FURNEX
See what your furnace can't.
Real-time visibility into cost, performance, and furnace efficiency — for the modern induction plant.
A PSM GROUP PRODUCT
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FURNEX
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Notifications
All caught up
Alerts and updates appear here.
Command Center
Live operations across all furnaces
Heat History
All campaigns and heats
Heats
Heat #1 Saved
Insights
Pattern analysis for lining campaigns
📋
Active Campaign
Live KPIs for the selected lining
🔮
Smart Predictions
Pattern-based forecasts and anomalies
🗺️
Performance Matrix
Cross-furnace cross-shift comparison
KPI Dashboard
Performance analytics and lining health
Reline Planning
Campaign timeline, reline scheduling & downtime management
Reline Plans
Schedule New Reline
PLANNED DATE
EST. HOURS
BRAND
CREW
Recent Campaigns
Analytics
AI predictions, KPIs, trends & supplier comparison
🔮
Predicted Lining Life
Heats this campaign will reach — from charge mix, carbon, tap temperature & bond
Loading lining-life prediction…
📊
KPI Dashboard
Cost, efficiency & lining health for the selected furnace
📈
Trends Over Time
Lining life, output, and cost trajectory
🤝
Supplier Comparison
Ramming-mass brand performance side-by-side
👥
Operator Performance
Per-operator outcomes and patterns
Materials
Prices, history & material list
Loading prices...
Team
Members & staff
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Export Data
Download or email campaign data as CSV
What to Export
🔥
Heat Log
All heats with timing
🏭
Campaign Summary
All lining campaigns
📊
KPI Report
Cost, efficiency, health
👷
Operator Analytics
Performance by operator
📊
Complete Report
All furnaces · 7 sheets with Summary & Insights
Furnace Filter
Delivery
Excel format (.xlsx) - opens in Excel and Google Sheets
Email:
User Guide
Learn every part of FURNEX — on the web console and the mobile app

What FURNEX does

FURNEX is the record book and the intelligence layer for your induction melt shop. Operators log every heat and charge as it happens; FURNEX turns that into live furnace status, lining-life prediction, cost and energy analytics, and reline planning — so the office and the floor always see the same picture.

STEP 1
Start a lining
Open a new campaign on a furnace, then sinter it.
STEP 2
Charge & log heats
Set the charge mix, drop the magnets, melt.
STEP 3
Tap out
Record tap temperature, output and meter readings.
STEP 4
Close the campaign
When the lining is worn, close it with a reason. The AI learns.
Web console vs mobile app. Use the web console in the office for analytics, history, team setup and planning. Use the mobile app on the floor to log heats, drop magnets and tap out. They share one live database — a heat logged on the phone shows on the web instantly.
Getting started Command Center Logging a heat Charge mix Lining & AI Analytics Reline History & export Team & setup Alerts Offline
Getting started
Sign in, find your way around, and understand the layout.
Signing in & your workspace
One account, your plant's furnaces only
What it is
Your admin creates an account for you and chooses which furnaces you can see. Everything you do is scoped to your plant — no other company can see your data.
How to
  1. Open the app and enter your email and password.
  2. If you forgot your password, tap Forgot password and follow the email link.
  3. Your session stays signed in; it locks after 15 minutes of inactivity for safety.
Tip: Install the mobile app to your home screen (Add to Home Screen) so it opens full-screen like a native app and works offline.
Finding your way around
The main sections and how they map across web and mobile
What it is
FURNEX has a handful of main sections. On the web console they sit in the left sidebar; on the mobile app they are on the bottom bar and the More menu.
The sections
  1. Command Center — live status of every furnace.
  2. Log Heat — start, charge and tap out heats.
  3. Analytics — AI prediction, KPIs, trends and supplier comparison.
  4. Reline — campaign timeline and downtime planning.
  5. History — every past heat, searchable.
  6. More / Settings — team, materials, prices, alerts, export.
Open Command Center →
Command Center
The live picture of your whole melt shop.
