Prabhat Kumar TiwariConsulting & Advisory

Steel automation & systems integration

Experienced judgment.
For complex
plant systems.

I help steel producers and engineering teams think through modernization, commissioning and integration decisions—with the realities of plant operations in view.

Discuss a project Explore how I can help View my experience

Based in India Remote advisory & project-based engagements

Experience across
the steel value chain

  • Ironmaking
  • Steelmaking
  • Casting & rolling
  • Utilities & material handling

01 / Selected experience

Grounded in
work inside the plant.

Selected work from my Tata Steel career and co-authored research. The publications report team results in their specific operating contexts.

Actual publisher article header showing the coil-quality paper’s title, Prabhat Kr Tiwari among the authors, and its DOI. Actual publisher page
Co-authored research2019

Predicting coil quality.

Neural-network research deployed on Tata Steel’s Level-II server for online monitoring of galvanised-coil mechanical properties.

25,000 coils in the development dataset

Read publication (opens in a new tab)
Study details & citation

The published system supported operator displays and online quality alerts. The paper reports a mean absolute error of 6.4 MPa for online yield-strength predictions evaluated against laboratory results for 1,180 coils.

Lalam, Tiwari, Sahoo & Dalal · Ironmaking & Steelmaking, 46(1), 89–96. Published online in 2017; journal issue 2019.

Original Diagnostyka paper header naming Prabhat K. Tiwari as a co-author of the cold-rolling chatter study.Actual Figure 2 from the paper: a vibration sensor installed on the rolling-mill stand. Original paper excerpts
Co-authored research2018

Detecting rolling chatter.

Research applying principal component analysis to mill vibration measurements to distinguish chatter in cold rolling.

10 kHz vibration data used in the study

Read publication (opens in a new tab)
Study details & citation

The study evaluated 14 chatter and 43 non-chatter coils of similar grades and sections, comparing frequency-spectrum and statistical-feature methods. It described integration with a central condition-monitoring system and web interface.

Usmani, Kumar, Velisatti, Tiwari, Mishra & Patnaik · Diagnostyka, 19(1), 73–81.

Indian Patent 578214 certificate naming Prabhat Kumar Tiwari as a co-inventor and Tata Steel Limited as patentee, granted 14 January 2026.View full certificate

Co-inventor · Indian Patent 578214

Monitoring wagon alignment
in real time.

“Method, device and system for monitoring alignment of uncoupled wagons in real-time.”

Granted
14 January 2026
Patentee
Tata Steel Limited
View the patent certificate (opens in a new tab)

Listed as a co-inventor alongside Abhilash Agnihotri and Kamalesh Singh. This credential does not represent an offer to license or supply Tata Steel’s intellectual property.

Applied computer vision

A practical focus on
plant safety applications.

Designed, developed and implemented a vision-based Ladle Vigilance System to support no-man-zone safety around ladle movement.

Also led COVID-era computer-vision monitoring for PPE use, restricted-zone entry and fire-related safety conditions, with Tata Steel Innovista recognition.

Explore the career behind these projects and publications.

View my professional background

02 / Professional background

Prabhat
Kumar Tiwari.

An electrical engineer’s foundation.
A systems leader’s perspective.

My experience spans plant controls, instrumentation, Level 1 and Level 2 systems, commissioning, production ramp-up and system restoration.

Across brownfield projects, I bring attention to the details that connect engineering decisions with production continuity, maintainability and the people who operate the plant.

Download résumé PDF

1996 — December 2024

Tata Steel

Head, System Integration Group

Jamshedpur, India

1991 — 1996

Rashtriya Ispat Nigam Limited

Electrical Engineer

Visakhapatnam, India

2014 — 2017

MBA

XLRI Jamshedpur

1987 — 1991

BE, Electrical Engineering

NIT Jamshedpur

Put this experience to work on your next technical decision.

Explore consulting support

03 / Consulting & advisory

A clear scope.
A useful next step.

For plant leaders, OEMs, system integrators and engineering consultancies who need an experienced perspective on a defined technical decision.

Select a service to see the decision, deliverable and how we would work together.

Legacy and modern control cabinets connected to retained plant equipment.Modernize plant controlsPlan upgrades around existing equipment and production.

Decision

What should change, what can be retained, and how could the transition fit around production?

Deliverable

A review of modernization options, interface risks and a phased migration outline.

Working together

Review the installed systems, operating constraints and vendor proposals with your engineering and operations teams.

Discuss modernization
Equipment, a control cabinet and a workstation linked through a network junction.Connect equipment and systemsClarify connections and responsibilities across suppliers.

Decision

How will existing controls, new equipment and vendor packages work together—and who owns each interface?

Deliverable

An interface and responsibility matrix, with gaps and technical questions for resolution.

Working together

Examine system architecture, signal lists and Level 1 / Level 2 requirements with the client and relevant suppliers.

Discuss integration
An equipment readiness checklist, test meter and industrial drive.Prepare for commissioning or restartReview readiness, interlocks and acceptance checks.

Decision

What needs to be checked, demonstrated or resolved before a planned change or restart?

Deliverable

A commissioning-readiness review, acceptance-check outline and prioritized list of open items.

Working together

Review test plans, interlocks, system dependencies and site readiness with those responsible for execution and authorization.

Plan commissioning
A diagnostic signal trace and inspection of a control-system connection.Diagnose recurring system faultsTrace problems through signals, alarms and operating history.

Decision

Which failure paths deserve investigation, and what evidence would help the team choose its next action?

Deliverable

A structured diagnosis, a ranked set of hypotheses and a plan for targeted checks.

Working together

Review event histories, trends, system changes and operating observations with plant specialists and equipment vendors.

Discuss a recurring fault
An industrial camera observing a steel coil and its image on an operator screen.Assess industrial AI and visionEvaluate a use case for day-to-day plant operations.

Decision

Is an analytics or vision use case practical, and what would it take to move into operational use?

Deliverable

A feasibility and integration assessment covering data, sensing, validation and operator workflows.

Working together

Define the operating problem with plant and technology teams, then review input quality, deployment constraints and acceptance criteria.

Explore an AI use case

Need a continuing technical sounding board? Ongoing advisory can be scoped around design reviews, vendor discussions and key project decisions.

Have a specific plant or systems challenge in mind?

Discuss your technical challenge

04 / Working together

How an engagement
works.

A focused assessment, support at a project milestone or ongoing advisory. We start with your question and agree what useful support looks like.

Let’s start a conversation

What decision
is ahead of you?

Share a little about your plant or project, the question you are working through and the kind of support you need.

A short introductory conversation can help establish whether there is a useful fit.

Discuss a project prabhat@goatai.io

Based in India · Remote advisory