Case Study

Restructuring of the main production and consumption calculations for the world's largest alumina refinery

How PIMS has helped improve analysis and decision making related to energy production and consumption

Steel & Metal

Projects and solutions for the entire steel production chain

Project Data

DIMENSION

+ 300 calculations

World's largest alumina refinery

Main KPIs of production, consumption and energy matrix, including forecasts

DEADLINE

4 months

from order to delivery

One month to prepare the project and three months to develop it

DEVELOPMENT

Agile methodology

Weekly Sprints

Delivery of minimum viable products addressed to functionalities that make up the solution

Context and Challenges

At the world's largest alumina refinery, most of the major KPIs of production and energy consumption were calculated using an Excel spreadsheet, which was developed and constantly modified by several people from different sectors. This led to doubts about the consistency of these indicators. To change this picture, we defined the main pillars of the project to, besides restructuring the calculations in the PI System, improve the decision-making process as a whole. This involved challenges such as:

  1. Generate an organized structure in the PI Asset Framework
  2. Centralize the information
  3. Ensure easy maintenance of the system
  4. Managing change
  5. Consolidate the calculations and ensure that they are repeated every hour
  6. Develop a Web visual layer for PI Vision
  7. Ensure information security

Solutions Used and Equipment Provided

PI System was present throughout the project: it was used to structure and organize the assets, it served as a data source for the calculations, and in it the visual layer of the system was made.

All the assets needed for the production and energy matrix calculations were structured in the PI AF, and the PI Analysis became responsible for repeating every hour all the steps of the calculations, thus generating the KPIs. In this way, control over the changes was ensured, which became centralized.

PI Vision was used as a web visual layer, with components developed in a customized way to meet the various forms of visualization required.

Experts

PIMS Consultant

Diogo Castro

IT Consultant - PIMS

Lucas Silva Guerra

Awards

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Restructuring of the main production and consumption calculations for the world's largest alumina refinery

How PIMS has helped improve analysis and decision making related to energy production and consumption

August 20, 2020

published by

Diogo Castro

PIMS Consultant

published by

Lucas Silva Guerra

IT Consultant - PIMS

DIMENSION

+ 300 calculations

World's largest alumina refinery

Main KPIs of production, consumption and energy matrix, including forecasts

DEADLINE

4 months

from order to delivery

One month to prepare the project and three months to develop it

DEVELOPMENT

Agile methodology

Weekly Sprints

Delivery of minimum viable products addressed to functionalities that make up the solution

At the world's largest alumina refinery, most of the major KPIs of production and energy consumption were calculated using an Excel spreadsheet, which was developed and constantly modified by several people from different sectors. This led to doubts about the consistency of these indicators. To change this picture, we defined the main pillars of the project to, besides restructuring the calculations in the PI System, improve the decision-making process as a whole. This involved challenges such as:

  1. Generate an organized structure in the PI Asset Framework
  2. Centralize the information
  3. Ensure easy maintenance of the system
  4. Managing change
  5. Consolidate the calculations and ensure that they are repeated every hour
  6. Develop a Web visual layer for PI Vision
  7. Ensure information security

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