Reading a furnace card
What each part of the card tells you
What it is
Every furnace shows as a card (web) or a row (mobile). It updates live as heats are logged anywhere in the plant.
IF-02 1On Track 2
Heat 14 / 30 3
ChargeDropTap4
1Furnace ID and name.
2Current status — see the next topic for every badge.
3Heats logged this campaign vs the predicted lining life, with a progress bar.
4Actions for the current state — here you can charge, drop a magnet, or tap out.
Status badges explained
Ready, Sintering, Running, On Track, Nearing Reline, Repair
What each status means
  1. Ready — lining sintered, no heats yet. Charge to begin heat #1.
  2. Sintering — the new lining is being baked in before its first heat.
  3. Running / Heat #N — a heat is live; the timer shows time since tap-in.
  4. On Track — between heats, comfortably inside predicted life.
  5. Mid-Campaign — past two-thirds of predicted life; start watching wear.
  6. Nearing Reline — past ~85% of predicted life; plan the reline now.
  7. Repair — furnace taken down for repair; resume when fixed.
  8. No Lining — furnace is empty; start a campaign to use it.
View density & search (web)
See 30+ furnaces at a glance
What it is
On the web console you can switch between a full-card view and a condensed one-line view, and search for a furnace by name.
How to
  1. Use the search box above the grid to filter by furnace ID.
  2. Toggle Default / Condensed view (or press V) — condensed packs many furnaces onto one screen.
Logging a heat
The core operator flow, start to tap.
Start a heat
Pick the furnace, set the charge, tap in
How to
  1. Tap Charge on the furnace card, or open Log Heat and choose the furnace.
  2. Set the charge mix (see the Charge mix section) and the quantity.
  3. Tap Tap in / Start to begin the heat. The card switches to Running and the timer starts.
Tip: The meter reading at start is captured automatically so power-per-heat is accurate.
Open Log Heat →
Tap out — record the heat
Temperature, output, duration, meters
How to
  1. When the heat is ready, tap Tap on the card (or open the running heat).
  2. Enter the tap temperature (required), the output in MT, and the end meter reading.
  3. Add any breakdowns, manpower or notes if your plant tracks them.
  4. Save. The heat count increases and the next heat number is ready.
Tip: Tap-to-tap time is measured automatically from your tap-in and tap-out — it feeds the lining-life prediction, so log promptly.
The Expected Life readout
A live prediction as you build the mix
What it is
While you set the charge mix, the Mix Intelligence band shows a live Expected Life — the heats this lining should last with this mix, computed by the FURNEX model. It updates as you move the sliders.
How to read it
  1. Expected Life — predicted heats for the current mix.
  2. A higher-quality mix (more HMS, less low-grade DRI) raises it; heavy low-grade DRI lowers it.
  3. It sharpens as real tap temperature, carbon and bond data come in.
Fixing a heat you already logged
Edit or correct from History
How to
  1. Open History and find the heat (filter by date or furnace).
  2. Open it and edit the field, then save — the change is logged in the audit trail.
Open History →
Charge mix
Tell FURNEX exactly what went into the furnace.
Setting the charge composition
The percentage slider
What it is
The charge mix is the recipe for a heat — what proportion of each material you charged. You set it with sliders that always add up to 100%.
Magnet 1ConveyorManual
HMS
60% 2
Sponge DRI
40%
Magnets: 8  =  2.4 MT total 3
1Charging method — Magnet (overhead magnet drops), Conveyor (belt feeder) or Manual (hand/trolley).
2Each material's share. Drag a slider and the others rebalance so the total is always 100%.
3Quantity — number of magnets (or total weight), which gives the tonnage per material.
Locking a percentage
Set one value and let the rest flow around it
What it is
When you set a material's exact percentage, FURNEX "locks" it and distributes the remainder across the others, so a deliberate value never drifts.
