- 15 min
In 2020, Shu Powders, Africa’s only cobalt manufacturing company, embarked on a transformative journey to modernise its operations. Partnering with Afrilek Automation, the company implemented a phased digital solution that leveraged Ignition, Sepasoft MES modules, and Canary to tackle operational inefficiencies, safety risks, and compliance requirements across its entire plant.
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Introducing the Project
At the heart of this journey were Rajiv Singh, Project Engineer at Shu Powders, and Damian De Arruda, Business Unit Manager for Smart Manufacturing at Afrilek Automation. Together, they drove the implementation of a unified, plant-wide system that consolidated information, digitised processes, and created a safer, more efficient work environment.
Rajiv explains:
“We produce cobalt for major clients in Europe, America, and Japan, including Bosch, Mitsubishi, and Sumitomo. Our industry is highly competitive and volatile, and ESG compliance is a must. To remain competitive, we started a lean manufacturing journey with PwC and were introduced to Afrilek, who guided us through a digital transformation.”
Damian adds:
“This was actually our very first Ignition Perspective project. Back in 2020, it was a bold move, but Ignition’s flexibility and scalability made it the right platform for this complex, plant-wide implementation.”
The Challenges
Shu Powders faced several significant challenges at the start of the project:
- Siloed information and manual processes: Data was scattered across clipboards, whiteboards, and paper logs.
- Complex operations: A furnace with 13 zones required precise control to produce a consistent product.
- High safety risks: The production of hydrogen from ammonia decomposition is explosive, necessitating real-time monitoring and alerts.
- ESG and customer compliance: European clients required strict traceability, quality control, and environmental auditing.
These challenges required a solution that could unify operations from raw materials to finished goods while enhancing safety and process control.
The Solution: Ignition, Sepasoft, and Canary
Afrilek implemented a modular, scalable system that combined:
- Ignition: Provided centralised visualisation and control, enabling a unified digital interface for operators, managers, and lab personnel.
- Sepasoft MES Modules: Introduced batch management, track-and-trace, and SOP automation, digitising previously manual processes.
- Canary: Addressed performance challenges with SQL-based historians, improving enterprise-level reporting and long-term data analysis.
This combination enabled Shu Powders to track materials, monitor processes, and generate reports in real-time, thereby enhancing decision-making and efficiency.
Key Features and Benefits
- Unified Operations: One consolidated platform connects operators, maintenance, labs, and management.
- Traceability: Every batch is tracked from raw material to finished product, with lab data integrated for compliance.
- Safety Improvements: Alerts and remote monitoring help prevent accidents in explosive environments.
- Cost Savings: Recycling rates decreased from over 6% to 1%, resulting in reduced scrap losses and improved yield.
- Mobile-First Design: Operators and managers access the system from workstations, web browsers, or mobile devices.
- ERP Integration Ready: The system is designed to integrate seamlessly with a future ERP for seamless enterprise reporting.
Implementation Highlights
- Raw Material Handling: Suppliers provide Excel sheets with stock and Certificates of Analysis (COAs). These are dragged and dropped into Ignition, validated, and allocated automatically, reducing manual entry and errors.
- SOPs and Forms: Operators complete digital forms for furnace startup, shutdown, and other processes, replacing paper logs and ensuring compliance with regulations.
- Work in Progress Tracking: Lab results are assigned to specific work orders, enabling real-time monitoring and corrective action.
- Visual Production Dashboards: The mobile-friendly interface closely mimics the desktop environment, providing scrollable and intuitive views of furnace and process parameters.
- Golden Batch Analysis: Specialised reporting modules allow detailed process comparisons to ensure quality.
- Downtime Monitoring: Maintenance teams track and categorise downtime per machine to optimise performance.
Rajiv notes:
“Before Ignition, operators spent hours tracking materials manually. Now, we can identify and correct issues before they happen. The system not only reduces scrap but also improves safety and operational control.”
Architecture and Flexibility
The system includes multiple PLCs, four databases, and redundancy for safety. It’s modular, allowing expansion into warehousing and ERP integration. Mobile security is maintained via secure tunnels, user permissions, and dedicated logins, ensuring safe remote access.
Results and Future Plans
The current system delivers:
- Unified operations and traceability
- Significant cost reduction
- Enhanced safety
- Improved compliance and reporting
Plans include integrating warehouse management and ERP connectivity to extend the system’s reach and capabilities.
Damian sums it up:
“With Ignition, Sepasoft, and Canary, we’ve created a platform capable of solving almost any production-related challenge. As data grows and processes expand, the system continues to evolve, providing a foundation for long-term operational excellence.”