Case Study: Tata Steel achieves higher steel plant throughput with AnyLogic Simulation Software

Steel Plant Simulation Helps Increase Unit Throughput

Tata Steel faced throughput bottlenecks in one of its steel manufacturing units due to uneven crane utilization and manual decision-making that disrupted ladle handling and vessel charging. The company worked with AnyLogic simulation software to study its internal logistics and test ways to optimize crane operations without affecting live production.

Using AnyLogic, Tata Steel built a full plant simulation from hot metal unloading to vessel charging and ran 90 experiments across three crane-operation scenarios. The best option increased output by 2 heats per day, saving millions annually, while reducing vessel waiting times and maintaining about 80% crane utilization; AnyLogic also enabled risk-free testing of process changes and set the stage for future AI and scrap-charging optimization.

Tata Steel