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Cement · CMMS & EAM

Maintenance Software for Cement Plants

Keep the kiln, mills and fans running between planned shutdowns. PlantOps360 brings preventive maintenance, spares, condition monitoring and work orders into one system for cement manufacturers.

Sample view · Cement · Live
PlantOps360
Equipment health
91%
Open work orders
19
PM compliance
96%
Availability
94.2%
Downtime trend · 12 wks▼ improving
AI alert: Preheater ID fan drive-end bearing temperature trending up
THE PROBLEM

Common maintenance challenges in Cement

A cement line runs close to continuously. When the kiln stops, everything behind it stops, and a restart costs hours of fuel and output.

Kiln stops that cost days

A refractory or drive problem that was visible in the shell scan becomes an unplanned stop with a long restart.

Heavy rotating equipment

Mill drives, gearboxes and fans are large, expensive to repair and slow to replace, so a late warning is costly.

Dust everywhere

Dust gets into bearings, conveyors and instruments, and filters and bag houses need regular attention to stay within emission limits.

Critical spares on the shelf, or not

Long-lead spares such as gearbox parts or kiln tyres are either over-stocked or missing when needed.

Shutdown scope built from memory

The annual shutdown list comes from notes and WhatsApp messages, so jobs get missed or repeated.

Power and fuel are most of the cost

Without metering by area, nobody can say which mill or fan is using more than it should.

PURPOSE-BUILT

Critical equipment managed with PlantOps360

Pre-configured preventive schedules, inspection checklists and condition parameters for the equipment that decides a cement plant's output. Hover any card to see failure modes, checklists and sensors.

Healthy

Rotary kiln

Pyro-processing
CriticalDaily rounds
Hover for details
Common failures
Refractory damage
Support roller and tyre wear
Girth gear and pinion wear
Seal leakage
Monitor
Shell temperatureDrive currentRoller bearing temperatureVibration
Recommended maintenance
Daily kiln round
Weekly gear lubrication check
Monthly alignment readings
Annual shutdown inspection
Healthy

Vertical roller mill / ball mill

Grinding
Critical30-Day PM
Hover for details
Common failures
Roller or liner wear
Gearbox bearing failure
Hydraulic system leaks
Separator fault
Monitor
VibrationMotor currentGearbox oil temperatureDifferential pressure
Recommended maintenance
Weekly oil analysis sample
Monthly hydraulic check
Quarterly liner measurement
Maintenance Due

Preheater ID fan and process fans

Pyro-processing
Critical15-Day PM
Hover for details
Common failures
Bearing failure
Impeller wear and imbalance
Damper actuator fault
Coupling misalignment
Monitor
VibrationBearing temperatureMotor current
Recommended maintenance
Fortnightly vibration route
Monthly lubrication
Annual balancing
Healthy

Clinker cooler

Pyro-processing
Critical30-Day PM
Hover for details
Common failures
Grate plate damage
Cooler fan failure
Hydraulic drive faults
Clinker breaker wear
Monitor
Grate drive pressureUndergrate pressureFan vibration
Recommended maintenance
Weekly grate inspection
Monthly drive check
Shutdown plate replacement
Healthy

Bag house and ESP

Emission control
High15-Day PM
Hover for details
Common failures
Bag failure
Cleaning valve fault
Rapper or field failure
Screw conveyor jam
Monitor
Differential pressureStack dust readingCompressed-air pressure
Recommended maintenance
Weekly bag and valve check
Monthly cleaning-cycle test
Quarterly field inspection
Healthy

Bucket elevator and belt conveyors

Material handling
High15-Day PM
Hover for details
Common failures
Chain or belt wear
Gearbox failure
Idler seizure
Belt mistracking
Monitor
Motor currentVibrationBelt speed
Recommended maintenance
Weekly belt and idler walk
Monthly gearbox oil check
Quarterly chain measurement
Healthy

Packing plant and loading

Dispatch
Medium15-Day PM
Hover for details
Common failures
Spout and sensor faults
Rotary packer drive wear
Weigh-cell drift
Bag placer jams
Monitor
Cycle countWeigh-cell readingAir pressure
Recommended maintenance
Daily sensor clean
Weekly weigh-cell check
Monthly drive lubrication
Equipment Health Dashboard
Sample view of a cement plant in PlantOps360 (illustrative figures)
● Live data
Healthy assets
184
Critical assets
6
Running
142
Idle
28
Maintenance due
12
Open work orders
14
Upcoming PM
23
Availability
97.8%
Downtime trend▼ illustrative
Asset health score
92of 100
DAY-TO-DAY

What changes in your cement plant

Four everyday situations in a cement plant, before and after PlantOps360.

Shutdown lists come from the system, not from memory

Before

The annual kiln shutdown scope is collected from notes, messages and the last shutdown report. Jobs are missed, and some are done twice.

With PlantOps360

Every job that needs the kiln to be stopped is raised against the asset during the year. The shutdown list is built from those open items and the PM tasks due, with parts and checklists attached.

Work orders →

Fan and mill vibration is tracked, not just walked past

Before

Vibration is measured on a route when someone has time, in a notebook or a spreadsheet, and trends are only noticed after a failure.

