AI-Powered Manufacturing Intelligence
Attn: Ashutosh Ramekar — Technical Assistant to MD · Business Analyst · Project Management & Operations
From siloed plant data to a living, adaptive brain across galvanizing, drawing, OPGW & fencing
About Trinesis
Gen AI–driven Software Product Engineering — trusted by global enterprises for 6+ years
Global Footprint
- HQ & Innovation Hubs
Pune, India
- Sales Offices
Germany & Austin, TX, USA
- Around-the-Clock Support
24×7 global availability — your business never stops
Recognition & Partnerships
A fast-growing team of visionary project managers, industry-specific domain experts, and cutting-edge technologists driving innovation.
Our Expertise
End-to-end engineering — from Gen AI to ERP, delivery to assurance
Our Solution
Meet FluxAI — an autonomous intelligence layer for steel-wire manufacturing
FluxAI connects ERP, galvanizing lines, drawing machines, OPGW/OFC lines, quality, inventory, procurement & dispatch data to answer three business-critical questions:
What is likely to occur?
Which demand, quality, or operational risk — line overload, coating drift, or scrap — is likely to occur.
When will it impact us?
When it will hit production, product availability, export delivery, or profitability — ahead of time.
What action to take?
What to do to maximise throughput, product quality, line utilization, and business performance.
Our Vision for Systematic Group
One adaptive operating brain across galvanizing, drawing, OPGW & fencing — over four plants
Overload Pattern Detection
Learns the load, vibration, tension & temperature signatures of your galvanizing lines and drawing machines — and flags an overload or breakdown hours before it trips, turning unplanned downtime into a planned action.
Coating-Drift & Scrap Prevention
Predicts zinc-coating drift on GI wire from bath temperature, line speed & N₂ wipe pressure — correcting set-points before a batch goes out of spec, cutting export-batch scrap and rejections (and zinc cost).
Agentic Line-Utilization Balancing
An Agentic AI that balances GI wire, OPGW & fencing line utilization across plants — recommending where each order should run to maximise throughput and on-time export dispatch.
AI Operations Assistant
Ask in plain English — “Which lines are at risk this shift?” — and get an instant, sourced answer from your ERP, line sensors, quality & dispatch data. Your team keeps working the way they think.
How FluxAI Works
Sits on top of your stack — then discovers, decides, builds & deploys, autonomously
SAP / Tally
Bath & N₂ wipe
Sensors & PLC
Durafiber
Coating & tensile
Rod, zinc & WIP
30+ export mkts
Connect & Unify
Taps every line & system and fuses them into one operational truth.
Discover Patterns
Mines line data for overload signatures, coating drift & hidden trends.
Decision Intelligence
Autonomously designs the ML pipeline — no data scientist required.
AutoML: Build & Train
Generates, tests & trains candidates — picks the best model.
Deploy & Serve
Pushes trained models live to power every use case below.
Use Case 1: Overload Pattern Detection
Drawing-machine cluster B, Daman — FluxAI predicts the overload before the line trips
Load is climbing toward the 85% safe limit — FluxAI projects a trip in ~90 min. Last month a similar pattern cost 6 hrs of unplanned downtime.
Redistribute load to Cluster D & inspect die #4 (rising friction). Projected to avoid the trip and protect ~6 hrs of output this shift.
Use Case 2: Coating-Drift & Scrap Prevention
Live zinc-coating vs spec across galvanizing lines — catch drift before the export batch ships
| Batch / Line | Product | Metric | Drift / Δ | Status | FluxAI Action |
|---|
Use Case 3: AI Operations Assistant
Ask in plain English. Get instant, sourced answers.
3 lines need attention this shift:
- Galv Line 3 — export batch GI-2207 drifting −12% on coating
- Drawing Cluster B — overload projected in ~90 min
- Galv Line 1 — barbed wire −4%, trending out of spec
Recommended: retune Line 3 N₂ wipe + bath temp now; shift load off Cluster B to Cluster D.
Three drivers, in order of impact:
- Zinc bath temperature dropped ~8°C against the recipe
- Line speed was raised 6% to chase the shift target
- N₂ wipe pressure ran low — thinner, uneven coating
FluxAI models all three together — and recommends the set-points to bring it back in spec.
Group Operations Dashboard
360° visibility for leadership — live, across all four plants
A fully interactive version of this dashboard ships with the pilot — live across Daman, Valsad & Kolkata.
Why Now
Steel & wire leaders are already moving from dashboards to AI
Manual / SCADA Today vs FluxAI
| Capability | Today | With FluxAI |
|---|---|---|
| Overload / breakdown | After the trip | Predicted hours ahead |
| Coating quality | Post-batch QC | Real-time drift control |
| Line scheduling | Manual / Excel | Agentic cross-plant |
| Export scrap | Found at inspection | Prevented on the line |
| Cross-plant view | Siloed per plant | One live truth |
| "Why?" analysis | Hours of digging | Instant, plain English |
The competitive signal
Tata Steel, JSW & Bekaert are investing heavily in Industry 4.0 — AI-driven predictive maintenance, coating control and smart scheduling — alongside the shift to green steel, which Systematic is already pioneering.
As India's 3rd-largest wire group — 4 plants, 1,00,000 MTPA, OPGW/Durafiber & 30+ export markets — your data is a moat. But only once it's turned into a model. That's exactly what FluxAI does.
What We're Proposing
Prove it on one plant & one line family — before scaling to all four
One plant (e.g. Daman) + your export GI-wire galvanizing & drawing lines. We connect your existing ERP & line data, on your environment.
FluxAI runs alongside your current SCADA & ERP. You judge downtime avoided, scrap cut & utilization gained — with your own numbers.
Convinced? Roll out across plants and into OPGW & fencing with agentic line balancing — same proven platform, at your pace.
Recommended Pilot
Best Starting PointOverload + Coating-drift on 1 plant
- Overload prediction for galvanizing & drawing lines
- Live coating-drift control & scrap prevention
- Plain-language AI assistant for the ops team
What we need from you
- Line / sensor logs & recent production / quality history (export is fine)
- Read access to ERP & coating / QC data for one plant
- One operations point of contact to validate outputs
Your Investment, De-Risked
Prove the value on one plant — before you commit to the group
Data Assessment
Short, free review of your line & quality data to confirm scope and lock a fixed price.
Pilot Build
We connect sources, train models, and stand up the cockpit & assistant on your environment.
Measured Results
Downtime avoided, scrap cut & utilization gained — measured against your own baseline.
Indicative scope — final pilot price confirmed after the data assessment. Group rollout priced per plant, improving with scale.
Next Steps
Let's move forward together
Let's prove it on one plant
NDA & Pilot Kickoff
Live on one plant in 6–8 weeks — proven against your own baseline
Scale Across Plants
Roll out to all four plants & into OPGW / fencing, at your pace
