TECHNOLOGY LED TRANSFORMATION
AND DIGITALISATION
- Economic performance
- Technology, product and process innovation
- Digitalisation and automation
Innovation at JSW Steel
Our digital function is led by a Chief Digital Officer (CDO), supported by various Digital Centres of Excellence (CoEs), i.e., Data Sciences, Digital Vision Platform, Digital Supply Chain Management, Digital Sales & Marketing, Digital Human Resources, Digital Sustainability.
Our objectives are:
- Integrated technology approach through collaborative Digital-IT-OT functions.
- Integrated system landscape to minimise manual data entry inputs.
- Dynamic and paperless interaction with customers.
- Automated shop floor driven by Industry 4.0 principles and AI/ML.
- Reports Dashboards & Analytics (RDA) for each function.
CENTRE OF EXCELLENCE
JSW Steel continues to redefine industry benchmarks through its bold commitment to innovation, integration, and sustainability. Central to this transformation is the Centre of Excellence (COE)—a strategic hub driving operational excellence across our Company’s facilities in India and the USA.
In FY 2024–25, the COE executed 565 high-impact projects, with 345 delivering tangible business benefits. The remaining initiatives played a crucial role in enhancing safety, environmental performance, and long-term operational resilience. By breaking inter-location silos and aligning all sites under a unified innovation-driven framework, the COE has fostered a culture of continuous improvement and collaboration. Leveraging partnerships with premier institutions like IIT Bombay, and a robust platform that recognises out-of-the-box thinking, have further amplified the COE’s impact. Enhanced leadership engagement on the ground strengthened its core philosophy: Don’t reinvent the wheel—solve together.
From driving innovation in Operations & Maintenance, enhancing logistics efficiency, and optimising energy utilisation to spearheading the SEED initiative for carbon reduction, the COE is actively shaping a smarter, greener future. More than just an operational unit, the COE embodies a transformative mindset—empowering over 20,000 stakeholders and reinforcing JSW Steel’s position as a global leader in agile, efficient, and sustainable steelmaking.
Digitalisation
Our digital journey is revolutionising operations through bold, strategic transformation. By embracing Industry 4.0 technologies across manufacturing, supply chain, sales, safety and sustainability, we are setting new benchmarks for performance and stakeholder value. Our digitalisation efforts are not just modernising systems, they are reshaping how we innovate, operate and lead.
Central to this transformation is our Agile Product Management approach, which drives continuous value through dynamic, incremental sprints. This method ensures our digital solutions adapt fluidly to evolving needs, maintaining momentum and delivering lasting impact. By embedding agility and innovation into our digital DNA, we continue to lead the way in redefining the future of steelmaking, strengthening resilience, accelerating excellence and unlocking smarter, more sustainable growth.
Principles of our digital transformation strategy
Maximising revenue and profitability while enhancing customer engagement
Ensuring safe workplaces and sustainable operations to uphold our commitment to safety and environmental responsibility
Driving higher productivity through simplified processes and active employee engagement
Each of our initiative is designed with an enterprise-level scope, ensuring seamless integration across plants and business units, aligned with our digital strategy pillars. These include operational excellence through enhanced uptime and reliability, sustainability with real-time emissions control, safety through proactive risk management, customer centricity with insights and automation. With scalable platforms for cross-business deployment, we continue to exemplify digital leadership, embedding intelligence into operations and creating a resilient, agile steelmaking ecosystem, ready for a low-carbon, high-efficiency future.
Progressing towards achieving a sustainable future
Digitalisation is a key driver of sustainability. With a dedicated Digital for Sustainability team, we have developed a roadmap to integrate digital solutions that support our sustainability goals. We are advancing data-driven climate action, environmental stewardship, and circular economy practices, establishing JSW Steel as a leader in decarbonisation and intelligent manufacturing.
Compliance driven reporting modernisation
JSW Steel has digitised SEBI-compliant Business Responsibility and Sustainability Reporting (BRSR), leveraging Cloud, Big Data, and Advanced Analytics. This has enhanced data governance, efficiency, and report transparency, with plans for phased digitalisation of all compliance reporting.
Value chain assessment
JSW Steel has assessed the sustainability practices of the supply chain through a digitalised monitoring system, proactively identifying operational risks and generating action plans. The system enabled monitoring and continuous improvement process guarantees transparency in evaluating the production process of the supply chain, through a intuitive scoring system.
