Client Introduction

Our client, Orient Cement is one of the leading, fastest growing cement manufacturers in India. The company has created benchmarks in the industry with the quality of its products from the time they began cement production in 1982 at Devapur.

The Challenge

One of Orient Cement’s projects was the implementation of an Intelligent Industrial Solution – UnifyTwin, to perform data acquisition from their plant’s machinery, monitor and archive the data for a longer duration (upto 5 years), to enhance the acceleration of intelligent insights.

Solution Overview

• We implemented UnifyTwin – Industrial Solution at Orient Cement Limited, Devapur, by interfacing the plant’s PLCs (Programmable Logic Controller) with in-built protocol support to perform real-time data acquisition of around 4000 parameters across 3 units totaling 9 PLCs to monitor the plant data, storage of historian data and provide dashboards.
• The data was stored in a highly scalable big data platform which served as a unified storage repository, to perform monitoring and analytics.
• Our solution UnifyTwin facilitated the storage of large amounts of data for a longer period of time, and a mechanism to back up and synchronize data from Plant network to Corporate network in a secure manner.

Benefits

• Centralized real-time platform for operators to monitor accurate voltage, current, rpm, temperature, weight etc, for consumption and possible forecasting.
• Smart Integration with PLCs with Plug and Play protocol support for data fetch.
• High scalability in-memory platform to crunch ingested data.
• Digital Dashboard with Live Monitoring at various levels.