
Bringing intelligence to steel: How SHS Group Is reshaping a traditional industry with AI
Steel has been shaped by fire and force for centuries. What happens when you add intelligence to that equation?This episode goes inside the AI operation at SHS, a major German steel group, where a 20-person interdisciplinary team is embedding AI across production, research, and administration. Guests Michael Schaefer, Anna Volker, Ulrike Faltings, and Tobias Bettinger cover how they grew from three people in 2017, the challenges of legacy systems and messy industrial data, and why close collaboration with domain experts has been key to their success, with honest reflections on data quality, model monitoring, and the future of AI in steel.Key Topics:Modern Steel Plant Explained — Today's steel facilities operate as digital ecosystems of sensors, simulation, and AI. High-quality steel, used in automotive and offshore wind, demands far greater precision than commodity alternatives.Building the AI Team — Starting with three people in 2017, SHS's AI function has grown to 20 specialists across three sub-teams: Specialised AI, Gen AI, and R&D — deliberately interdisciplinary across physics, maths, computer science, and engineering.Infrastructure and Data Complexity — SHS runs its own data centres for real-time, low-latency production control. Managing a heterogeneous landscape of legacy systems and up to 10,000 sensors creates significant integration challenges.Data Quality and Pipelines — Messy data — from Excel records and missing values to sensor drift — is the biggest obstacle to AI development. Robust pipelines depend on domain expert input, strict guardrails, and continuous model monitoring.High-Impact Production Use Cases — Standout projects include an input material cost optimisation model, a defect detection system that saved a major customer relationship, and AI-driven temperature and oxygen prediction models that outperform traditional physical approaches.Gen AI in Administration — LLMs are being used to automate feasibility analysis and process unstructured customer enquiries via a centralised, governed internal platform. Gen AI is kept out of live production due to hallucination risks, with human-in-the-loop built into all workflows.Domain Expert Collaboration — Plant engineers and operators are central to every stage of AI development — shaping pipelines, detecting model failures, and bringing unsolved problems to the team. Years of shared successes have built deep mutual trust and a genuine two-way knowledge exchange.Future Outlook and Advice — SHS aims to make the entire group AI-powered. Key advice for data scientists in heavy industry: understand processes and people before algorithms, embrace imperfect data, and play the long game. Smaller specialised models are an exciting near-term development; physical AI a longer-term frontier.