How to
  1. Type or drag a material to the exact percentage you charged.
  2. It shows a small set badge — it's now held.
  3. Tap the badge to release it if you want it to rebalance again.
Drops during a running heat
Record each magnet load over time
What it is
A heat is rarely one charge — you keep dropping magnet loads as the bath melts down. Each drop is recorded so the total charge and timing are accurate.
How to
  1. On a running furnace, tap Drop.
  2. Confirm the mix for that load (or repeat the last drop with one tap).
  3. The card shows a running count of drops and total kg.
Ferro-alloys & additives
Added once the heat is running
What it is
Ferro-alloys, carbon and flux are added after melting begins, not as part of the base charge mix. FURNEX only shows these fields once the heat is running so the charge recipe stays clean.
How to
  1. Start the heat first.
  2. In the running heat, open the materials panel and enter the additive weights.
Charge mix presets
Save a recipe, reuse it in one tap
What it is
If you charge the same recipe often, save it as a preset. Presets are shared across your plant and remember the typical tonnage.
How to
  1. Build a mix you use often.
  2. Save it as a preset with a name (e.g. "80/20 clean DRI").
  3. Next heat, pick the preset and adjust if needed.
Lining campaigns & the AI prediction
The flagship: how long this lining will last, and why.
Starting a lining campaign
Bond type, brand, and what they're for
What it is
A lining campaign is the life of one ramming-mass lining — from the first heat until you close it. The details you set at the start feed the prediction.
How to
  1. On an empty furnace, choose Start Campaign (admins only).
  2. Enter the ramming-mass brand and the bond type (boric / boron / other) — boron-bonded linings typically last a few heats longer.
  3. Optionally set an expected life; the AI will refine it.
  4. Sinter the lining, then it's Ready for heat #1.
How the Predicted Lining Life works
Endurance ÷ tap-to-tap, in plain terms
The idea
FURNEX predicts how many heats a lining will give as endurance hours ÷ hours per heat. A lining can take roughly so many hours of hot duty before it wears out; divide that by how long each heat takes, and you get the number of heats.
Predicted Lining Life
17 1heatsPREVIEW 2
Changes with: charge mix · carbon · bond · temperature 3
1Predicted heats for this lining with how it's being run.
2Confidence — Preview early on, rising to Ready as more campaigns close and the model learns your plant.
3The levers that move the number, strongest first.
What changes the prediction
Charge mix matters most, then carbon, then bond
The levers, strongest first
  1. Charge mix quality — clean HMS and high-grade scrap are gentle; heavy low-grade or dirty DRI is abrasive and cuts life hard.
  2. Carbon — matters more on DRI-heavy charges; high carbon helps protect the lining.
  3. Bond type — boron-bonded linings outlast boric by a few heats.
  4. Tap temperature — repeated over-superheating shortens life.
Why two furnaces differ: the same brand of lining can give very different heats depending on the mix and how hot you run — that's exactly what the prediction captures, per furnace.
Why it gets smarter over time
Self-learning from your closed campaigns
What it is
Early predictions use sensible starting values, so they're rough. Every time you close a normal-wear campaign, FURNEX compares predicted vs actual and nudges the model toward your plant's reality.
What you should do
  1. Log heats consistently (mix, temperature, tap times).
  2. Close campaigns with an honest reason (see below) — only normal-wear closures train the life model.
  3. Within a handful of campaigns the numbers tighten up.
Closing a campaign
The reason matters for learning
How to
  1. When the lining is spent, open the furnace and choose Close & Archive Lining (admins only).
  2. Pick the closure reason / failure type — normal wear, or a one-off failure (erosion, crack, cold start, etc.).
  3. Confirm. The furnace becomes empty and ready for a new campaign.
Important: Mark one-off failures honestly. FURNEX only learns lining life from normal-wear closures, so a freak crack won't poison your predictions.
Analytics
One tab: AI prediction, KPIs, trends and supplier comparison.
The Analytics tab
Everything analytical in one place
What it is
Analytics brings the AI prediction, performance KPIs, trends and supplier comparison together, per furnace. Pick a furnace at the top and everything below updates.
