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Steel and Metals · CMMS & EAM

Maintenance Software for Steel and Metals Plants

Cranes, furnaces, rolling mills and hydraulics work in heat, load and dust. PlantOps360 keeps their preventive maintenance, spares and failure history in one place for steel, rolling and foundry plants.

Sample view · Steel and Metals · Live
PlantOps360
Equipment health
89%
Open work orders
23
PM compliance
94%
Availability
92.6%
Downtime trend · 12 wks▼ improving
AI alert: EOT crane hoist gearbox vibration above its alert limit
THE PROBLEM

Common maintenance challenges in Steel and Metals

In a steel plant the process does not wait. A stopped caster or mill stand means molten or hot metal with nowhere to go.

Heat and load on everything

Furnace and mill equipment works at the edge of its rating, so wear is fast and failures are severe.

Cranes that cannot go down

Overhead cranes carry ladles and coils. A hoist or brake fault stops the whole bay, and they need statutory examination too.

Hydraulic and lubrication faults

Leaks, contaminated oil and failed seals are a leading cause of stoppages on mills and presses.

Rolls, bearings and gearboxes

Costly, long-lead items are bought in a hurry after a failure instead of planned.

Records for statutory inspections

Cranes, pressure vessels and lifting tackle have inspection dates that live in registers and files.

High energy cost per tonne

Furnaces, compressors and pumps use large amounts of power, but few plants know where it goes by area.

PURPOSE-BUILT

Critical equipment managed with PlantOps360

Pre-configured preventive schedules, inspection checklists and condition parameters for the equipment that sets a steel plant's output. Hover any card to see failure modes, checklists and sensors.

Healthy

Electric arc or induction furnace

Melting
Critical30-Day PM
Hover for details
Common failures
Electrode or coil faults
Cooling water leaks
Transformer overheating
Tilt hydraulics failure
Monitor
Cooling water flowTransformer temperaturePower draw
Recommended maintenance
Weekly water circuit check
Monthly electrical inspection
Quarterly refractory survey
Healthy

EOT crane and ladle crane

Material handling
Critical30-Day PM
Hover for details
Common failures
Brake wear
Hoist gearbox failure
Wire rope damage
Limit switch fault
Monitor
VibrationMotor currentBrake temperature
Recommended maintenance
Daily operator check
Monthly brake and rope inspection
Annual load test and statutory examination
Maintenance Due

Rolling mill stands and gearboxes

Rolling
Critical15-Day PM
Hover for details
Common failures
Roll neck bearing failure
Gearbox tooth wear
Coupling failure
Roll breakage
Monitor
VibrationBearing temperatureMotor currentOil temperature
Recommended maintenance
Weekly lubrication check
Monthly vibration route
Roll change checklist
Healthy

Hydraulic power packs

Utilities
High15-Day PM
Hover for details
Common failures
Pump wear
Filter blockage
Hose and seal leaks
Oil contamination
Monitor
Oil pressureOil temperatureFilter differential pressure
Recommended maintenance
Weekly leak walk
Monthly filter check
Quarterly oil sample
Healthy

Continuous caster

Casting
Critical15-Day PM
Hover for details
Common failures
Mould oscillation fault
Spray nozzle blockage
Segment bearing failure
Cooling pump fault
Monitor
Water pressureMould levelOscillation amplitude
Recommended maintenance
Shift nozzle check
Weekly segment inspection
Scheduled segment overhaul
Healthy

Dust extraction and ID fans

Emission control
High30-Day PM
Hover for details
Common failures
Impeller wear and imbalance
Bearing failure
Duct leaks
Bag failure
Monitor
VibrationDifferential pressureMotor current
Recommended maintenance
Weekly vibration check
Monthly bag inspection
Annual balancing
Healthy

Air compressors

Utilities
High30-Day PM
Hover for details
Common failures
Valve wear
Cooler fouling
Oil carry-over
Unloader fault
Monitor
Discharge pressureTemperatureMotor current
Recommended maintenance
Weekly drain and filter check
Monthly cooler clean
Quarterly service
Equipment Health Dashboard
Sample view of a steel and metals plant in PlantOps360 (illustrative figures)
● Live data
Healthy assets
184
Critical assets
6
Running
142
Idle
28
Maintenance due
12
Open work orders
14
Upcoming PM
23
Availability
97.8%
Downtime trend▼ illustrative
Asset health score
92of 100
DAY-TO-DAY

What changes in your steel or metals plant

Four everyday situations in a steel or metals plant, before and after PlantOps360.

Crane inspections are scheduled, recorded and visible

Before

Crane checks and statutory examination dates sit in a register. When one is overdue, someone finds out at the next audit.

With PlantOps360

Daily checks, monthly inspections and annual examinations are recurring tasks against each crane, with the result and certificate attached.

Preventive maintenance →

Mill and gearbox wear is trended

Before

Vibration and oil readings are noted on paper or not at all. A gearbox that has been running hot for a month is noticed when it stops.