Abatement Initiatives monitoring
The abatement tracking initiatives supported by the SEED program, centralising environmental data across all plants, providing a single version of digital truth for effective progress monitoring.
Energy system optimisation
JSW Steel’s strategic energy optimisation program, using AI for flare stack gas flow calculation, is progressing step-by-step, with plans to optimise fuel gas consumption. Efforts are underway to responsibly optimise power, water, gas, steam, and acid consumption across JSW Steel’s operations.
Data as an asset
The progress achieved this year highlights the growing institutional adoption of data as a strategic asset. A total of 25 data products were developed and deployed, tailored to specific operational needs. As part of our data democratisation efforts, 15 training programs were conducted. Notably, 12 data products were co-developed by business users, showcasing a shift towards self-service analytics and decentralised innovation.
Mining
Digital transformation in logistics at our Odisha iron ore mines has enhanced mine-to-plant connectivity, improved resource utilisation and boosted visibility. This shift has streamlined operations, enabling smarter planning and significantly improving overall efficiency across the logistics value chain.
ENSURING SEAMLESS MATERIAL SHIFTING
To enhance transparency and efficiency in material movement, we introduced a digital IMS (Internal Material Shifting) tracking system across our Odisha mines. Previously reliant on manual logs and prone to errors, the process has been revolutionised through automation. Geofencing at loading, unloading, and weighbridge points, coupled with Global Positioning System (GPS) devices, enables real-time trip monitoring and weight verification. A bespoke IMS software now automates trip verification, eliminating discrepancies and ensuring accuracy. Since implementation, over 80,000 weighments have been digitally processed. The time required for management information calculations has dropped dramatically, from 45 minutes to just 3 seconds. This innovation not only boosts operational accuracy and efficiency but also reduces logistics costs.
Manufacturing
At the heart of our Industry 4.0 journey is an AI-powered Predictive Maintenance Platform, now live across 10 plants and over 2,900 critical assets is helping us avoid an impressive 25,000 hours of unplanned downtime. Enabled by real-time condition-based monitoring with smart sensors, this has significantly boosted asset reliability, energy efficiency, and availability. Complementing this is the deployment of Digital Twins which are virtual replicas of key assets which integrate IoT sensor data with AI diagnostics. With up to 12% downtime reduction and maintenance cost savings, these innovations are reshaping asset performance and ROI.
~10%
Increase in asset lifespan through early detection and optimised maintenance
~12%
Reduction in unplanned downtime
INTELLIGENT AUTOMATION AND IOT INTEGRATION
We have transformed our manufacturing processes by deploying over 13,500 sensors, to enable Condition-Based Monitoring (CBM). This initiative has helped avoid over 25,000 hours of unplanned downtime, enhancing equipment reliability and enabling proactive maintenance. Our Digital Twin platform leverage IoT data for real-time diagnostics, predictive maintenance, and 3D visualisation of critical assets, significantly improving mean time between failures (MTBF) and maintenance efficiency
13,500+
Sensors deployed
VISION AI-POWERED SHOP FLOOR INTELLIGENCE
We are enhancing manufacturing ecosystems with AI-powered Computer Vision and Edge Computing for real-time visibility and anomaly detection. At our Vijayanagar plant, an AI- Powered computer vision monitoring system reduces gas flaring. AI vision systems on conveyor belts optimise raw material handling by identifying materials and monitoring conveyor health, improving safety and operational throughput. Additionally, our Digital Vision AI Platform enforces safety behaviours and improves safety culture and practices with 15+ AI use cases, enabling rapid response and reducing safety incidents across plant premises.
Supply chain
We have strategically integrated advanced data analytics and digital platforms to transform our supply chain into an intelligent, resilient value network. Through initiatives like the Advance Planning & Scheduling, we leverage real-time data, automated decision-making, and integrated analytics to drive operational excellence.
DIGITALISED ADVANCE SUPPLY CHAIN PLANNING
Advance Planning & Scheduling system has been implemented to provide a seamless customer experience and improve order fulfilment. By integrating customer-facing platforms with core planning systems and manufacturing execution systems, APS has enabled optimal inventory management and reduced order-to-cash cycles, enhanced capacity utilisation and improved production efficiency.
