Our in-house 3D printing capability strengthens process innovation by enabling rapid development and production of customised components for pattern-making applications. Using the 3D printer, we can produce patterns and supporting components for pattern development such as runner bars, pouring sprues, vents, pattern attachments and markings using materials including PLA, ABS, Carbon Fibre and PETG. This capability supports faster prototyping, greater design flexibility and reduced dependence on conventional development methods, helping accelerate new product development and process improvement.
At Electrosteel, advanced robotics brings precision and consistency to the manufacturing process. A robotic arm is used to create flawless sand cores for DI pipes, ensuring the core is accurately formed to the required dimensions and specifications. By automating this critical process, the technology enhances precision, repeatability and production efficiency while minimising human error. This integration of robotics reflects Electrosteel’s commitment to using advanced manufacturing technologies to deliver high-quality ductile iron pipes with greater reliability and consistency.
Electrosteel Castings has implemented the Tracking and Traceability Solutions(TTS) for Fittings Tracking System, a QR-code-based digital solution that brings greater visibility, traceability, accuracy and control to the DI fittings lifecycle. Replacing paper-based records, Excel tracking, manual follow-ups and verbal communication, the system assigns a unique QR code to each fitting at the coating stage and digitally tracks it through coating, quality assurance, packing, racking and dispatch. TTS provides real-time visibility of WIP, finished goods, QA status, packing status, rack location and dispatch readiness, while digitally recording QA decisions such as approved, rework and reject. QR-based stock counting and box-to-item mapping further improve inventory accuracy and packing integrity, while user-level activity tracking strengthens accountability. By integrating traceability with process control, TTS enables faster decision-making, reduces errors and supports more reliable dispatch operations.
Our in-house developed and implemented AI-enabled Safety Vision system leverages AI to strengthen safety practices across the shop floor by analysing CCTV streams and identifying PPE violations in real time. The system helps reduce safety risks, accidents and near misses by ensuring compliance with required protective gear, while automating safety monitoring to minimise manual effort, bias and errors. It also identifies and tracks repeat offenders, enabling greater accountability through violation tracking and corrective action, including the generation of warning letters by respective departments. A dedicated dashboard provides insights into non-compliance patterns, supporting data-driven decision-making and continuous improvement in workplace safety.