Yamama Cement – Journey to Operational Excellence

Revolutionizing Reliability: Unleashing the Power of Digitization 4.0 for plant maintenance.

Yamama is a leading player in the cement industry. It faced significant challenges in monitoring and assessing reliability across their expansive field of assets. They had been using predictive maintenance since some years and it had proven very effective in improving reliability across their assets. They wanted to expand it across larger number of assets without compromising on the quality of their inspection and analysis. But expanding the program across larger number of assets with the same team had its own challenges.

Yamama explored various technologies with the vision to expand predictive maintenance and reliability program. They finally chose an AI and IoT sensors driver approach as it solved their two critical problems – time spend on data collection and second the time spend on analyzing data from  healthy machines that had no issues.

After a detailed evaluation of suppliers they chose SenseGrow’s ioEYE Predict solution. They carried out a pilot and a detailed evaluation of the battery life, wireless communication, data accuracy and prediction capabilities. The ioEYE Predict wireless sensors, ease of installation and AI accuracy was the winner.

Yamama chose to install the entire system themselves. The ease of installation of the system allowed them to could retrofit their assets without any major shutdown or hot work. No communication or power cables were needed to be run. They used IoT gateways with a SIM card to provide the sensors connectivity to the ioEYE predict cloud. Since the system was not infringing or connecting with any of their IT systems it ensured high security through isolation.

With the implementation of ioEYE Predict, monitoring and inspecting each asset became a seamless process. The vibration and ultrasonic sensors, strategically placed on assets, ensured accurate data collection at regular intervals. This not only addressed the accuracy issue faced during manual data collection but also provided a continuous stream of reliable asset health information.

Furthermore, ioEYE Predict’s advanced AI algorithms, fueled by historical data, enabled Yamama to predict potential failures with unparalleled precision. The system’s predictive maintenance capabilities allowed them to proactively address issues before they escalated, minimizing downtime and optimizing asset performance.

In conclusion, Yamama’s adoption of ioEYE Predict marked a transformative turning point in their operations. The challenges of manual data collection and the overwhelming task of inspecting numerous assets were effectively overcome. With ioEYE Predict, Yamama not only streamlined their monitoring processes but also elevated their ability to predict and prevent asset failures, ultimately enhancing their overall reliability, efficiency and success in the cement industry.