With PlantOps360

Readings are logged per asset or arrive from connected sensors. A rising trend opens a work order while there is still time to plan the stop.

Predictive maintenance →

Rolls, bearings and gearbox spares are planned

Before

A failed bearing means phone calls to suppliers and a long wait while the line is down.

With PlantOps360

Critical spares carry minimum levels and are linked to the equipment. The repair job reserves the part, and long-lead items are reordered in time.

Spare parts →

Breakdown history guides the next decision

Before

The same hydraulic hose or coupling fails repeatedly and nobody can show how often or at what cost.

With PlantOps360

Each failure is recorded with its cause, time and parts. Repeat failures show up by asset, so repair-or-replace is decided on data.

Asset management →

Rules and standards that touch steel and metals maintenance

A plain-language summary of what each one asks of maintenance, and where PlantOps360 fits.

Standard or regulationWhat it expects from maintenanceHow PlantOps360 helps
Factories Act, 1948 / OSH Code, 2020Safety of machinery, lifting machines and plant (India)
ExpectsMachinery maintained and safeguarded, and cranes, hoists and lifting tackle examined at the required intervals by a competent person, with records.
PlantOps360Examination due dates as recurring tasks, with the result and certificate stored on the crane or tackle. Preventive maintenance →
Indian Boilers Act, 2025Boilers and steam pipes
ExpectsBoilers and steam piping inspected and certified as the law requires.
PlantOps360Inspection dates, certificates and repairs kept on the asset. Document management →
CPCB emission normsStack and fugitive emissions, consent conditions
ExpectsPollution control equipment kept working so that emissions stay within consent limits.
PlantOps360Dust extraction and filter maintenance scheduled and logged. Preventive maintenance →
PAT scheme (Bureau of Energy Efficiency)Iron and steel are designated sectors
ExpectsSpecific energy consumption tracked and reported against a target.
PlantOps360Energy readings by area stored beside the equipment, so a rise can be traced to a machine. Energy management →
ISO 45001Occupational health and safety management
ExpectsHazards controlled, with inspections and corrective actions recorded.
PlantOps360Inspection checklists and corrective work orders with a time and user on each entry. Work orders →
ISO 55001Asset management systems
ExpectsA documented approach to asset condition, risk and lifecycle decisions.
PlantOps360Asset register, criticality, history and cost per asset. Asset management →

This is a plain-language summary for orientation. Always follow the current text of each law and standard, and the rules of your own site and licence.

Key workflows in a steel or metals plant

Three real situations, step by step, and where each step happens in PlantOps360.

Overhead crane hoist gearbox runs rough

A bay-stopping asset with a statutory dimension.

  1. The operator reports noise on the daily check, or a vibration reading crosses its limit. Mobile app
  2. A work order opens on the crane with the inspection checklist; the crane is marked out of use. Work orders
  3. The technician inspects, replaces the failed part from reserved stock and records the findings. Spare parts
  4. The examination certificate and repair record stay on the crane for the next statutory check. Document management
The fault, the fix and the certificate are in one record.

Mill stand hydraulic leak

A small leak that stops a mill when ignored.

  1. The operator photographs the leak and raises a request from the stand QR code. Mobile app
  2. The supervisor approves it; the job is planned for the next roll change with the seals reserved. Work orders
  3. The seal and hose are replaced and the oil sample result is attached. Spare parts
  4. The hydraulic walk stays on the weekly PM schedule. Preventive maintenance
Leaks are fixed in a planned stop, and repeat leaks are visible by asset.

Furnace cooling water flow drops

A safety and availability issue on the melt shop.

  1. A flow reading below its limit raises an alert. Predictive maintenance
  2. A corrective work order opens with the cooling circuit checklist. Work orders
  3. The cause is found and recorded: pump, strainer or valve. Asset management
  4. The pump and strainer inspection interval is reviewed. Preventive maintenance
The event, the cause and the changed interval are on record.

Steel and Metals maintenance software: questions

Yes. Inspection and examination dates can be set as recurring tasks on each crane, with the result and the certificate attached to the asset, so an overdue examination is visible before it becomes a finding.
Yes. The asset register, schedules and work orders are not tied to plant type. You set up the equipment and checklists that match your lines.
Yes. Readings can be entered by hand on a round or arrive from connected sensors and gateways. Limits can raise a work order automatically.
They are linked to the equipment, given minimum and reorder levels, and reserved when a work order is raised.
Work orders carry failure codes and times, so you can see which assets and which causes account for the most downtime over any period.
Yes. The offline-first mobile app lets technicians create and close work orders, run inspections and open documents with no connection. Everything syncs when the device is back online.
PlantOps360 offers integration with SAP, Oracle and other ERPs, and REST APIs to sync assets, materials and financials. The scope of an integration is agreed during the demo and planning.

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