Digital

Transformation

@ TITAN

Antonis Kyrkos

Σ.Ε.Β.«Τεχνητή Νοημοσύνη στις Επιχειρήσεις»,

Τετάρτη 13 Ιανουαρίου 2021

Fokion Tasoulas

Fully sensorized, web-connected, predictive and self-optimizing cement plants

Dynamic, real-time transparent, customer-enabled and seamless supply chain

Data-enabled decisions, analytics-driven insights, paperless workflows and

individual-customized internal processes

Collaborative dynamic ecosystem with customers, business partners, service

providers, suppliers, and communities.

Best in-house team with new capabilities to support all the above.

3

“Test and Learn”

“Scale up”

Scale-up in all

BUs

Roll-out

successful

initiatives

Implement across

different areas of

activity

Align with TITAN’s

strategy

Experiment with many

pilots: No regret moves

Verify impact &

implementation

requirements

A

Build digital capabilities

& infrastructure

Acquire digital talent

Monitor market &

potential partnerships

B

“Capture impact

across areas”

Some of our digital pilots in the past 24 months

f. Spare parts inventory optimization

e. Supply Chain: network modelling

d. BIM for new infrastructure construction

a. Asset Optimization (Real-Time Optimizers)

b. Assets’ Failure Prediction/Remote Monitoring Center

c. Customer App

g. Electrical energy price forecasting

h. Infrastructure project: 1. sensors upgrading (plants); 2. OT Cybersecurity

Transform Cement Plants to Smart Factories

An average cement

plant

generates >1 TB of data

annually

Real Time Reporting & Data based

Decision Making

Real Time Optimization for throughput

Improvement

Prescriptive (Data-Based) Maintenance

for Reliability Improvement

Predictive Quality Analytics for Enhanced

Performance Consistency & Product Quality

DAEDALUS PROJECT : OUR PoC FOR THE END-TO-END REAL

TIME OPTIMIZATION IMPLEMENTATION (ENTIRE CEMENT LINE)

Q1 2020

Ball mills prototype development

Q2 2020

FM6 development

Kiln development

Kiln RTO completion

Finalization of kiln RTO for close loop operation

Development of an accurate FCaO soft sensor

Initiation of operation in close loop for FM6

Q3 2020

FM3 and FM4 development

Initiation of operation in close loop for FM3 and FM4

Improvement of VRM RTO

Increase in run factor for VRM

Q4 2020

Adjustment of kiln RTO to natural gas

Development of an automatic procedure for cement type change

Daedalus Project

Completion

One plant fully operated in closed loop under AI RTO

1 Vertical Raw Mill

1 Kiln

3 Ball mills

Development starting point: end of 2017

VRM 1st implementation completed into 2018

DAEDALUS PROJECT IN : THE BUSINESS CASE

RTO VRM THROUGHPUT IMPROVEMENT VS MANUAL BASELINE

473

545

583

620

450

475

500

525

550

575

600

625

650

TH

RO

UG

HP

UT

[T

PH

]

ManualOperation

PXP (Jan 2017 – Apr 2018)

DaedalusCurrent Status

Daedalus Maximum

improvement

+15.2%

+23,2 %

Step 1 gain:

Traditional

process control

tools

+15.2%

Step 2 gain:

Daedalus

process control

Digital tool

The first

integrated AI tool

for all cement

plant assets

The only AI Real

Time Optimizer

running in closed

loop (i.e.

autonomously)+31 %+7 %

Reactive “Run to Failure”

Preventive(or Time-Based)

“Fix it before it Breaks”

Predictive(or Condition Based)“Fix it when needed”

Equipment Operation is

continuously

monitored using

sensors, then real-time

and historical data is

analyzed by advanced

software to detect

anomalies which then

can be used to

prescribe specific

maintenance activities

that ensure optimal

equipment uptime.

Prescriptive(or Data Based)

“Fix it before is needed”

Equipment operation

is monitored using

sensors and periodic

measurements

(typically vibration and

oil analysis)

attempting to predict

pending failure and

address it proactively.

Equipment is

maintained at regular

intervals regardless of

condition. Frequency

is based on average

past performance or

OEMs

recommendations

Historical & Current

Plant Data from all

Available Signals

Equipment & Process

HierarchiesThe digital twin of the

Physical Asset

• AI Software captures anomalies (or changes) at very early stages• cemAI experts identify root cause(s) & assist the front-line operators to effectively troubleshoot & correct the

issue

The earlier the diagnosis:

The easier the repair

The less the downtime

The less the repair cost

• World Class Reliability & MTBF • Manufacturing Cost and Overtime Reduction

RF > 98%

MTBF > 2X

RF > 97%

MTBF > 6X

Mnf Cost 10% < PY

Overtime ($)15% < PY

Mnf Cost 6% < PY

Overtime ($)20% < PY

Deliveryexperts

IMPACT

DATA

PEOPLE

Subject

Matter

Experts

Capture

Store

Structure

Clean

Analyze

Configure

Impro-vement measures

Imple-ment

Automate

Problem

solve

PMOUI/UX Designers Product owners

OEMslooking to co-develop solutions

CONSULTANTSbuilding newservice lines

STARTUPSwith own

(but immature) algorithms

ACADEMICSwanting to try lab pilots

in the real world

Combination of skills required Ecosystem of partners

• Our main source for ‘Junior Data Scientists’

• 800 applicants

• 30 selected participants

started classes on Monday

7/12/20

• Expected graduation at end of

January 2021

• Titan planning to recruit Data

Scientists’ to staff our

Manufacturing and Supply

Chain teams at the Group

Digital CoC