Steel Mill Mainframe Upgrade

How We Helped a Steel Mill Resolve a Production Floor Network Issue

The steel mill had recently updated its operations by transitioning from an aging mainframe system to a modernized setup. While the new system worked smoothly in the office and testing environments, problems arose during deployment on the production floor. Equipment kept losing connection, frustrating workers and disrupting schedules. The mill’s team and their software consultants were unable to resolve the issue, so they reached out to us for assistance.

Steel mills are challenging environments for electronics. Heavy machinery generates vibrations, heat, and significant electromagnetic interference (EMI). The mill’s older system had used simple, robust serial terminals with shielded cables that were resistant to these conditions. In contrast, the new system relied on standard PCs and Ethernet cables, which proved vulnerable to the EMI on the production floor.

That’s where we came in.

After assessing the situation, we identified that the interference was overwhelming the unshielded Ethernet network. The solution was to replace the standard network components with fiber optic cables, which are unaffected by electrical noise. Fiber optics use light to transmit data, making them ideal for noisy industrial environments like this one.

Once the fiber optic network was installed, the production floor systems operated reliably. Machines synchronized properly, and data flowed without interruption, allowing the mill to fully utilize their modernized system. This fix not only resolved the immediate issue but also restored confidence in the upgrade.

By understanding the specific demands of the mill’s environment, we provided a practical solution tailored to their needs. Sometimes, achieving progress isn’t just about new technology—it’s about applying the right technology to the problem.