Plan the heats, and the app works out a charge that hits the chemistry — with the fewest additions, or at the lowest cost. Then it keeps up as the heat is made: the crane's loads, the alloy bins' scales, the furnace panel and the spectrometer land on the heat as they happen, and every heat comes out costed.
A heat is planned against a drawing's chemistry, charged by the crane, melted, sampled, alloyed and completed — and the app keeps up with each step as it happens, not at the end of the shift.
Heats queued against a drawing's chemistry bands and charge rules.
Two suggestions worked out in the background: fewest additions, lowest cost.
The crane's loads land on the charge mix by themselves; stock drawn oldest batch first.
The furnace panel's kW, kWh and times live on the card — it can start and close the heat.
The spectrometer's results arrive by heat and stage, with the kg each element still needs.
The bins' scales weigh the addition; the heat closes costed, and its next one moves on.
Every planning is one heat of one drawing. The drawing carries its chemistry — an aim per element with its band — and the charge rules a charge of it is made of.
Heats in progress on one side, planned and not started on the other, in one drag-and-drop order across the days. A heat can queue as a furnace's next: the crane feeds it the moment the heat before it is completed.
A drawing's aim holds each element's target with its minus and plus band. Its charge rules say which raw materials and cored wire go in — a must or optional, each within a min–max % of the charge — and a grade's rules are inherited by every drawing that has none of its own.
From the moment a heat is planned, the app works out how to charge it — twice: once for the fewest additions, once for the lowest cost — and checks again every five minutes until it is charged, as stock and prices move.
Every element as close to its band as the charge rules allow.
The least alloy to add afterwards, or the lowest spend at the current batch prices; the other one breaks a tie.
The stock on hand, each material's charge step — a crane load, a bag — and whole metres of cored wire.
Read only, beside your own charge mix: the fewest additions — each raw material within its rule, every element's expected % inside its band, the kg left to add and what the raw materials cost — with the lowest cost and the two compared a tab away.
Use in charge mix fills the lines; the values you had are kept, and Revert to your values brings them back. The first save charges the heat: the heat no., melt no., lining and ladle life move on, and stock is drawn oldest batch first.
The charge as entered beside either suggestion — the % each gives, the additions each leaves, what each costs — and the Suggestion Dashboard adds up how every heat's charge mix came about.
A UWB tag on the crane and the crane's PLC report over MQTT. The app reads each lift against the bay's layout — which bunker it came from, what it settled at on the hook, whether it was let go over the furnace — and puts it on that heat's charge mix as it lands.
The bay's furnaces across the top, the crane live over the bay, and every bunker tagged with the stock it has left — amber at its min level, red when it is out.
Target kg against actual kg per material, live, beside the bay from above — in 2D, or in 3D.
A designer for the crane bay: the bunkers and the raw material each holds, the furnaces — the layout every lift is read against.
One row per furnace: what it is melting and how far it has got — its panel's readings live, its charge mix, its lab results and the kg each element still needs.
The nameplate, the lining and the ladle's life (amber from 90 %), the panel's readings — kilowatt, kilowatt-hour, kilogram, on, off and hold time — and the heat's timeline. Under it, each element's aim %, lab %, required kg and actual kg, with the formula a tap away.
The same dashboard on a tablet by the furnace. Furnace Readings draws each panel's last 24 hours — a point a minute, the heats on the furnace shaded.
The lab's results arrive on their own, filed by heat and stage. The app works out what each element still needs, and the bins' scales weigh what goes in.
Results come in from the spectrometer through the lab's desktop app — I-Initial, II-Initial, I-Final — and a late final still reaches the completed heat.
Each bin's load cell reports on the PLC's feed. Weigh up from empty and press Done — or simply pick from the bins, and the drop in each one's weight is the addition.
The Furnace TV is an Android TV app — or any browser — that shows a location's furnaces live. Set up once, it finds its way back after a power cut.
Then it reopens its location by itself, five seconds after the power comes back.
Nothing to press and nothing to break on the shop floor.
Pushed the moment something changes — nothing waits for a refresh.
Elements, raw materials and cored wire are kept as the batches you received. A heat draws the oldest first, and an item is priced by its latest received batch — so every heat's cost is the cost of what it used.
GRNs come in from your ERP — raw materials and elements, each GRN line a batch — beside the batches you receive by hand.
Opening, received, used by the heats and closing — in kg and at the batches' own prices, read again as the stock moves.
Built from the heats themselves — their charge, their lab results, their alloys — not from a form somebody fills in at the end of the shift.
Each heat judged at its first initial lab result — an element low, high or in spec — by element, furnace, grade and shift, with the heats that missed.
Raw materials, alloys and cored wire in kg, in ₹ and per tonne, against the period before.
As suggested, changed after using, typed by hand or the crane's — and how each kind did.
A shift — or a whole day: the heats it saw and where each stood at its end, the lab, right first time, what it used, the crane's lifts and the low stock now.
A line per bin, the weigh-ups for a heat in green — with seven days of the bins' board's health above them.
The Planning Report lists the completed heats with their charge mix, alloys and total cost, and prints each heat's charge list and lab results as PDFs.
Completed heats by charge time — each with its steps, charge mix, lab results and cost — with the totals and the alloys used. Filter by how the suggestion was used; export to Excel.
The heat's charge mix, additions and lab, on your plant's form.
Alloy out of the bins against what the heats needed — what went unrecorded, in kg and ₹.
The charge list and the inspection record follow your own paper forms — show us yours. Talk to us about your format →
The app mails the people you pick when a heat completes, when stock runs low and when a board on the floor goes quiet — through your own mail server.
Picked per mail on Settings → App settings, sent through Gmail, Zoho Mail or your own mail server.
| Furnaces & bays | Induction furnaces in locations (bays); lining, ladle life, melt no. and heat no. kept per furnace. |
|---|---|
| Planning | Heats against drawings: element bands, charge rules by drawing or grade, one queue, a furnace's next heat. |
| Charge plan | Two suggestions per heat — fewest additions, lowest cost — by linear programming within stock, charge steps and whole metres of wire; checked every 5 minutes. |
| Crane | UWB position and the crane PLC over MQTT; lifts read against the bay's layout; auto-fill onto the charge mix; 2D and 3D bay views. |
| Alloy bins | Load cells on the PLC feed; weighed up from empty or picked from; the addition lockable to the bins; Bin Pick Audit. |
| Furnace panels | Modbus TCP: kW, kWh, kg, on, off and hold time, polled every 1–60 s; the panel can start and complete heats. |
| Lab | Spectrometer results through the lab's desktop app and an IoT board, by heat no. and stage; required kg per element. |
| Stock | Elements, raw materials and cored wire as batches; first in, first out; priced by the latest received batch; min levels mailed. |
| ERP | Grades, raw materials, products and GRNs pulled over REST — on demand and every night. |
| Dashboards | Right First Time, Usage, Suggestion, Shift Summary, Bin Weights, Raw Material Stock, Furnace Readings. |
| Reports | Planning Report with costs; charge list and lab results PDFs; Bin Pick Audit; Excel exports. |
| Floor screens | The Furnace TV as an Android TV app or in any browser; tablet layouts. |
| Alerts | Heat mail, low stock mail and the no signal alert, through your own SMTP account. |
| Access control | Roles with view, add, edit, delete and export per screen. |
| Deployment | A server on your plant network; every screen in a browser; the database backed up from the screen. |
We will walk you through a heat on a demo bay — the charge plan, the crane's loads landing, the lab result and the bins' correction — and then look at how your melt shop would run on it.
Runs on a server on your plant network. Every screen in a browser.