Real-Time Ladle Activity Monitoring Achieved 50% Reduction in Non-Compliant Lifting

Ripik AI's Ladle Activity Tracker enhanced ladle operations in steel plants with comprehensive real-time monitoring, providing insights into ladle movements and automated controls that halt crane operations during safety violations, achieving a 50% reduction in non-compliant ladle lifting.

Trusted by leading global enterprises

Problem Statement

Ladle handling in steel and metal industries faces challenges in ensuring safety, efficiency, and adherence to SOPs due to inadequate monitoring.

Our client in the steel industry faced challenges in ensuring safe and efficient ladle handling in their steel plant while maintaining SOP compliance. Their monitoring systems relied heavily on manual operator reports instead of visual evidence, resulting in missed incidents and delayed responses. Outdated equipment further limited continuous monitoring of ladle conditions, increasing the risk of safety hazards, material losses, and operational inefficiencies. They required a solution that provided real-time insights and proactive monitoring to address these issues.

Improper ladle
Hooking

Ladles are often improperly hooked to cranes, increasing the risk of instability

Improper hooking of ladles to cranes in steel plants increases the risk of instability, leading to potential spills, accidents, and material losses. This often results from misalignment or operator error.

Time Delay & Human
Error

Manual tracking of ladle movements and usage leads to errors, delays & under utilization

Manual tracking of ladle movements and usage often results in errors, delays, and inefficient utilization, impacting overall operational efficiency. This lack of real-time visibility makes it challenging to track ladle conditions, maintenance needs, and optimal usage patterns.

Risk of
Spills

Manual metal level tracking in ladles increases the risk of spills

Manual tracking of metal levels in ladles increases the risk of spills, leading to safety hazards, material losses, and operational disruptions.

Costly
Breakdown

Poor ladle refractory condition monitoring causes premature wear and costly downtime

Solution

Ripik AI's Ladle Management System tracks every ladle movement, improving OEE by 15%.

Real-Time ladle Monitoring

Ripik AI's real-time ladle management system provided continuous tracking and instant detection of unsafe hooking. Equipped with optical cameras, it accurately tracked ladle, crane, and ladle car movements.

Integrated Plant Control Systems

The platform seamlessly integrated with plant control systems, utilizing closed-loop controls to automatically prevent crane movement during safety violations, enhancing workplace safety and minimizing risks.

Infrared-based monitoring of steel ladle refractory

The ladle management system used infrared-based monitoring to assess steel ladle refractory conditions in real-time, detecting temperature variations to identify wear, hotspots, or potential failures early, enhancing safety, minimizing downtime, and extending refractory lifespan.

Instant real-time Alerts

Instant real-time alerts provided to operators with notifications for any deviations or process parameters, enabling prompt corrective actions and smooth operations.

Automated Anomaly Detection

Automated Anomaly Detection enabled real-time identification of irregularities in ladle movements, hooking, and refractory conditions, allowing for immediate corrective actions.

Impact and Validation by End Users

Optimized Operations with Automated Ladle Tracking for Enhanced Efficiency

Our ladle management system enhanced operational efficiency by providing continuous, real-time monitoring. It ensured precise tracking of ladle movements, detected unsafe hooking instantly and minimized errors. Integrating with existing HMI and PLC/DCS systems, enabled faster identification of process bottlenecks. This proactive approach improved safety, reduced delays, and optimized production workflows.

250+

Non-compliant lifting prevented in 3 months

Over 250 non-compliant ladle lifting incidents were prevented within the first three months of deployment, significantly improving safety and adherence to operational standards.

50%

Reduction in non-compliant ladle lifting

The solution resulted in a 4.5kT volume improvement, enhancing material efficiency and boosting overall production capacity by optimizing raw material handling and process control.

OUR success stories

Our role in driving
customer success

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