Cement is quite a competitive industry where daily downtime costs up to $300,000 (1.0 MTPA plant) and margins are also razor-thin. UptimeAI bridges the gap between legacy inefficiencies and AI-driven precision.
In this case, the cement producer faced key challenges in reducing the cost per ton of cement production across all 45 sites. One of the key drivers to achieve this objective is to ensure asset reliability.

Challenges:

  • Although equipment anomalies were flagged with their in-house DCS solutions, the alerts were reasonably delayed until the asset performance deteriorated.
  • Inability to learn best practices & standardise across the 45 lines.
  • Analysing correlations between different operating conditions in the plant units revealed that sometimes the sensor data deviated from the expected behaviour, triggering multiple false alarms.

Learn how UptimeAI empowered this 146 MTPA Cement Producer to enhance Asset Utilisation and achieve the goal of reducing the Cost per Ton of Cement Production.

 

  

Get a copy of the Customer Story: