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Kirloskar Brothers Ltd. (Kirloskarvadi Plant): Melt Shop Digital Transformation with Meltix

Kirloskar Brothers Ltd. (Kirloskarvadi Plant): Melt Shop Digital Transformation with Meltix

Kirloskar Brothers Ltd. (KBL)

About the Client

Kirloskar Brothers Ltd. (KBL) (Kirloskarvadi Plant) is one of India’s most respected engineering organisations, with multiple manufacturing plants producing a wide range of alloys for critical industrial applications. Given their scale, multi-plant operations, and strong focus on quality and cost control, KBL required a robust, secure, and intelligent digital solution to standardise and optimise melt shop operations across locations.

Challenges

Kirloskar Brothers Ltd. faced several operational and analytical challenges across their melt shops:
  • Charge recipe optimisation to reduce alloy and raw material costs
  • Lack of real-time visibility into melt shop operations and shop-floor activities
  • Multiple plants producing multiple alloys, but operating with limited spectrometers
  • Requirement to maintain strict data separation between plants, with no cross-mixing
  • Need for a consolidated dashboard for monitoring operations
  • Plant-wise access control for material data, consumption data, reports, and analytics, while allowing select materials to be shared across plants
  • Requirement for a centralised management dashboard for group-level trend analysis
  • Need for seamless integration with SAP to avoid data silos and duplicate entries
  • Need for a highly secure application suitable for a large enterprise
  • Requirement to track and analyse standard cost vs actual cost for each melt
  • Adoption of SPC charts to support process optimisation and consistency

Solution

Meltix was implemented as a unified digital platform across all Kirloskar Brothers Ltd. plants, addressing both plant-level execution and corporate-level visibility.
Solution
  • SAP Integration: Meltix was seamlessly integrated with SAP, ensuring smooth data flow, eliminating redundancy, and maintaining consistency across enterprise systems.
  • Charge Recipe Optimisation: Using linear programming–based on inventory and weighted average value for each item fetched from SAP. Meltix enabled least-cost charge recipe formulation while meeting strict chemistry targets.
  • Real-Time Shop Floor Visibility: LIVEVIEW dashboards provided instant visibility into running heats, furnace status, chemistry progress, and corrective actions across plants.
  • Spectrometer Integration with Data Isolation: Through SPECTROCONNECT, Meltix connected the spectrometer to multiple plants while accurately mapping readings to the correct plant, furnace, and heat, ensuring complete data segregation.
  • Multi-Plant Architecture: Each plant operated independently with its own inventory, production data, and reports, while still being part of a unified system.
  • Role-Based Access Control: Plant teams accessed only their respective material, consumption, and performance data, while shared materials were intelligently managed where permitted.
  • Consolidated & Management Dashboards: Meltix delivered plant-wise dashboards for operations teams and a high-level consolidated dashboard for senior management, enabling cross-plant trend analysis and decision-making.
  • Cost Monitoring & Analysis: The standard cost vs. actual cost chart on the dashboard helps track and identify deviations, cost drivers, and improvement opportunities.
  • SPC Dashboards: Run charts and control charts enabled continuous monitoring of process stability, helping teams proactively detect drift and improve consistency.
  • Enterprise-Grade Security: The platform was deployed with strong security controls (VAPT approved), to meet KBL's stringent security requirements to ensure data protection suitable for a large organisation.

Results

With Meltix in place, Kirloskar Brothers Ltd. achieved:
  • Improved control over alloy costs through optimised charge recipes
  • Real-time operational visibility across all melt shops
  • Standardised yet plant-specific digital processes
  • Better cost transparency through standard vs actual cost comparison
  • Enhanced process stability and quality control using SPC tools
  • Faster, data-driven decision-making at both plant and corporate levels

Results

With Meltix in place, Kirloskar Brothers Ltd. achieved:
  • Improved control over alloy costs through optimised charge recipes
  • Real-time operational visibility across all melt shops
  • Standardised yet plant-specific digital processes
  • Better cost transparency through standard vs actual cost comparison
  • Enhanced process stability and quality control using SPC tools
  • Faster, data-driven decision-making at both plant and corporate levels

Client Feedback

The Meltix team provided excellent support throughout development and implementation. Their deep understanding of melt shop operations, responsiveness, and hands-on approach ensured the solution was effectively aligned with our operational and business requirements.

Kirloskar Brothers Ltd. (Kirloskarvadi Plant): Melt Shop Digital Transformation with Meltix
Kuchi Venkataramana
Kirloskar Brothers Limited

Client Feedback

The Meltix team provided excellent support throughout development and implementation. Their deep understanding of melt shop operations, responsiveness, and hands-on approach ensured the solution was effectively aligned with our operational and business requirements.
Kirloskar Brothers Ltd. (Kirloskarvadi Plant): Melt Shop Digital Transformation with Meltix
Kuchi Venkataramana
Kirloskar Brothers Limited

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