THE CHALLENGE
A fully integrated cement plant, producing a significant share of the local clinker and cement market and recognized as a key player in the region, is on an expansion trajectory with the goal to drive its revenue growth. In an effort to ensure strategic clarity with data-driven decision-making, they faced the need for real-time tracking of production and resource management. They were experiencing an increasingly complex business that requires accurate and transparent communication with stakeholders. The CEO reached out to A³&Co.® to craft a systematic reporting system that organizes and presents data in a digestible format, empowering decision-makers with the information needed to make strategic and operational decisions that positively impact the business.

THE SOLUTION
A³&Co.® proposed our Industrial Reporting System, founded on a comprehensive and harmonized data model. The essential components of the A³&Co.® Industrial Reporting Model include:

1. Complete and Harmonized Data Model: Ensuring alignment and traceability of Key Performance Indicators (KPIs) from institutional reports down to the raw data on which the KPI calculations are based.
2. Pre-calculated KPIs (PI Codes): An intermediate layer that records physically pre-calculated KPIs in a data warehouse, ensuring alignment regardless of the report they are published on.
3. Accessible Granularity: Any level of granularity is accessible through a shared Folder Reporting, complementing the already-created Institutional Reports.

THE OUTCOMES
The A³&Co.® Industrial Reporting System successfully covered the entire plant operations, from the quarry up to dispatch. The methodology designed for the system ensures sustainability and efficiency in the reporting process through the following components:

• BI Front End Tools: Utilization of BI tools, specifically Tableau, for reporting and analysis, providing a user-friendly interface for stakeholders.
• A data repository storing data required for reporting and analysis, ensuring data availability for any reporting or analysis need.
• Three-layered Data Storage: The data is stored at three layers based on granularity and transformation criteria:

• Source System Integration: Refers to all transactional systems generating data required for reporting, ensuring a seamless flow of information.

Our client gained significant benefits from our complete Cement Industrial Reporting System, including enhanced accuracy in data analysis, improved cost management strategies, and insightful analysis of various aspects of their operations.
Key components of the Cement Industrial Reporting System encompass:

• Plant Daily Report
• Plant Daily Performance Review Report
• Weekly Performance Review Report
• Raw Material Consumption Report
• Energy Booklet
• Energy Report (Weekly, Monthly) (Dashboard)
• Monthly Performance Review Report, (Dashboard)
• Down Time Report. (Dashboard)
• Automatic calculation of Energy consumption Material

These components collectively empower our client to make informed decisions and optimize their operational efficiency.

The effective implementation of the A³&Co.® Industrial Reporting System granted our client enhanced operational insight, streamlined reporting processes, and a resilient framework for adjusting to dynamic market landscape.