IT IN MANUFACTURING

How to optimise your mill and kiln

processes with Plant Pilot System
As we navigate the digitalisation of various
industries, we need to consider how energy
management, process optimisation, emissions
control, and environmental monitoring can
all play an indispensable role in preserving
our planet for future generations. Artificial
intelligence (AI) and machine learning (ML)
have huge potential to solve complex
multiple-input multiple-output (MIMO)
problems, and they play a key role in building
sustainable, high-performance expert systems.
Developing a real-time optimiser (RTO)
for vertical roller mills requires advanced
statistical and machine learning algorithms in
order to dynamically adjust and optimise their
processes in real time, based on constantly
changing conditions, to deliver optimal results.
LOESCHE is able to assist by leveraging
cutting-edge technologies with its Plant Pilot
System, powered by aixprocess. It can optimise
your mill and kiln processes, either on a
standalone basis or as a total solution.

Mill PILOT
Remote sites need to be able to operate
autonomously, with remote analysis. Mill PILOT
combines LOESCHE’s digital expertise with its
experience in solids processing, providing a
powerful digital assistant for mill operations in
the cement, mining and minerals, and chemical
industries. Operating a mill with the Mill PILOT
real-time optimiser can result in energy savings of
up to 15%. Automated reports keep staff informed
regardless of their location, and data collection
from remote machines enables monitoring and
adaptive control, whilst diminishing the need for
on-site human resources.
Kiln PILOT
Kiln PILOT is the result of 20 years of cement
production know-how, embedded into a digital
platform that enables continuous kiln process
optimisation. LOESCHE’s unique aixprocess
solutions, RealTime CFD and FlowSheet, draw
on AI and deterministic engineering models
to handle the complexity of the cement
production process. They continuously monitor
the entire bandwidth of information from
the process control system, to the laboratory
system, to additional optical or vibration
sensors. The data is used to build a self-learning
and adaptive data model of the process. This
allows for short-term process variable and KPI
predictions and results in a high performance,
optimised process.
“The Plant Pilot system is an intelligent and
patented combination of deep learning and
artificial intelligence, first principle engineering
models, real-time CFD, flowsheet models, and
smart sensors. We are proud of our willingness
to meet the unique needs of each customer,
and adapt to where the market is headed,” says
digital sales manager for LOESCHE South Africa,
Janie Scholtz.” We know past performance
is no guarantee for future success. Only by
challenging the status quo, and constantly
striving for new and better solutions and
technologies can we remain relevant.”
For more information contact
Janie Scholtz, LOESCHE South Africa,
+27 66 113 9297, jscholtz@loeschesa.co.za,
www.loesche.com

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www.instrumentation.co.za July 2023 21

 IT IN MANUFACTURING

The power of unified namespace

in the digital era
In the rapidly evolving landscape of South
African manufacturing, staying competitive
means embracing digitalisation. One crucial
aspect of this transformation should be the
adoption of a unified namespace architecture.
But what exactly is a unified namespace, and
why is it so important? If you’ve managed to
focus on manufacturing IT this past year, you’ll
have noticed an increased chatter about the
unified namespace, which is nothing new,
really. Made famous by Walker Reynolds, the
unified namespace turned the manufacturing
industry on its head.
The key role of unified namespace in
South African manufacturing
Unified namespaces provide a standardised
approach to managing and accessing data
and resources, making them the backbone of
digitalisation in South African manufacturing.
Let’s delve into how they benefit the industry.
Let’s take a closer look at how unified
namespaces benefit the industry:
Data integration: Manufacturing plants
generate vast amounts of data from different
sources, such as production lines, machines,
and supply chain systems. Unified namespaces
make data integration a breeze by establishing
consistent naming conventions and structures.
Device and asset management: In the diverse
landscape of manufacturing, managing various
devices and assets can be challenging. Unified
namespaces bring order to this complexity by
providing a standardised approach to managing
and monitoring assets. With consistent naming
and monitoring mechanisms, manufacturers
can easily locate, maintain, and optimise the
performance of their assets.
Process and workflow orchestration:
EEfficiency is the name of the game in
manufacturing, and unified namespaces play
a vital role in streamlining processes and
workflows. By acting as a common language
and structure, they facilitate seamless
communication and collaboration among
software applications, systems, and devices.
This enables efficient coordination and
synchronisation of manufacturing operations.
Digital twins: Digital twins hold great promise
for South African manufacturing, and there are
many success stories. Unified namespaces make
their implementation smoother. By providing a
common framework for managing digital twins,
manufacturers can bridge the gap between
physical assets and their virtual counterparts.
Digital twins enable predictive maintenance,
performance optimisation, and real-time
monitoring, enabling manufacturers to unlock
new levels of operational efficiency.
Challenges on the path to implementing
unified namespace in South African
manufacturing
While the benefits are clear, implementing a
unified namespace architecture is not without
its challenges. Let’s explore some of the hurdles
specific to the local context.
Skills gap: The South African
manufacturing industry faces a skills gap in
digital technologies and IT expertise. This gap
can impede the successful implementation of
a unified namespace architecture. Here, the
divide between IT and OT must be bridged to
get the best of what digitalisation has to offer.
No longer can you have one skill; the unified
namespace requires an understanding of
digital technologies and how use them.
Cost considerations: Like any
transformative initiative, implementing a
unified namespace architecture requires
investments in infrastructure upgrades,
retrofitting legacy systems, and training
employees. Watching podcasts and reading
about unified namespace success stories
certainly makes the implementation process
seem easy and cost-effective. However, limited
budgets and financial constraints can pose
challenges for South African manufacturers
who want to ‘try something new’.
Regulatory compliance: South African
manufacturing operates within a regulatory
framework that emphasises data privacy,
security, and compliance. Implementing a
unified namespace architecture requires
careful consideration of these regulations
to ensure data integrity, protection, and
compliance throughout the digitalisation
journey. The industry has evolved to allow
many platforms to speak the same language
to share data. Whether this has a bearing on
accepted standards utilised in certain plant
processes, time will tell.
Collaboration and knowledge sharing:
Successful digitalisation in South African
manufacturing depends on collaboration and
knowledge sharing among stakeholders – my
pet peeve: IT and OT integration. Establishing
platforms for collaboration, sharing best
practices, and fostering a culture of innovation
can address implementation challenges and
accelerate the adoption of unified namespaces.
The IT guys don’t know manufacturing, the
manufacturing guys think they know IT.
Unified namespaces should be a game-
changer for South African manufacturing,
unlocking new levels of efficiency, productivity,
and competitiveness. While challenges such as
the skills gap, cost considerations, regulatory
compliance, and the need for collaboration
between IT and OT exist, the benefits of a unified
namespace architecture outweigh these obstacles.
By embracing this standardised approach
to data acquisition and resource management,
South African manufacturers can finally
navigate the digital era with confidence, but it
will take some work to do.

Lance Turner
Lance Turner is an MES/IIT/OT specialist employed at Sasol’s Secunda plant. He has an
honours degree in Information Systems and an Adv. Diploma in Industrial Data
Communications, Networks and IT. A certified MESA MES/MOM student, his passion is
amalgamating general IT across the manufacturing spectrum. Lance’s vision is for a
converged IT and manufacturing discipline that will become the reality of Industry 4.0. His
team motto is MES services that are always available, always stable, and always dependable.
For more information contact Lance Turner, lancegta007@gmail.com,
www.lanceturner.co.za

22 July 2023 www.instrumentation.co.za