What you'll find, top to bottom
  1. Predicted Lining Life — the AI forecast, featured first.
  2. KPIs — campaign health, cost, energy and efficiency.
  3. Trends — electricity, output, tap time and kWh/MT over the campaign.
  4. Supplier comparison — how each ramming-mass brand performs.
  5. Operator performance — at the bottom.
Open Analytics →
KPIs & health
Is this campaign healthy?
What it is
A snapshot of the current campaign — heats done vs predicted, average tap temperature and time, output per heat, material cost and energy. A health score summarises it.
How to use it
  1. Watch the health score trend — a steady drop signals accelerating wear.
  2. Compare cost/MT and kWh/MT against your other furnaces.
Supplier comparison
Which ramming-mass brand actually lasts
What it is
FURNEX groups your campaigns by ramming-mass brand and compares average heats per campaign, cost/MT, temperature, power and wear. Best values are highlighted.
How to use it
  1. Close a few campaigns on each brand so the comparison is fair.
  2. Use it at purchase time — the cheapest brand per bag is rarely the cheapest per heat.
Reline planning
See what's wearing out and schedule downtime.
The reline board
Campaign timeline & scheduling
What it is
The reline board lays out each furnace's campaign against its predicted life, so you can see which lining will need replacing first and plan the downtime, materials and crew around it.
How to
  1. Open Reline.
  2. Furnaces nearing reline are flagged — schedule the reline a comfortable margin before the warning.
  3. Save the plan so the team sees it.
Open Reline →
History & export
Every heat you've ever logged, and how to get it out.
Browsing heat history
Filter by date and furnace; see every captured field
What it is
History is the full record of every heat with all the data captured — heat number, times, charge mix, temperature, output, power, manpower, breakdowns and cost. On the web console it's a dense grid you can sort and filter.
How to
  1. Open History.
  2. Filter by date range and furnace (or all campaigns).
  3. Sort by any column; open a row to see or edit the full detail.
Open History →
Exporting to Excel
Heat, campaign or plant-level reports
How to
  1. Open Export (under Manage / More).
  2. Choose what to export — heat log, campaign summary, KPI report, operator analytics, or a complete multi-sheet report.
  3. Download the .xlsx or have it emailed to you.
Team & setup
People, materials, prices and furnace configuration.
Adding team members & access
Roles and per-furnace access
How to
  1. Go to Settings → Team → Add User.
  2. Set their role: Operator (log heats), Supervisor (plus analytics), or Admin (full control).
  3. Optionally restrict them to specific furnaces.
Note: Anyone with access to a furnace can run its full operations. Deleting data and starting/closing campaigns are admin-only.
Open Settings →
Materials & prices
Your charge materials and what they cost
What it is
FURNEX costs every heat from the materials you charge and the prices you set. Prices are stamped at log time, so a later price change never rewrites past heats.
How to
  1. In Settings → Materials, add or load your charge materials and additives.
  2. Keep prices current under Price Update (typically weekly).
  3. To fix one heat's price, use Override Heat Material Price.
Furnace settings & fields
Tailor what operators capture
What it is
Admins can configure each furnace (capacity, default charge method) and choose which fields appear on the heat log, so operators only see what your plant actually tracks.
How to
  1. Settings → Furnaces to add or edit a furnace.
  2. Heat Log Fields (admin) to switch fields on or off.
Alerts & notifications
Know about problems without watching the screen.
The notifications panel
Live operational alerts, by severity
What it is
The bell opens the notifications panel — furnaces nearing reline, idle furnaces and other operational items, colour-coded by severity. Clear an item with the ✕.
How to
  1. Tap the bell (top bar).
  2. Act on the item, or dismiss it.
WhatsApp & email alerts
Daily summaries and warnings on your phone
How to
  1. Go to Settings → Notifications.
  2. Turn on Email and/or add a WhatsApp/Telegram webhook and recipients.
  3. Choose which events to be alerted on, and send a test.
Open Settings →
Working offline
The plant floor isn't always online — FURNEX copes.