With PlantOps360

Readings are entered on the round or flow in from connected sensors. A rising trend on a fan or gearbox opens a work order before the bearing fails.

Predictive maintenance →

Long-lead spares have an owner and a minimum

Before

Gearbox bearings, kiln seals and similar parts sit in the store without a clear minimum. Nobody knows what is on hand until the breakdown.

With PlantOps360

Critical spares are linked to the equipment that uses them, with minimum levels and reorder alerts. A repair job reserves the part when it is raised.

Spare parts →

Power use is seen by area

Before

The plant reads the main meter. Mill and fan power is estimated, so poor performance goes unnoticed for months.

With PlantOps360

Meter readings are captured per mill, fan and compressor, and compared over time. A fan drawing more current than last quarter gets looked at.

Energy management →

Rules and standards that touch cement plant maintenance

A plain-language summary of what each one asks of maintenance, and where PlantOps360 fits.

Standard or regulationWhat it expects from maintenanceHow PlantOps360 helps
Factories Act, 1948 / OSH Code, 2020Safety of machinery and plant (India)
ExpectsMachinery safeguarded and maintained, and lifting machines and pressure plant examined at the required intervals, with the records kept.
PlantOps360Statutory inspection due dates as recurring tasks, with the result and certificate attached to the equipment. Preventive maintenance →
Mines Act, 1952Captive limestone mines
ExpectsMine machinery and equipment kept in safe condition and inspected as the mining rules require.
PlantOps360The same asset history and inspection records for crushers, conveyors and mobile equipment at the mine. Asset management →
CPCB emission normsStack and fugitive dust, continuous monitoring
ExpectsPollution control equipment kept working so that emissions stay within the limits in your consent.
PlantOps360Bag house, ESP and CEMS upkeep scheduled and logged, so a drifting filter is fixed before it shows up in the stack reading. Preventive maintenance →
PAT scheme (Bureau of Energy Efficiency)Energy targets for designated consumers
ExpectsSpecific energy consumption tracked and reported against a target.
PlantOps360Energy readings by area stored alongside the equipment, so the cause of a rise can be traced to a machine. Energy management →
ISO 50001Energy management systems
ExpectsEnergy use monitored, significant users identified, and improvement actions recorded.
PlantOps360Meter data and the maintenance actions on the big consumers kept in one place. Energy management →
ISO 55001Asset management systems
ExpectsA documented approach to asset condition, risk and lifecycle decisions.
PlantOps360Asset register, criticality, history and cost per asset to support those decisions. Asset management →

This is a plain-language summary for orientation. Always follow the current text of each law and standard, and the rules of your own site and licence.

Key workflows in a cement plant

Three real situations, step by step, and where each step happens in PlantOps360.

Bearing temperature rises on the preheater ID fan

A fan that cannot be stopped without slowing the kiln.

  1. A sensor or an operator round shows drive-end bearing temperature rising over several days. Predictive maintenance
  2. A work order opens on the fan with the bearing change checklist and the spare reserved. Work orders
  3. The job is planned for the next available stop instead of waiting for a trip. Preventive maintenance
  4. The technician records the new bearing details and the readings after the change on a phone. Mobile app
The fan is repaired in a planned window, with the bearing, time and readings recorded.

Annual kiln shutdown

A short window with a long list of jobs.

  1. Through the year, jobs that need a kiln stop are raised against the asset. Work orders
  2. Before the shutdown, open jobs and PM tasks due are grouped by equipment into one list. Preventive maintenance
  3. Spares and consumables for each job are checked against stores and ordered. Spare parts
  4. During the shutdown, crews close jobs on their phones and the list shows what is left. Mobile app
The shutdown is run from one list, and what was found is kept for the next one.

Bag house differential pressure climbs

A dust-control problem that can become an emission problem.

  1. Operators log the differential pressure on the round, or it arrives from the control system. Predictive maintenance
  2. A threshold breach raises a work order for the cleaning valves and bags. Work orders
  3. The technician checks valves, replaces failed bags and records what was changed. Mobile app
  4. A recurring bag house inspection stays on the schedule. Preventive maintenance
The cause and the repair are recorded, so the next high reading starts with history.

Cement maintenance software: questions

It helps you plan and run it from data. Jobs that need a stop are raised against the equipment during the year, and PM tasks and open work orders can be grouped into one list with the spares for each. During the shutdown, crews close jobs on their phones.
Yes. Readings can be entered on a round or arrive from connected sensors and gateways. Trends on vibration, temperature and current can raise a work order when a limit is crossed.
Yes. Crushers, conveyors and mobile equipment can sit in the same asset register as the plant, with their own schedules and history.
Spares are linked to the equipment that uses them, with minimum and reorder levels. A work order can reserve the part, so a repair does not stall on a missing item.
Yes. The energy module captures meter readings by area or machine and lets you compare consumption over time, which helps with energy targets and audits.
Yes. The offline-first mobile app lets technicians create and close work orders, run inspections and open documents with no connection. Everything syncs when the device is back online.
PlantOps360 offers integration with SAP, Oracle and other ERPs, and REST APIs to sync assets, materials and financials. The scope of an integration is agreed during the demo and planning.

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