“Digital Twin light” for a metal foundry

Management wanted a clear, real-time view of melting-furnace temperatures and cycle efficiency to optimize energy use. But the furnace operators were legally required to keep handwritten logbooks right at the furnace — double entry into a terminal was out of the question.

Instead of double entry, we mounted contactless infrared thermal sensors above the furnaces. Our two-person team developed a clear web dashboard that processed the sensor data streams passively and left the furnace operators entirely to their mandated physical logging.

Management gained a real-time dashboard that noticeably reduced energy peaks.

No additional data entry arose for the furnace operators — their legally required handwritten documentation remained the only capture path.