Cement producers that already run AVEVA PI System often face a fair question when AI analytics comes up: replace the historian, or build on it? For most plants the honest answer is neither extreme. PI is a proven data foundation, and iFactory is an OEE analytics and AI platform that can read the tags PI already holds. This guide compares the two on stated criteria for kilns, mills and quarries, shows where each one fits and is open about where PI alone is the better call. To see both working together on cement data, book a 30-minute walkthrough.
iFactory vs AVEVA PI System for Cement OEE and Analytics
AVEVA PI System collects, stores and adds context to plant data. iFactory turns that data into OEE losses and asset warnings on a turnkey on-site AI server. They do different jobs, and in many cement plants they run side by side.
Two Products, Two Different Jobs in the Data Path
The clearest way to compare them is to follow one kiln signal from sensor to decision. PI System's job is to collect that signal, keep its history and serve it with context. AVEVA describes PI Server as an operations data store with Asset Framework for asset models, event frames for periods of interest, built-in analytics and notifications. iFactory's job starts after that point: turning the signal into OEE losses, failure warnings and a clear next step for a person. Our integration team can map this path for your own plant.
Side by Side on Stated Criteria
This matrix compares what each product is and what it asks of the plant. It gives no scores and no competitor prices. AVEVA facts come from AVEVA's own product material. Where something is not public, the right move is to ask the vendor, and the last column suggests the question. Bring this list to a side-by-side review call.
Three Ways Cement Plants Get OEE From Their Data
OEE for a kiln or a cement mill is less about the formula and more about the states behind it: running, stopped, reduced feed or waiting on material. PI holds those signals well. The open question is who turns them into availability, performance and quality losses. AVEVA's own conference sessions show plants doing this with Asset Framework, event frames and partner tools, such as a shift log app that reads PI event frames so crews can confirm OEE data. Review your current OEE setup with our support engineers.
Kilns run long campaigns, so planned refractory stops, feed cuts and coal mill trips can swing OEE sharply. Decide which stops count as planned, and how reduced-rate running is booked, before you judge any product's numbers.
Keep PI. Add the AI Layer on Top.
iFactory reads kiln and mill tags from your existing PI System, works out OEE losses and flags asset risk on a turnkey on-site server. PI remains your historian and system of record.
Five Cement Use Cases, Two Starting Points
Both products can play a part in each use case below, but they start from different places. PI gives you history and context; an analytics layer has to turn that into a warning someone acts on. Read this as a scoping guide, not a scorecard. Walk through your priority assets in a use-case scoping session.
Cases Where Investing in PI Itself Comes First
A fair comparison should say when the other product is the better choice. If the points below describe your plant, more effort in PI itself may beat adding a new layer now. AVEVA also sells separate operations and MES software, so ask AVEVA what it would propose. We are happy to talk it through openly with our support team.
Cost Factors to Price Before You Choose
We don't publish competitor prices, and you should be wary of any comparison page that does. Licence models depend on tag counts, users and contract terms, and they change. What you can do is list every cost factor, then ask each vendor to price the same scope in writing. The last line uses assumed inputs only. For a written quote on your scope, talk to our team.
Add the value of fewer surprise kiln stops only when your own downtime records support a figure. Keep the two products' costs separate, since many plants keep paying for PI either way.
Questions to Send Both Vendors
Use the same questions for both vendors so the answers line up. Ask for written answers and named cement references you can call. Our support team can send an editable copy.
An AI Server That Sits Beside Your PI Server
iFactory ships as a turnkey bundle. A pre-configured NVIDIA AI server ships racked and ready, connects to your PI Server and plant network, and runs OEE and reliability models on site, so no plant data has to leave the fence. You rack it, plug in power and Ethernet, and the AI is live. To size it for your kilns and mills, request a turnkey scoping call.
- Pre-configured NVIDIA AI server, racked and ready
- PI tag connection and Asset Framework mapping
- OEE analytics for kilns, mills and crushers
- Reliability models for drives, mills and kiln shell
- AI vision option for clinker and belt cameras
- Alerts and work requests sent to your CMMS
- 24×7 remote monitoring of models and hardware
Server racked, PI tags and AF hierarchy mapped, OEE states agreed for each kiln and mill.
Models run silently on live PI data while your engineers review every warning.
Alerts switched on, weekly OEE reviews started, pilot success measures checked.
An OEE and AI Layer That Respects Your Historian
iFactory is built to add value to the data you already collect, not to make you start again. Our support team can review your PI setup before any pilot.
What Cement Teams Ask When Comparing iFactory and PI
Get More From the PI Data You Already Own
Keep AVEVA PI System as your historian and add OEE analytics and AI warnings for kilns, mills and crushers. The turnkey server runs on site and goes live in 6 to 12 weeks.
