The Challenge
As the leading European cement manufacturer, the company faced a critical business challenge — the delicate balance between maximizing profits and minimizing costs. Energy consumption emerged as a major cost, constituting 30% of the expenses in cement production. Committed to refining operations, the company embarked on a comprehensive initiative to standardize and optimize procedures across its manufacturing facilities.
The Solution
Leveraging the expertise of ei3’s Data Science team proved to be a game-changer for the cement manufacturing company. Through detailed analysis, certain factories consistently outperformed industry averages, achieving up to a 40% reduction in energy consumption for identical production volumes. This discrepancy was linked to experienced operators who, through their seasoned judgment, made exceptional choices to optimize energy use.
These insights were seamlessly integrated into standardized operating procedures, applicable across all facilities. The system, functioning as a proactive advisor, not only observed but also recommended similar efficiency actions to less experienced operators, drawing from the success of their seasoned counterparts. Importantly, it provided a collaborative platform for operators to seek explanations and understand the reasoning behind the recommendations, empowering them to make informed decisions.
About The
Cement Manufacturer
- $30.6 billion annual revenue in 2022
- 60,000 employees as of 2022
- Presence in 70 countries
Recognized for its commitment to quality and environmental responsibility, this industry giant has significantly contributed to shaping the modern landscape through cutting-edge solutions and dedication to sustainable development.
STEP 1
HISTORICAL ANALYSIS
Developed mathematical models to explain and predict mill behavior.
STEP 2
OPTIMIZATION
Integrated models with operator behaviors to formulate an optimization strategy.
STEP 3
RECOMMENDED SETTINGS
Implemented an automated machine learning process for widespread accessibility to prediction models.
Results
€18 Million Annual Savings
Witnessed a significant impact as the collective effort yields an impressive annual saving of €18 million in energy costs across the entire European manufacturing network.
Transformative Success
The cement manufacturing company’s success story serves as a testament to the transformative potential of ei3’s Data Science for streamlined resource optimization. Cut costs, optimize energy usage, and enhance environmental sustainability, fortifying your bottom line with efficient business practices.
Discover the potential of ei3's Data Science capabilities
