Client & context
Commercial heat treatment shop, batch furnaces, quench tanks, and ageing ovens serving forging and automotive clients.
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Process optimizationReference benchmark
Heat treatment: weekend furnace holding waste
Batch furnaces held temperature over empty weekends, 15–25% of furnace energy with no parts scheduled. Holding schedules aligned to production calendar.
−18%
Non-prod energy
−60%
Weekend holding
₹3–6L
Monthly savings
The challenge
Furnaces maintained soak temperature through weekends because operators feared long re-heat times Monday morning, but production schedules showed 40% of weekends had zero batches.
Our approach
Correlated furnace holding registers with production calendar and customer dispatch data.
Prescribed safe ramp-down windows when no batches were scheduled within 36 hours.
Set Monday pre-heat sequences timed to first confirmed batch, not fixed clock time.
Outcomes
18% reduction in non-production furnace energy within 60 days.
60% reduction in weekend holding hours when no batches scheduled.
₹3–6L monthly savings without capital expenditure.
Reference benchmark from heat treatment segment pilots.
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