Element8
A Single Version of the Truth for PPC Cement South Africa
By Clarise Rautenbach
Marketing Manager, Element8
Product:

A Single Version of the Truth for PPC Cement South Africa

PPC CEMENT SA (PTY) LTD

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.

Industry

Cement Manufacturing

Integrator

Darner Engineering provides a full scope of automation control services to manage any size project. From
initial plant construction, to commissioning and start-up. A great wealth of industrial and commercial
experience, services and product skill resides in Darner Engineering to ensure that any project, plant, and
business is well planned, executed and maintained.

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

The Flow Information Platform was selected as the solution to solve PPC’s problem. It is designed to provide
a single version of the truth, that one place to get information you can trust. PPC, in conjunction with Darner
Engineering set about planning the KPI definition and dashboard standards that would be rolled 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 dayto-day KPI information and production management tool. Making it possible for anyone in the organization to
see, interpret and trust the information on the dashboards, from anywhere.

Project Info

  • 3 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. Process orders
    are automatically assigned 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.

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