AIC India was contracted to upgrade SMW ISPAT’s existing automation systems based on S7-400 using the most recent software in order to increase availability and yield. The upgrade is being carried out in two phases. 1st phase involved the control systems replacement for the crop shears and divide shear including aprons and rake. The 2nd phase will upgrade the speed control system of the continuous mill comprising 18 continuous stands by implementing AIC’s algorithms for cascade control, MTC and Looper control.The achieved results obtained after 1st stage of AIC intervention are1.5% yield gainImproved productivity due to the elimination of cobbles in the finishing areaHigh cutting accuracy and repeatability as well as cutting optimization strategy as the system automatically calculates an optimal cutting strategy to minimize material scrapping. This system can also take advantage of a pre-optimization shear to scrap the material in the middle of the rolling process.The 2nd phase is due for commissioning in the month of November and the overall availability of the control system is expected to be improved to 99.5%.Wardha Maharashtra based SMW Ispat, formerly Known as Mahalaxmi TMT, offers steel and square bars, billets, and flat steel products. The plant is equipped with state-of-the-art pieces of machinery and the latest technology, making the plant one of the best in India. Commission Council of India has recently approved acquisition of majority stake in SMW Ispat by OFB TechAIC Capitanio Tailored Automation is a global system integrator that designs, manufactures and commissions’ turn-key plants worldwide, providing advanced and tailored automation and mechatronics solutions for the steel industry, with the aim to continuously improve efficiencies, competitiveness and safety of the production processes.