Votorantim Cimentos
Votorantim Cimentos optimizes predictive maintenance with AVEVA Predictive Analytics
Votorantim Cimentos wanted to better understand the performance of its assets and deploy a condition-based maintenance program using machine learning to predict equipment behavior. The organization aimed for rapid implementation, a user-friendly interface and a significant return on investment, all in a particularly challenging context due to a fully remote deployment imposed by the pandemic. The group selected AVEVA Predictive Analytics, whose ease of use allows both management teams and operators to work independently without relying on a vendor. The results are remarkable: a 10% reduction in recurring maintenance costs, savings of 16 million rand per site ($5.5 million), totaling $88 million across the fleet, asset reliability up 6% to 91.2%, unplanned maintenance reduced from 52% to 42% of the total, and greater transparency paving the way for plant-to-plant benchmarking.
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FAQ
How does AVEVA Predictive Analytics transform cement operations in one year?
Votorantim Cimentos transformed its operations in one year with AVEVA Predictive Analytics by rolling out a machine learning-based condition-based maintenance program. The platform predicts the behavior of critical assets (mills, kilns, fans) and anticipates failures before they turn into shutdowns. This rapid transformation, despite a fully remote deployment imposed by the pandemic, demonstrates the maturity of the solution and AVEVA's ability to support accelerated digital transformations in heavy industries.
How can predictive maintenance save $88 million across a cement fleet?
AVEVA Predictive Analytics enabled Votorantim Cimentos to save 16 million rand per site ($5.5 million), or $88 million cumulatively across the fleet. These gains come from a 10% reduction in recurring maintenance costs, a drop in unplanned maintenance from 52% to 42% and a 6% improvement in asset reliability. For a cement producer operating under margin pressure, these recurring savings largely fund the digital transformation and support the group's international competitiveness.
Why is a user-friendly interface critical to adopting a predictive solution?
Votorantim Cimentos required a user-friendly interface that would allow both management teams and operators to work independently without relying on a vendor. AVEVA Predictive Analytics meets this requirement with ergonomics designed for business users. This autonomy is a key adoption factor: teams take ownership of the solution, use it every day and spread best practices between sites. User experience is therefore not a detail but an essential condition for the success of a large-scale predictive analytics project.
How can a 100% remote deployment succeed during a pandemic?
Votorantim Cimentos deployed AVEVA Predictive Analytics entirely remotely during the COVID-19 pandemic. This feat, unthinkable a few years earlier, was made possible by the maturity of the AVEVA cloud platform, tailored support for local teams and a rigorous project methodology. The success of this remote deployment shows that industrial digital transformations can now overcome geographic constraints, opening up opportunities for international multi-site groups that want to roll out their initiatives quickly.
How does AVEVA enable benchmarking between cement plants?
AVEVA Predictive Analytics gives Votorantim Cimentos greater transparency into asset performance, paving the way for benchmarking between plants. The best-performing sites for a given piece of equipment become the benchmark, and their best practices spread across the group. This continuous improvement dynamic, driven by a single platform of comparable data, is one of the most powerful levers for harmonizing performance across a multi-site fleet and accelerating convergence toward operational excellence in an industry as demanding as cement.