Digitization of sensor-based data to reach Cement 4.0

Guests: Berkan Fidan, Performance and Process Director, Oyak
Cement
Martin Provencher, Mining Metals and Materials Industry
Principal, AVEVA


Berkan Fidan describes a team approach to improving cement
operations with sensor-based data. He started a 2016
digitalization project at Oyak Cement in Turkey, which leads
Europe in cement production. As the performance and process
director of his nation's largest cement producer he was trying to
address the realities of cement production: enormous energy and
heat costs and a product that sells for less than bottled water.
He created a team consisting of production personnel from 7
cement plants and 3 grinding plants around the world and
implemented a data collection and visualization system they
referred to as Cement 4.0.  Fidan reports his team did 90%
of the work themselves. Among their accomplishments are 1)
creating digital twins of their plants in Analysis Framework
where they used a template of a kiln ID fan they created
themselves to enforce common benchmarks and visualizations across
their entire organization, 2) defining conditions for email
notifications to local and corporate stakeholders of cement
rotary kiln stoppage, and 3) creating event frames definitions to
track and analyze mean time between failure.


By engaging local production personnel who found the system easy
to use and popular, the system has seen organization-wide
adoption and he attributes a clear improvement in KW per ton to
the cultural change that has resulted. 




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