Logistics
Project SAMPARK is revolutionising road logistics by introducing a unified, end-to-end digital platform that enhances efficiency, transparency and sustainability at the Vijayanagar and Dolvi plants. Tackling key challenges such as lack of real-time visibility, manual dependencies and suboptimal resource use, SAMPARK replaces outdated processes with automation and smart tracking. With features like pre-validated vehicles, optimised dispatch planning, and integrated workflows, it ensures safety, reduces delays and cuts emissions, saving around 5,000 tonnes of CO2 annually. By digitalising over 10 million transactions, dispatching goods worth `160 crore daily and saving 2 million man-hours each year, the initiative is transforming logistics operations while equipping over 500 employees with future-ready digital skills. With plans to scale across all JSW Steel sites, the platform integrates with ERP systems, enable real-time tracking through control rooms, and offer seamless updates via mobile and IoT technologies, ushering in a smarter, greener logistics future.
10 million+
Transactions digitised
5,000 tonnes
Of CO2 saved annually
Sales and marketing
Digitalisation is transforming sales and marketing through AI/ML-driven insights, automated lead engagement and smarter channel partner management. These initiatives enhance customer experience, streamline sales operations and optimise inventory liquidation, driving stronger conversions, improved responsiveness and greater overall efficiency across the value chain.
DIGITALLY DRIVEN CHANNEL EXPANSION & EXTRACTION
Our Salesforce-powered distribution platform is transforming the way we manage sales and distribution by digitising over 80 key channel processes—including inventory management, returns, and retailer engagement—through mobile-first applications and real-time analytics. This ecosystem enables seamless operations and data-driven decision-making across the entire sales network.
Key Highlights of the Distributor Management System (DMS) implementation:
- End-to-End DMS Rollout: Successfully deployed across distributors, covering all major product categories (HR, CR, WR, TMT & Coated).
- Productivity Gains with Integration: eliminating duplicate entry of secondary sales and saving productive time daily for distributor representatives
- Enhanced Secondary Sales Visibility: Improved secondary sales tracking post-DMS implementation
- Improved distributor lifecycle management & governance.
Digital capability development
We understand that successful digital transformation hinges not just on advanced technologies, but on empowering our people. We have embraced a remote-first, hybrid training model that aligns with the demands of Industry 4.0. By integrating digital learning into operational excellence, we have developed a workforce that is technologically proficient, driven by innovation, and prepared for the future.
Leveraging Cloud, Big Data, Advanced Analytics, and Business Intelligence, this transformation has strengthened data governance, boosted efficiency and enhanced transparency. Over the past two years, SEBI-compliant BRSR reports have been generated digitally, setting a benchmark in responsible business practices. Future plans include phased digitalisation of all external disclosures to elevate reporting standards further.
Collaboration with IIT Bombay
Change management and the adoption of new technologies are crucial for the success of digital transformation. At JSW Steel, the digital team prioritises the end user, conducting numerous training programmes, particularly for employees in operational roles. These include a full-day onsite training on IoT, Analytics, AI and Digital Twin, a three-day hybrid certificate course on Data Science in collaboration with IIT-B, and a 9-month project-based Smart Manufacturing course with BITS Pilani. These courses cater to all employees, data-driven decision-makers, and leaders driving digital transformation at their plants.
Collaboration with BITS Pilani
We believe digital transformation is not just about adopting new technologies but empowering people to harness their full potential. To ensure continuous learning, JSW Steel Coated Products Ltd. has partnered with BITS Pilani to offer a Post Graduate Diploma in Smart Manufacturing under the Work Integrated Learning Program (WILP). Tailored for JSW employees, this hybrid programme covers emerging technologies like robotics, IoT and data analytics, with a focus on practical application. The 11-month course, culminating in a capstone project, aims to build a digitally empowered, future-ready workforce, supporting JSW’s smart factory transformation initiatives.
Technology enabling safer workplaces
We are redefining industrial safety through advanced digital innovation, moving from reactive measures to a proactive, predictive system. Our flagship initiatives ‘Project RAKSHAK’ and the AI-driven ‘Digital Vision Platform’ ensure a safer workforce, delivering measurable improvements and critical operational value. Enhancing this transformation, we have introduced VRbased immersive training to simulate high-risk scenarios like crane operations, working at heights, and confined space entry. These realistic modules sharpen hazard perception, decisionmaking and procedural accuracy while cutting training time. By integrating AI, IoT and immersive tech, we are creating a digitally enabled safety culture that is smarter, stronger and future-ready.
