Achieved a 70% reduction in temperature-related failures with AI-powered monitoring of switchyard assets, ensuring early detection of thermal anomalies and potential equipment faults for enhanced reliability and predictive maintenance.
Achieved 70% Reduction in downtime of conveyor failures with Ripik AI conveyor belt monitoring system. This ensured smoother operations, minimized downtime, and delivered significant cost savings.
Achieved an 82% reduction in crusher blockages and a 20% decrease in unwanted stoppages in cement crusher operations by detecting oversized rocks in real time. This led to smoother operations, reduced downtime, and substantial cost savings.
In the world of cost-competitive steel market, our client managed to improve fuel rate and throughput by real time Nut Coke tracking, resulting in sustainable steel production.
Real-time camera intelligence to monitor materials, equipment, and processes, driving efficiency and consistency in industrial operations.
Hosts and manages hundreds of Vision AI Agents, enabling you to customize, deploy, and scale real-time monitoring solutions instantly across operations.
Let us walk you through a tailored demo experience.
Achieved a 70% reduction in temperature-related failures with AI-powered monitoring of switchyard assets, ensuring early detection of thermal anomalies and potential equipment faults for enhanced reliability and predictive maintenance.
Achieved 70% Reduction in downtime of conveyor failures with Ripik AI conveyor belt monitoring system. This ensured smoother operations, minimized downtime, and delivered significant cost savings.
Achieved an 82% reduction in crusher blockages and a 20% decrease in unwanted stoppages in cement crusher operations by detecting oversized rocks in real time. This led to smoother operations, reduced downtime, and substantial cost savings.
In the world of cost-competitive steel market, our client managed to improve fuel rate and throughput by real time Nut Coke tracking, resulting in sustainable steel production.
Real-time camera intelligence to monitor materials, equipment, and processes, driving efficiency and consistency in industrial operations.
Hosts and manages hundreds of Vision AI Agents, enabling you to customize, deploy, and scale real-time monitoring solutions instantly across operations.
Let us walk you through a tailored demo experience.
With accurate real-time molten level tracking, the system saved over 10,000+ man-hours annually and increased production efficiency by 1–2%, enabling safer operations and more consistent performance.
One of the top steel manufacturer struggled with inconsistent and inaccurate molten metal level measurements across its furnaces. Manual inspections exposed operators to safety risks and often failed to catch sudden level fluctuations, leading to operational inefficiencies and unplanned downtime.
Harsh furnace conditions like extreme heat, glare, smoke, and splashes obstructed visibility, while manual checking based on visual judgment often led to errors. This resulted in inaccurate molten metal level measurement, causing unplanned stoppages.
High molten metal levels created a severe risk of overflows, bursts, and splashes, exposing operators to safety hazards and causing potential damage to furnace walls, tap holes, and equipment. These incidents disrupted production and increased maintenance needs.
Manual inspection of molten metal levels relied on visual judgment and dip rods, exposing operators to hazardous conditions and inaccurate readings. This manual process increased safety risks and often caused operational inefficiencies
Repeated thermal shock and metal contact weakened structural components, as frequent overflows and splashes damaged furnace walls, tap holes, and surrounding equipment—resulting in higher repair costs and unplanned downtime.
The computer vision–based level monitoring platform enabled operators to take timely action by reducing molten metal inflow when high levels were detected, restricting access to unsafe areas for enhanced worker safety, and making prompt operational adjustments to maintain optimal furnace conditions and prevent disruptions.
1.5M$
Annually saved
The molten level measurement system reduced equipment damage, optimized molten metal inflow, and minimized unplanned shutdowns, collectively contributing to substantial annual financial savings of $1.5 million.
10,000+
Man-hours saved annually
By eliminating manual level checks and reducing operator exposure to hazardous furnace zones, the plant saved over 10,000 man-hours annually, improving safety and operational efficiency.
1-2%
Increase in production efficiency
Accurate real-time molten metal level tracking ensured more stable furnace operations, reduced process delays, and improved consistency—resulting in a 1–2% increase in overall production efficiency.
See how leading companies across steel, cement, oil & gas, energy, automotive, chemicals, pharmaceuticals, FMCG, and other industries are transforming their operations with Ripik AI’s Vision AI solutions—driving real-time insights, enhanced safety, and intelligent process optimizations across the industrial landscape
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