Gerdau Ouro Branco: The Evolution of Predictive Monitoring and APM Journey

To handle the complexities and risk of managing steel plant assets, Brazil-based global steel producer Gerdau is adopting an asset management model driven by data, risk assessment, and reliability improvements.

Gerdau Ouro Branco was dealing with operational complexities that require an integrated approach. They needed to cover more than 10,800 assets with 581,000 systems and components. They were managing 57,000-plus maintenance plans and over 500K maintenance work orders. But, to adopt new technology in a risk-averse and cost-focused industry, they also needed to prove a business value case for software implementation.

Using SmartSignal predictive analytics software at the Gerdau Asset Monitoring Center (CMAG), the team enabled:

Through predictive monitoring, CMAG prevented potential failures in critical assets and strengthened operational reliability through a condition-based strategy.

Gerdau also undertook an integrated assessment of events, failure modes, backlog, and operational losses with GE Vernova. The analysis identified opportunities in Failure Mode and Effects Analysis (FMEA), Reliability-centered Maintenance (RCM), strategy management, lifecycle costs, and traceability of recommended actions. This review has helped establish the business case for future Asset Performance Management (APM) innovation.

According to the team, the gains from predictive maintenance at Gerdau with SmartSignal were not only technological, but also organizational and methodological, establishing a proactive maintenance culture. Predictive monitoring was elevated from a detection function to a role of strategic transformation.

The program impact for 2026 includes:

Their vision is to move beyond isolated predictive maintenance and advance toward a complete and integrated APM ecosystem.