Use Case 02
Cement Industry

Challenge

Priority in the upstream cement industry is to shift towards environmentally friendly production. Plants face pressure to reduce downtime, maximize margins and improve health and minimize environmental impact.

Solution to these challenges had the potential to improve two key business areas in phase l of the transformation:

➜ Real-Time Anomaly Applications
Data was present in the historian database but lacked contextualization and flexibility. The treatment also disallowed leveraging of data. Simple monitoring and anomaly detection models need to be applied to real-time telemetry data, but the existing infrastructure does not allow the execution of new real-time calculations.

➜ Predictive and prescriptive maintenance on key assets like Motors, Gearboxes, Pumps, and ID Fans to reduce and predict time to failure. The empirical programmed maintenance shifted to Al-based prescriptive maintenance.

Approach

Wizata and the local experts wor­ked closely with business leaders to ensure that the project was aimed at produ­cing the biggest business impacts and generating measurable ROI.

The following activities were per­formed:

➜ The Wizata platform, hosted within customers’ Azure tenant

➜ Ingest metadata from OSlsoft Pl, MES, Historians, and engineering data sheets

➜ Design and build a process Centric Digital Twin based upon the target equipment

➜ Transform and contextualize process and maintenance data

➜ Use the embedded ML models of the platform and produce real-time recommendations

➜ Build customized dashboards for relevant stakeholders

Outcome

➜  Wizata is demonstrating the power of asset data modeling and replication at scale. With the implementation, the company is experiencing a 3% reduc­tion in energy consumption. CO2 emissions have also been reduced. Unexpected stoppages have decreased by 25%.

➜  The Wizata Anomaly Detection system is currently running 16 models onto 35 assets included in the first phase. The scalability of the whole solution is facilitated by digitalizing each production process through Digital Twin and applying replication templates to adapt, deploy and maintain intelli­gence algorithms within the group.

➜  The contextualized data within Wizata now allows for quick responses to incidents in real-time to prevent unplanned downtime and improve reliability.