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Heidelberg Cement

Real-Time Mobile Access to OSIsoft PI for Process, Production, Maintenance and Compliance Information


“With Visual KPI, real-time information about our plants is only one touch away on the iPhone. We are just seeing the tip of the iceberg in terms of what Visual KPI has to offer. It has huge potential to help us improve operational efficiency at our plants.”

François Léonard, Manager,
Automation & Control
Lehigh Hanson (Essroc/HeidelbergCement)

The Challenge

Essroc, a leading cement manufacturer that is now owned by Lehigh Hanson and part of the Heidelberg Cement Group, has eight plants in North America, all of which have a data historian (OSIsoft PI System) that is critical for tracking plant data. However, their PI data and other sources were not easily accessible to supervisors, managers, and executives. Essroc needed a front-end visualization solution to give executives access to process, production, maintenance and compliance dashboards in real-time directly from their phones and other mobile devices.

Essroc’s Experience

Essroc selected Visual KPI because it was real-time, obvious, easy to deploy and manage, and could aggregate multiple data sources on-the-fly without moving the data (no big project). Visual KPI’s lightweight analytics aggregate operational data from existing IT systems, including the OSIsoft PI System data historian and Essroc’s Lab Management System (LMS). It offers a real-time snapshot of manufacturing performance, including bearing temperatures, equipment failure and overall production levels of the company. Additionally, the software delivers key performance indicators (KPIs), dashboards and alerts for users to track the status of the company’s eight PI servers and other data sources without moving any data.

Results with Visual KPI

  • Real-time monitoring of manufacturing performance with KPIs for improved operational efficiency
  • Flexible and obvious solution enables implementation of dashboard changes and modifications in a matter of minutes
  • Self-service analytics and ad-hoc reporting without the need for training, so management, executives and others can create reports without impacting analysts or relying on static reports
  • 24/7 troubleshooting and alerting ensures immediate response to critical conditions

About Lehigh Hanson

Lehigh Hanson Essroc

Lehigh Hanson is a leading North American cement producer with over 6.5 million metric tons of annual capacity. The company operates production facilities strategically located throughout the U.S., Canada and Puerto Rico. They are linked through an integrated supply network connecting all Essroc plants, terminals and markets. Lehigh Hanson, headquartered in Irving, Texas, is a member of the Heidelberg Cement Group. HeidelbergCement is one of the world’s largest integrated manufacturers of building materials with leading market positions in aggregates, cement and ready-mixed concrete. The company employs some 57,000 people at more than 3,000 locations in around 60 countries.