The Operations Podcast with Fexingo · 2026-07-17 · 8 min
Episode 119 of The Operations Podcast with Fexingo. Lucas and Luna dive into the specific case of Nucor's Crawfordsville, Indiana mini-mill, which used digital twin technology to simulate its electric arc furnace and optimize power usage in real time. They break down how the model integrates sensor data, predicts temperature distributions, and adjusts electrode positioning to reduce energy consumption by 25 percent while maintaining melt quality. The conversation covers the three prerequisites for success: accurate sensor calibration, a physics-based model rather than a pure black-box AI, and operator buy-in through visual dashboards. Lucas explains why this approach works better for continuous processes than batch operations, and Luna questions whether the model can transfer to older mills. A concrete, numbers-driven look at how digital twins move from hype to measurable operational savings.
Other episodes covering the same guests and topics, from across The B2B Podcast Index.
From Sales to Spare Parts - Festo´s AI solutionsIndustrial AI Podcast · on Digital Twin80 / 100
Big River 2: The Mill that LearnsSteel Stories by U. S. Steel · on Electric arc furnace61 / 100
The Geothermal Breakthrough: Heating Homes Smarter, Cheaper, and Cleaner with Dan YatesHardware to Save a Planet · on energy consumption
Introducing Jim², my digital twin that is here for you 24/7/365Jim A. James & The UnNoticed Entrepreneur · on Digital Twin
How a Steel Plant Cut Unplanned Downtime by 70 Percent with Ops82 / 100
How a Hospital Cut Readmissions by 25 Percent with Operations86 / 100How a Container Port Cut Dwell Time by 40 Percent94 / 100How a Coffee Chain Cut Employee Turnover by 50 Percent90 / 100How a Data Center Cut Energy Use by 40 Percent91 / 100