JSW Steel achieves optimum illumination in Nuagaon Iron Ore mine, installs 350 lights across the region
Companies worldwide trust Bidaal to enhance workplace safety and empower their workforce. Learn how our AI-driven solutions proactively protect employees and improve operational efficiency.
Identify Areas Of Risk With Scaling Workforce
JSW Steel, one of India’s leading integrated steel producers with a substantial installed crude steel production capacity, requires approximately 1.5 to 1.6 tonnes of iron ore to produce a single tonne of steel. To meet this high demand for raw materials, JSW Steel has progressively expanded its mining operations beyond Karnataka into other regions across India. In 2020, the company successfully secured bids for four iron ore mines in Odisha, thereby significantly enhancing its resource base. However, this expansion also introduced new challenges related to safety compliance and adherence to regulatory requirements set by the Directorate General of Mines Safety (DGMS).
Among these newly acquired assets, the Nuagaon iron ore mine emerged as the most substantial in terms of reserve capacity, surpassing the combined reserves of the other three mines. The vast and uneven terrain of the Nuagaon mine necessitated mining operations to be carried out at multiple, often shifting, locations. This created a critical need for mobile and efficient illumination infrastructure to ensure safety, maintain operational productivity, and comply with DGMS guidelines.
JSW Steel sought not just to identify gaps in their existing illumination systems, but also to implement a comprehensive and intelligent solution. At the same time, due to the strategic importance of the project, JSW required a system that provided control and oversight to its internal teams rather than complete dependency on an external partner.
"Bidaal Technology not only met our requirements with the illumination survey but exceeded expectations. What began as a pilot in one of our mines has now been successfully rolled out across all four of our Odisha mines. The project has been implemented smoothly and has consistently delivered reliable performance over time."
Shree Chandan AcharyaSr. Manager- E&I, JSW Steel Ltd
Identify Areas Of Risk With Scaling Workforce
To address these operational and regulatory challenges, JSW Steel partnered with Bidaal, adopting its W.I.S.E (Workplace Illumination Safety & Efficiency) system across all its Odisha-based mines, including the Nuagaon mine.
Recognizing JSW’s preference for internal control over critical functions, Bidaal structured a phased implementation approach to onboard and train JSW personnel on the W.I.S.E system. The system comprises two key components: a hardware device for data acquisition and a software platform for data analysis, reporting, and simulation-based design optimization.
Initially, a representative from Bidaal conducted an on-site demonstration at the Nuagaon mine to familiarize the JSW team with the hardware component. Although the W.I.S.E device is designed for simplicity and quick deployment, a technical briefing was provided to ensure smooth adoption. Unlike conventional lux meters that require manual operation over extended periods (typically 2-3 days), the W.I.S.E hardware could be mounted on a vehicle, enabling a comprehensive survey within a few hours. The system also includes a coordinate tracking mechanism, allowing for precise geo-mapping and data accuracy.
Following data acquisition, a secondary training session focused on the software platform was conducted. JSW personnel were trained to upload survey data, generate automated illumination reports, and use the simulation tool to design optimized lighting layouts. This AI-driven platform replaced the traditional manual and paper-based methods with a streamlined, visual system that compared real-time data against DGMS standards through graphical representations.
The AI component of W.I.S.E effectively addressed JSW’s two primary objectives: first, to enhance existing lighting infrastructure to meet DGMS standards where deficiencies were identified, and second, to propose new illumination layouts in cases of widespread non-compliance. These improvements not only ensured regulatory compliance but also delivered additional benefits in terms of energy efficiency and operational productivity.
80% Reduction In Incidents
The primary objective was to achieve and maintain compliance with DGMS illumination guidelines. The implementation of W.I.S.E enabled JSW Steel to identify and address gaps in illumination coverage, resulting in a measurable reduction in non-compliance incidents over successive survey cycles. While initial surveys revealed areas of concern—largely due to frequent changes in operational zones—subsequent assessments reflected continuous improvements, owing to the proactive use of the system by JSW teams.
Moreover, given the expansive area of the Nuagaon mine, the previous method of manual illumination assessment demanded significant manpower and time, rendering the process inefficient. By incorporating the W.I.S.E solution into its operations, JSW was able to substantially reduce labor hours, thus improving productivity and optimizing resource utilization.
The efficacy of the W.I.S.E system was demonstrated during the initial joint survey undertaken by JSW and Bidaal. This involved a comprehensive assessment of a 63.1 km stretch, including haul roads and approach roads. The AI system analyzed the collected data and identified both compliant and non-compliant zones. Based on these insights and the mine’s geographical layout, the simulation recommended targeted upgrades, such as the installation of 200W lighting fixtures in specific zones to meet DGMS standards.
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