Root cause analysis for kiln stoppages
Dual-mode analysis for a cement business: rapid hypotheses during a live disruption, rigorous investigation afterwards.
The problem
Root cause analysis for kiln stops and production disruptions ran from days into weeks, leaned heavily on the experience of a few individuals, and lacked mathematical rigour or a standard method. Corrective action was delayed at exactly the moments it mattered most, and the quality of the analysis varied with who was available.
How it works
The agent is connected to the plant's technical data management system and its site-specific standard operating procedures. Firefighting Mode produces candidate root causes within minutes for a live disruption. Deep Analysis Mode runs a fuller investigation, taking operator input and experiential knowledge as evidence alongside the process data.
The value case
Bring an RCA cycle down from days to minutes, and let a less experienced engineer run an investigation to the standard a specialist would. The commercial case built with the client centres on avoided kiln stoppages and engineering capacity released back to fixing problems rather than diagnosing them.