Wipro gave Vedanta real-time visibility into 890 production parameters and delay accounting information for 18 critical locations at one of its alumina reﬁnery by implementing an MES solution.
Vedanta Limited is a diversiﬁed resources group that produces oil and gas, aluminum, silver, zinc, lead, copper, etc. The company operates in several geographies including South Africa, Australia, India and Ireland. In India, it has a captive cogeneration power plant and a 1 MTPA greenﬁeld alumina reﬁnery at Lanjigarh in Orissa.
Market volatility, high input costs, lack of captive bauxite and a slump in prices have been hitting the aluminum industry hard, forcing many alumina reﬁneries to either shut down or operate at a quarter of their actual production capacity. Leading market players are looking to reduce operating costs, optimize asset utilization and increase productivity to stay competitive.
edanta was dealing with challenges related to time-reliable data availability at its Lanjigarh plant. The decision makers needed more visibility into data from various sources across the plant. For this, it needed a partner who could put together a digitally integrated solution to monitor key parameters related to production and operational efﬁciency as well as to capture KPIs in real time.
In an effort to reduce operating costs amid the global price gloom, the company was looking to improve asset utilization while producing high quality alumina. Vedanta wanted to make its Lanjigarh plant a self-sustained manufacturing unit in terms of cost advantage and resource availability.
“Wipro’s automation and reporting tools have helped our users and production staff, and also improved our process control. We have seen a significant drop in effort for creating reports every day”
- Satish Kumar, Head of Process Control at Vedanta Limited, Lanjigarh
Wipro rolled out a state-of-the-art MES solution for Vedanta’s Lanjigarh alumina reﬁnery.
The solution was implemented using the ISA-95 framework and provide the following beneﬁts:
The solution provided a seamless integration of legacy and new systems for production, quality, weighbridge and log book applications. It established a single platform through which disparate data sources and applications were converged and helped to secure data ﬂow between the control and the IT networks.
“Wipro has helped digitize our plant operations end-to-end and provided real-time visibility into plant control and management. We can now make the right decisions at the right time and assimilate past data for business improvement”
– Bimalananda Senapati, Plant Head at Vedanta Limited, Lanjigarh