AVEVA (Schneider Electric) Case Studies Avantis Solution provides solid Enterprise Planning, Scheduling and Compliance Management for Ash Grove Cement

	Avantis Solution provides solid Enterprise Planning, Scheduling and Compliance Management for Ash Grove Cement AVEVA (Schneider Electric)

Avantis Solution provides solid Enterprise Planning, Scheduling and Compliance Management for Ash Grove Cement

AVEVA (Schneider Electric)

Technology Category	Functional Applications - Enterprise Asset Management Systems (EAM)
Applicable Industries	Metals Mining
Applicable Functions	Maintenance Procurement
Use Cases	Predictive Maintenance Inventory Management
Services	System Integration
Challenge	Ash Grove Cement Company, the fifth largest cement manufacturer in the United States, was facing the challenge of maximizing profit in a highly cost-competitive market. The company needed to continuously innovate and find better ways to balance both availability and utilization of its production assets. This challenge was compounded by having to develop a standardized solution that worked for each of its nine separate production facilities. The company's long-term goal was to automate maintenance data collection at each of its facilities for a well-defined enterprise asset management process to support equipment performance reliability while interfacing with its financial software, JD Edwards One World. They needed a system that they could implement to improve operations, with the scalability to contribute to sustainable development. Read More
About Customer	Ash Grove Cement Company is the fifth largest cement manufacturer in the United States, with an annual production capacity of more than 8 million tons per year. The company's headquarters are in Overland Park, Kansas, with production facilities located throughout the U.S. The Portland and masonry cements produced at these plants are used in the construction of highways, bridges, commercial and industrial complexes, residential homes, and numerous other applications. The company's enterprise includes management, finance, and administration functions at headquarters in Overland Park, Kansas, and autonomous mining, transportation, production, and distribution facilities in nine U.S. states. Read More
Solution	Ash Grove Cement Company implemented Avantis.EAM, Avantis.PRO, and Avantis VIP Advanced Scheduling to automate all data collection on kiln-related maintenance activity at one plant and extended it to remaining facilities in the following year. The Avantis software builds a detailed history of equipment information based on day-to-day maintenance activities. Equipment statistics include hours of operation, cause and frequency of downtime, and labor and material changes, all of which can be easily reviewed and analyzed. The software also supports contingency planning for unanticipated equipment failures. Technicians can review work backlogs easily, adjust work schedules, and determine appropriate maintenance procedures by studying the equipment history. Pre-entered coding helps technicians determine which equipment must be shut down during the maintenance and which can continue running. Read More Log in to view content
Contents

Technology Category

Functional Applications - Enterprise Asset Management Systems (EAM)

Applicable Industries

Metals

Mining

Applicable Functions

Maintenance

Procurement

Use Cases

Predictive Maintenance

Inventory Management

Services

System Integration

Challenge

Ash Grove Cement Company, the fifth largest cement manufacturer in the United States, was facing the challenge of maximizing profit in a highly cost-competitive market. The company needed to continuously innovate and find better ways to balance both availability and utilization of its production assets. This challenge was compounded by having to develop a standardized solution that worked for each of its nine separate production facilities. The company's long-term goal was to automate maintenance data collection at each of its facilities for a well-defined enterprise asset management process to support equipment performance reliability while interfacing with its financial software, JD Edwards One World. They needed a system that they could implement to improve operations, with the scalability to contribute to sustainable development.

About Customer

Ash Grove Cement Company is the fifth largest cement manufacturer in the United States, with an annual production capacity of more than 8 million tons per year. The company's headquarters are in Overland Park, Kansas, with production facilities located throughout the U.S. The Portland and masonry cements produced at these plants are used in the construction of highways, bridges, commercial and industrial complexes, residential homes, and numerous other applications. The company's enterprise includes management, finance, and administration functions at headquarters in Overland Park, Kansas, and autonomous mining, transportation, production, and distribution facilities in nine U.S. states.

Solution

Ash Grove Cement Company implemented Avantis.EAM, Avantis.PRO, and Avantis VIP Advanced Scheduling to automate all data collection on kiln-related maintenance activity at one plant and extended it to remaining facilities in the following year. The Avantis software builds a detailed history of equipment information based on day-to-day maintenance activities. Equipment statistics include hours of operation, cause and frequency of downtime, and labor and material changes, all of which can be easily reviewed and analyzed. The software also supports contingency planning for unanticipated equipment failures. Technicians can review work backlogs easily, adjust work schedules, and determine appropriate maintenance procedures by studying the equipment history. Pre-entered coding helps technicians determine which equipment must be shut down during the maintenance and which can continue running.

Impact #1	Improved ability to manage inventory, as many as 8,000 items at each plant, maintaining between $2 million to $12 million in inventory.
Impact #2	Compliance with the Federal Environmental Protection Agency (EPA) regulation called the Portland Cement Maximum Achievable Control Technology (PC MACT).
Impact #3	Minimizes the potential loss of $3,000 per hour for every hour the kiln is offline.

Impact #1

Improved ability to manage inventory, as many as 8,000 items at each plant, maintaining between $2 million to $12 million in inventory.

Impact #2

Compliance with the Federal Environmental Protection Agency (EPA) regulation called the Portland Cement Maximum Achievable Control Technology (PC MACT).

Impact #3

Minimizes the potential loss of $3,000 per hour for every hour the kiln is offline.

Benefit #1	A $2 million first year inventory reduction.

Benefit #1

A $2 million first year inventory reduction.

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Overview

Avantis Solution provides solid Enterprise Planning, Scheduling and Compliance Management for Ash Grove Cement

Operational Impact

Quantitative Benefit