Case Study
Improving Real-Time Visibility and Operational Response for a Metal Filtration Technology Leader
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Improvement in output efficiency
About the Client
A global leader in metal filtration technology, pioneering the use of ceramic foam and driving innovation in filtration, melt treatment, and transfer processes for all types of molten metals. Facing challenges in real-time Kiln monitoring, inconsistent visualization and workflows across old and new Kilns, and risks of data inconsistencies from PLC and database integration gaps, the client partnered with ITHENA. The outcome was seamless Kiln onboarding, operator-centric visualization, reliable data integration, and structured alarm workflows, delivering enhanced real-time visibility, standardized operations, faster issue detection, and improved operational efficiency, reducing errors and boosting overall plant performance.
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%
Improvement in output efficiency
ITHENA’s solution gave us real-time visibility into our Kiln operations, standardized workflows, and intuitive dashboards. It has improved our operational efficiency, accelerated issue resolution, and increased overall efficiency.
Vice President, Plant Operations
Vice President, Plant Operations
Opportunity for Impact
Improvement in output efficiency
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%
Faster operational response time
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Reduction in operator error
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Key Challenges Faced
- Lack of real-time visibility for the newly commissioned Kiln within the existing system
- Inconsistent visualization, alarms, and workflows across old and new Kilns
- Risk of data inconsistency from PLC tag mapping and database integration gaps
- Lack of intuitive operator interfaces, slowing issue detection and resolution
Our Solution
ITHENA, in partnership with Ignition, empowered the client with:
Seamless Kiln Onboarding
Integrated new Kiln into the existing Ignition V8.1.12 environment with minimal disruption to live plant operations
Operator-Centric Visualization
Designed and deployed intuitive operator screens using the Ignition Vision Module, including Kiln Overview, Zone Analysis, Trending, and Alarm dashboards for real-time and zone-level visibility
Reliable Data Integration
Established direct PLC tag connectivity and MS-SQL database integration to enable accurate real-time and historical data capture across Kiln operations
Alarm Management & Drill-Down Workflows
Configured intelligent alarms and structured drill-down navigation to accelerate identification of abnormal conditions and support faster operational response