PROJECT RAKSHAK DRIVING WORKPLACE SAFETY
Project RAKSHAK is revolutionising workplace safety at JSW Steel through IoT-enabled wearables that offer real-time location tracking, fall detection, geo-fencing alerts and proximity monitoring. These smart Safe Pass devices enhance visibility across high-risk zones, enabling quicker emergency response and proactive safety interventions. With features like immobility detection and instant alerts, the initiative has led to fewer incidents, stronger compliance and improved morale. By combining technology with accountability, we are cultivating a culture where every employee feels protected, empowered, and digitally safeguarded.
USING AI FOR A SAFER WORKPLACE
Our AI-powered ‘Digital Vision Platform’ revolutionises workplace safety by using advanced computer vision to monitor PPE compliance, detect overcrowding, flag intrusions and identify hazards, ensuring 24/7 vigilance without human fatigue. This real-time, automated system has significantly reduced manual inspections and non-compliance incidents while enhancing the speed and precision of hazard response. By merging AI with IoT-driven insights, we are setting new industry benchmarks in proactive safety, creating a smarter, safer and more responsive environment across our operations.
Cyber security
We have implemented a comprehensive suite of cybersecurity measures to protect sensitive corporate data and operational technology (OT), ensuring the integrity, confidentiality and availability of our information assets. Led by Chief Information Officer, these initiatives include next-gen firewalls, unified threat management devices and the adoption of the Purdue model for secure IT-OT network communication. We conduct cloud security risk assessments, implement secure data transit protocols. Other measures include deploying dark web monitoring, continuous security event monitoring, phishing simulations and secure remote access with multi-factor authentication (MFA). These efforts significantly enhance employee awareness and mitigate cyber threats.
Industry 4.0 for steel manufacturing value chain
We are redefining steelmaking through digital intelligence. Anchored in Industry 4.0, our smart factory ecosystem enables data-driven agility, predictive insights and autonomous operations. In FY 2024-25, we accelerated this transformation by piloting and scaling next-generation digital technologies across all functions of our integrated operations.
Smart manufacturing
Our approach to manufacturing has evolved into a self-optimising, data-driven ecosystem powered by Intelligent automation. Our Ferro Alloy Optimisation Model uses real-time data and algorithms to calculate ideal alloy combinations, reducing costly overuse and enhancing quality consistency. The Blend Mix Optimiser enables PPC teams to determine the most cost-effective raw material mix within seconds, based on live inventory data. Additionally, use of IoT sensors to monitor real time condition of assets, cloud computing for accurate prediction of asset health and product quality, Digital Twins of Assets and Optimisation of gas recovery efficiencies support sustainable and predictable operations. Together, these technologies are transforming our operations into agile, intelligent manufacturing environments focused on efficiency, sustainability and continuous improvement.
OUTLOOK 
Near-term
We are advancing our digital transformation by embedding artificial intelligence and Industry 4.0 technologies across our manufacturing and commercial operations. Our immediate focus is on intelligent process optimisation through AI-driven predictive quality and maintenance systems, integrated with real-time monitoring platforms. These initiatives are enhancing operational agility, reducing downtime, and improving product consistency.
Key initiatives include the development of an integrated raw material supply chain control tower to enhance endto-end visibility and responsiveness, the launch of an AI-enabled digital pricing platform to drive dynamic and data-driven pricing strategies, and the deployment of an IoT and cloud-integrated process optimisation platform to unlock new levels of operational efficiency, safety, and environmental stewardship.
Simultaneously, we are sharpening our customer focus by leveraging data analytics to better understand market dynamics and customer preferences. This enables us to, improve service responsiveness, and strengthen market penetration.
Our digital-first approach is not only driving efficiency on the shop floor but also empowering our commercial teams with actionable insights to expand reach, deepen customer engagement, and unlock new growth opportunities.
Long-term
Looking ahead, we are committed to building a digitally empowered enterprise that leverages AI as a strategic enabler. Our long-term vision is anchored in creating a unified, AI-driven view of the customer, product, and market—powered by a robust data infrastructure. We foresee a future where manufacturing is deeply integrated with IoT, cloud, and advanced analytics, enabling a shift from reactive to predictive operations.
