AI Production Planning & Control System

Application 03 · Helious Platform

Production planning that thinks ahead. Gen AI PPC is the agentic planning application on the Helious platform — it generates schedules, forecasts demand, detects bottlenecks, and re-plans in seconds when reality changes, learning continuously from your plant's own data.

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6 modules

Planning fails not because planners are wrong but because plans go stale the moment something moves — a rake arrives early, a furnace trips, an order jumps the queue. Gen AI PPC is built for that reality: connected to the live events TAT Guard and Rake Guard already capture, it re-runs thousands of scheduling scenarios in seconds and pushes the updated plan back into operations. When 2,800 tonnes of iron ore is six hours out, the schedule already knows.

One application. 4 core modules, 2 extensions. Deploy what you need, expand when ready.

Schedule Generation

Planners build Monday's schedule from what they knew on Sunday. By Tuesday, a furnace has tripped, a rake has landed early, and an order has jumped the queue, and the plan is being held together by phone calls. Schedule Generation builds from live demand, material availability, and resource state rather than a snapshot, respects the constraints your plant actually runs under, and regenerates in seconds when any of them move. The output is not a better Monday plan. It is a plan that is still true on Thursday.

Demand Forecasting

Most forecasting tools are trained on industry averages, which means they describe a plant that is not yours. Demand Forecasting learns from your own order history, seasonality, and customer behaviour, so the pattern it finds is the one you actually run. That closes both sides of the same error: working capital tied up in stock against demand that never arrives, and shortfalls on the grades you could have made instead. Forecasting is not about predicting a number exactly. It is about being wrong at a lower cost.

Bottleneck Detection and Load Balancing

A bottleneck is rarely found when it forms. It is found when a shift misses its target, and someone works backwards to explain why. Bottleneck Detection watches capacity, queue depth, and resource state continuously, surfacing the constraint while there is still a shift left to act on it. Crucially, it arrives with a rebalancing recommendation rather than an alarm. An alert tells you the shift will be short. A recommendation tells you what to move.

What-If Simulation

Every significant plant decision is currently settled by experience and argument. Can we take the rush order? Can maintenance go in this weekend? What happens if the raw material lands two days late? What-If Simulation runs each question against the live plant model before anyone commits, so the trade-off appears as a number instead of an opinion. You see what the decision costs across the whole schedule, then you make it.

Extend the chain

Same spine, same login, Switch these on when the core chain is running.

Smart Store - Warehouse Management System

Material becomes inventory, and inventory is where the next leakage begins. Smart Store extends the platform into the store and warehouse: RFID-tagged identification of every item, live bin-level visibility, RFID portal gates controlling movement, automated reconciliation, and real-time sync with SAP, Oracle, and legacy ERPs — every GRN, issue, and transfer reflected in seconds, not overnight batches. The results plants buy it for: zero stock-outs, zero pilferage, and one data spine from gate-in to shelf to issue. Smart Store is among the most-demanded Helious products in the steel sector, where MRO and spares inventory discipline directly protects furnace uptime — and it deploys standalone or as part of TAT Guard.

Explore Smart Store - Warehouse Management System →

Secure Sight - Access Management System

AI-driven access control and workforce management system ensuring secure entry, real-time tracking, and efficient operations across industrial and institutional environments.

Explore Secure Sight - Access Management System →

Client Success Stories

What Our Clients Say

Hear what our clients say about our AI solutions and their impact on their business.

The mining management system improved our operational efficiency and provided valuable insights. A great experience working with them.

Gurpreet Sabharwal

MD, Tirupati Group

At Welspun, we needed complete operational control across weighbridges and loading yards — not just automation. Helious delivered exactly that. Zero Manpower 30 sec operations at weighbridges, automated loading intimations, real-time anomaly escalation, and a VAPT-certified dashboard connecting every touchpoint. Every scenario we could think of was already accounted for. AI adoption in heavy industry requires that level of trust, and Helious has built it.

Karthikeyan M

Resident Director, Welspun World

Gallantt’s first AI-powered weighbridge at Gorakhpur is now live, fully integrated with SAP S/4HANA for seamless data integrity. With AI material identification, ANPR, and human detection, it has improved plant TAT and reduced congestion — a major Industry 5.0 milestone delivered with Helious Tech Solutions.

Jagroop Singh

President & CIO, Gallantt Group

The AI-Unmanned Weighbridge System from Helious Tech Solutions has improved our weighing operations with greater accuracy, faster processing, and reduced manual effort. The team’s support and seamless execution made the entire experience highly effective.

Dinesh Gupta

AVP, Godawari Power and Ispat Limited

FREQUENTLY ASKED QUESTIONS

Frequently asked questions

Gen AI PPC is an agentic AI system that automates production planning and control for industrial plants. It generates optimized production schedules, forecasts demand, detects bottlenecks, and runs what-if simulations — all by learning continuously from your plant's own operational data, reducing manual planning effort entirely.

Gen AI PPC uses historical data and real-time trends to accurately forecast future demand, enabling proactive production scheduling. By predicting shortages and overproduction risks in advance, it ensures resources are available when needed — significantly reducing unplanned downtime and idle time across steel plants and manufacturing facilities.

Yes. Gen AI PPC continuously monitors plant operations and identifies bottlenecks in real time. It automatically suggests corrective actions and redistributes workloads across resources — ensuring smooth, uninterrupted production flow without waiting for manual intervention or end-of-shift reviews.

What-if scenario analysis allows production managers to simulate different planning scenarios — changes in demand, resource availability, or machine downtime — before executing them. This AI-driven production planning feature enables smarter, data-backed decisions that improve scheduling accuracy and reduce costly last-minute adjustments on the shop floor.

Gen AI PPC is built for any heavy industry with complex production cycles — steel plants, cement, manufacturing, and process industries. Any facility looking to replace manual PPC with smart manufacturing planning, automated scheduling, and AI demand forecasting can deploy Gen AI PPC to maximize throughput and resource utilization.

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