Manufacturing
Making Smarter Decisions
with PI System®
Business Challenges
Our client, one of the largest cement manufacturers in the world with operations spread across India and abroad, needed a system that could deliver real-time insights into asset performance, plant operations, and production KPIs. With operations distributed across multiple facilities, key challenges included:
- Limited integration of process data from multiple plants and units
- Need for a standardized, asset-centric data model across facilities
- Lack of real-time alerts and visibility into operational exceptions
- Heavy reliance on manual monitoring processes
- Minimal use of analytics to drive proactive operations
Curious how real-time insights could change your operations? Let’s explore the possibilities together.
Solution
To address these challenges, we implemented the PI System® to serve as a centralized data infrastructure. Key solution components included:
Deployment of the PI System® across all major production units
Creation of a standardized Asset Framework (AF) for hierarchical asset modeling
Implementation of calculated data points to enable KPI tracking
Development of ProcessBook screens tailored for different roles and operations
Configuration of real-time notifications using PI System® Notifications
Integration of a custom SMS module for urgent operational alerts
These enhancements enabled production teams to shift from a reactive to a proactive approach, with role-based visualizations and event-driven insights.
SERVICES INVOLVED
Business Impact
The implementation of the PI System® brought immediate operational benefits and positioned the organization for continuous digital growth. Impact highlights include:
- Unified, real-time visibility across over 50 production facilities
- Standardized monitoring using a consistent asset hierarchy
- Reduction in downtime through timely alerts and escalations
- Faster response to process anomalies via mobile SMS notifications
- Increased adoption of centralized dashboards for performance management
- Scalable platform ready for future analytics and optimization initiatives
OUR CLIENT QUOTE
"The PI System® has transformed how we monitor and manage operations. With real-time visibility and role-specific dashboards, our teams are now more proactive, efficient, and confident in decision-making."
Operations Head
