular AI-native platform uses piezoelectric & MEMS sensor data, even in extreme conditions, to enable scalable predictive maintenance for steel & heavy sectors

• Case studies such as JSW Steel demonstrate substantial impact: over 25,000 added production hours, multi-million dollar ROI within 6–12 months, across 214 global plants

• Applications span mining, sinter plants, blast furnaces, cold rolling, coating & galvanizing lines, using AI-powered insights & sensors even in extreme operating environments

• Their co-innovation included crane, gearbox, and steam fan monitoring, forming a model of predictive maintenance and production reliability for global steelmakers