The proposed tuyere puncherTuyere puncher is an innovative machine specifically designed for use with the Peirce-Smith ConvertersPeirce Smith Converter (PSC) or similar converters, to increase their campaign duration and operational efficiencyOperational Efficiency. This paper demonstrates how various machine features address common issues in PSC tuyere maintenanceTuyere maintenance,, including premature tuyere wear, tuyere clogging, and misalignment between the converter and punching system. Knowing that the actual tuyere puncherTuyere puncher accounts for a smaller fraction of PSC operationOperation cost, its effects on the process gains can be tremendous. Since some features can be retrofitted to existing PSCs or punching systems, this work should be of interest to operators of new as well as existing converters. A primary advantage of the new tuyere puncherTuyere puncher is its compact designDesignabout half the size of conventional equipmentEquipmentwhich simplifies installation and reduces the required workspace around the PSC. The modularModular designDesign allows the machine to easily integrate additional features and extensions, providing flexibility. The machine offers a new pneumaticPneumatic punching mode that reduces compressed air consumption and at the same time enables a smoother punching bar movement. This is a significant benefit, as compressed air is an expensive energy source, and smoother movements reduce the wear on the tuyeres and on its check valves. Operators can select either the conventional or the new punching mode on the fly, depending on the operating conditionsOperating conditions. It is known that the length of the tuyeres is decreasing over their lifetime, thereby affecting the surrounding refractoryRefractories and leading to premature need for relining. A full penetration of the punching bar through the tuyere into the copperCopper bath deteriorates the fragile tuyere end and exposes the tip of the punching bar to excessive heat. As a distinctive solution, the punching bar’s stroke can be adjusted precisely for each tuyere individually, enabling operators to adapt the punch depth to the earlier recorded measurement value. In addition, the correctness of the tuyere length measurement is verified after each punch by a camera-based analysisAnalysis of the punching bar, such that the measurement can be updated online. This functionality has a significant impact on PSC maintenance costs and extends campaign duration. To address clogged tuyeres, the machine can be fitted with a specialized drilling function. A drilling test campaign has proven that with adequate drilling tools, clogged tuyeres can be re-opened within a short time. Reactivating lost tuyeres restores the productivity of the PSC and helps distribute operational load amongst all tuyeres, thereby reducingReducing tuyere and refractory wearRefractory wear. A tuyere position detection system, combined with automatic recalibration, monitors and ensures precise alignment of the punching system with each tuyere. Horizontal misalignment can occur due to issues during tuyere installation. The vertical alignment confirms whether the PSC has been properly rotated into its working position. This function prevents operational errors before any damage occurs.