Case Study: S&P 500 Cement Manufacturing Company reduces induced-draft fan downtime with Seeq Corporation

S&P 500 Cement Manufacturing Company - Customer Case Study

S&P 500 Cement Manufacturing Company faced costly unplanned downtime in its induced-draft fans, which are essential for creating kiln vacuum and supporting clinker drying. Dust buildup on fan blades caused rising vibration levels and breakdown risk, while overmaintaining the equipment also wasted resources. The company needed a better way to predict failures and optimize maintenance, and it turned to Seeq Corporation for advanced analytics.

Seeq Corporation implemented a predictive condition-based monitoring solution using Seeq’s Prediction tool, with data from Wonderware Historian and OSIsoft PI, to forecast fan vibration based on time since last maintenance. The solution helped reliability engineers plan cleaning before vibration reached critical limits, reducing unplanned outages and avoiding roughly $20,000 per hour in downtime costs. Seeq also enabled better maintenance scheduling, improved troubleshooting with cycle overlays, and made it easier to share reports with plant management.