Success Story

PPC Cement SA (PTY) Ltd

A Single Version of the Truth for PPC Cement South Africa

End-User

A leading supplier of materials and solutions into the basic services sector in southern Africa, PPC has 11 cement factories in South Africa, Botswana, DRC, Ethiopia, Rwanda and Zimbabwe. PPC’s capacity is around eleven and a half million tonnes of cement products each year. PPC’s Materials business comprises of Pronto Readymix (including Ulula Ash) and 3Q Mahuma Concrete.

Problem

PPC required an enterprise-wide manufacturing reporting and information management solution to standardize KPI collection, calculation, and visualization across all sites. The solution needed to implement PPC’s existing KPI standards to provide actionable, trustworthy information per site and per department, allowing responsible departmental managers to make better quality decisions more frequently.

Solution

PPC chose the Flow Information Platform to solve their problem since Flow can provide a single version of the truth - that one place to get the information you can trust. PPC, in conjunction with Darner Engineering, set about planning the KPI definition and dashboard standards planned for roll out to PPC Cement SA’s three Mega Sites:

  • PPC Slurry
  • PPC De Hoek
  • PPC Dwaalboom

Darner Engineering was then tasked to implement the solution at the above three sites.

Results

The departments at each of these sites have now transitioned from using Excel to using Flow as their day-to-day KPI information and production management tool. This makes it possible for anyone in the organization to see, interpret and trust the information on the dashboards.

Project Info

  • Three sites
  • Approx. 8500 Measures per site
  • Approx. 130 Events per site
  • Data Sources:
    – Canary Historian
    – Laboratory Information Management System (SQL)
    – Energy System (SQL)
    – SAP (SQL)
    – Wayware (SQL)
  • Approx. 60 Reports generated per site.
  • SAP integration using SQL to publish shift production information to SAP once verified. Flow automatically assigns process orders to bags produced by matching process order context with product selections on the SCADA.
  • 50+ people per site are using Flow reports and dashboards daily.

You might also like

Flow Bridges Coca-Cola Beverages Africa’s OT and IT with Analytics-Ready Information
Flow Bridges Coca-Cola Beverages Africa’s OT and IT with Analytics-Ready Information

CCBA needed a solution to automatically capture and account for downtime, speed losses, and production numbers on all their filling lines. In addition, they required trustworthy information to support confident, timely, and accurate decision-making.

May 10, 2022
Read
Thanks to real-time intelligence, Woodlands Dairy cuts water costs and raw material usage
Thanks to real-time intelligence, Woodlands Dairy cuts water costs and raw material usage

“I cannot express the ease with which Flow can be implemented, configured and used as well as the aggregated, timebased information value it delivers from a multitude of sources.”

April 3, 2022
Read
Flow helps one of the largest coal and heavy mineral companies in South Africa
Flow helps one of the largest coal and heavy mineral companies in South Africa

The main challenge facing the production team was the lack of timely decision making and protracted delays in picking up production glitches which impacted on-the-go decision making.

March 30, 2022
Read