Logging heats offline
Save now, sync automatically later
What it is
If the connection drops, heats you log are saved on the device and a badge shows how many are waiting. When you're back online they sync automatically, in order.
What to do
  1. Keep working — log heats as normal.
  2. Watch the offline-queue badge; it clears itself when synced.
  3. If a heat can't sync within a few days it's flagged so nothing is silently lost.
Keyboard shortcuts (web)
Home
GH
Command Center
GC
Log Heat
GL
Analytics
GI
Refresh dataR
Toggle view (CC)V
Close dialogEsc
Need more help?
Phone support during IST business hours
FURNEX v2.0 · PSM Orechem
🔒 Security & Privacy
How FURNEX protects your plant data
Settings
Account, furnaces, plant configuration & alerts
Account
Company
Email
Role
🌐 Language
Furnaces
🎨 Branding (White-label)
Customize the app for your plant. The display name appears in the top bar; add a logo and support email.
⚡ Electricity Tariff
Set the ₹/kWh rate from each time of day. Each band runs until the next one; the last wraps past midnight. The live clock picks the active rate — operators see it on a chip during the heat.
📦 Materials
Manage the materials operators can pick when logging a charge drop — DRI, Pellets, Scrap grades, Ferro alloys, etc. Per-plant list, fully customizable.
Loading…
Change Password
Add Furnace
Define a new furnace for your plant
Loading…
Drop —
Add Charge
Record a magnet drop into the running heat
Total this drop: 300 kg
No Active Lining
Furnace -
This furnace has no active lining. Has a new lining been installed and is ready to start?
Start New Lining Campaign
Furnace -
Total lining cost tracked for supplier comparison: Rs 0
📷 Click to upload lining photo
Sintering
Sintering will start automatically when you create the campaign. You can achieve sintering later from the furnace card.
Add Employee Account
Create login for a team member
Full Access
Can add members, view all data, edit heats
Can edit heats
Can view all history
Can export / download reports
📊 Can view analytics & prices
Insights, KPIs, AI Predictions, brand comparisons and material prices. Operators should usually be OFF.
Select which furnaces this user can access.
Permissions
Control data access
Admin (full access)
Manage users & settings; do everything on all furnaces
Can edit heats
Can view all history
Account active
Can export / download reports
📊 Can view analytics & prices
Insights, KPIs, AI Predictions, brand comparisons, material prices.
Leave unselected for all furnaces. Select specific furnaces to limit plant-floor access.
🔒 Close Lining Campaign
Furnace -
Campaign Summary
Closure Details
📷
Click to upload closure photo
Photo of lining after final heat
Add Material
Materials are visible to operators during heat logging
💡 Prices are set in Price Update (weekly). This keeps all cost analysis based on a single authoritative source.
Add Staff
Plant workforce that can be assigned to heats — not a login account
Update Material Prices
Set prices with effective dates - system always uses latest price on or before the heat date
Account
Company
Email
Role
Review Heat Data
Verify all details before saving
FURNEX
Welcome to FURNEX
Let's set up your plant in a few minutes
Add Furnaces
Load Materials
Create Presets
Add Team
Add Your Furnaces
Add each induction furnace in your plant
Materials & Charge Presets
Set up your material library and quick charge presets
Material Library
Load 22 standard furnace materials (Scrap, Pig Iron, DRI, Ferro Alloys, Carbon, Flux)
Charge Mix Preset (Optional)
Create a quick-select charge mix for common operations
Add Team Members
Create accounts for operators and supervisors
Start Your First Campaign
Set up the active lining for each furnace
Set Your Password
Welcome! Please set a new password for your account. You cannot use the app until you do this.

🤖 FURNEX AI

SMART
Create Charge Mix Preset
Select materials and quantities for this preset
Total: 0 kg