Case Study: Baosteel Group achieves 96.4% operator accuracy and 90% fewer stoppages with Honeywell Forge (Honeywell)

The World’s Biggest Steel Manufacturer Becomes One of the Smartest

Baosteel Group, the world’s largest steel manufacturer, faced costly inefficiencies from manual, trial-and-error welding setups—an incorrectly set welding machine could cause $545K in stoppages and labor alone. To tackle this, Baosteel Group partnered with Honeywell, deploying Honeywell Forge capabilities and IoT/AI services to modernize and automate its welding operations.

Honeywell analyzed 6,000 welding sessions and built an intelligent High-Performance Fusion welding machine management system using AI and predictive modeling. By automating Baosteel Group’s core process with Honeywell’s solution, operator accuracy rose 96.4%, stoppages fell 90%, and labor costs were reduced by $450K per year.

Baosteel Group