Complete CMMS solution for cement plant operations

A cement plant in Georgia experienced a conveyor belt contact incident that resulted in a hand injury. The supervisor filed a paper incident report, but it sat in a folder for three weeks before the safety...

A cement plant in Vietnam passed their first OSHA inspection without citations after implementing a systematic EHS compliance audit program that identified and corrected 47 deficiencies before regulators...

A cement plant in Morocco avoided a fatal asphyxiation incident when atmospheric monitoring during a silo entry detected dropping oxygen levels 47 seconds before the entrant would have lost consciousness. The...

A cement plant electrician in Maharashtra suffered fatal injuries when a 6.6kV motor feeder was energized while he was performing maintenance—the electrical isolation had...

A cement plant in Texas faced a $156,000 OSHA citation after an employee entered a raw mill without proper confined space clearance—the clearance had expired 36 hours earlier, but...

A cement plant in Pakistan reduced recordable injuries by 67% within 18 months of implementing an EHS dashboard that gave supervisors real-time visibility into leading indicators—catching safety gaps before...

A cement plant in Pennsylvania ran SAP for enterprise resource planning and Oxmaint for maintenance execution—but the systems operated as separate islands. Work orders created in Oxmaint required manual entry...

An EPA inspector arrived at a cement plant in Texas requesting documentation for their Title V operating permit, CEMS calibration records, and quarterly emission reports. The environmental coordinator spent two...

A cement plant shift supervisor in Nevada needed to know which equipment was currently locked out before starting the ball mill for the morning production run. Three different maintenance crews had worked...

A cement plant in Brazil eliminated 100% of LOTOTO documentation gaps after replacing paper-based procedures with a digital system that enforces step completion and captures photo evidence at each isolation...

A cement plant in Alabama experienced a near-miss when welding operations ignited residite dust in a storage silo—a hot work permit had been issued, but the required atmospheric testing wasn't completed before...

Connecting SAP S/4HANA with Oxmaint transforms how cement plants manage maintenance operations. This guide walks you through every step: from gathering prerequisites and...

Connecting SAP S/4HANA with Oxmaint transforms how cement plants manage maintenance operations. This guide walks you through every step: from gathering prerequisites and...

A cement plant in Indonesia prevented a fatal electrical contact incident when a maintenance technician followed the 7-step LOTOTO verification process and discovered the kiln drive motor remained energized...

A cement plant in Kentucky scheduled major ball mill maintenance during what they thought was a low-production window—only to discover production had committed to a large order requiring maximum mill capacity...

Connecting SAP S/4HANA with Oxmaint transforms how cement plants manage maintenance operations. This guide walks you through every step: from gathering prerequisites and...

A cement plant in Kentucky scheduled major ball mill maintenance during what they thought was a low-production window—only to discover production had committed to a large order requiring maximum mill capacity...

A cement plant in Madhya Pradesh faced a regulatory audit that revealed 23 incomplete incident investigations and 8 expired work permits in their SAP EHS system—all from maintenance...

A cement plant in Egypt reduced maintenance part search time from 23 minutes to 47 seconds after integrating their CMMS with SAP Warehouse Management. Previously, technicians walked the warehouse manually...

A cement plant in Indiana ended their fiscal year $1.8 million over their maintenance budget—but couldn't explain where the overrun originated. Work orders posted costs to generic cost centers, making it...

A cement manufacturer with two plants in Gujarat discovered their maintenance costs were 23% higher than budgeted—but only found out during quarterly financial review, weeks after the...

A cement plant in Turkey reduced their spare parts procurement cycle from 14 days to 3 days after implementing automated purchase requisition creation from work orders. Previously, maintenance technicians...

A cement plant maintenance team needed to add 340 new spare parts for a kiln upgrade project. Manually creating each material master in SAP—entering basic data, plant data, purchasing views, and storage...

A cement plant in Ohio ran SAP for materials management but struggled with maintenance spare parts coordination. Technicians couldn't see real-time stock availability from their CMMS—they'd create work orders...

A cement manufacturer with three plants across Rajasthan struggled with fragmented maintenance data—SAP stored equipment masters and cost centers, spreadsheets tracked daily work, and paper...

A cement group operating six plants across three countries reduced cross-plant equipment failures by 41% after implementing unified IoT visibility that enabled corporate engineering to identify maintenance...

A cement plant in Georgia needed to connect 47 different data sources—PLCs from three vendors, legacy Modbus sensors, and new wireless vibration monitors—to their cloud-based maintenance platform. Direct...

A cement plant in Madhya Pradesh installed 52 vibration sensors on critical equipment—and lost 38 of them within the first four months. The sensors had IP65 ratings, adequate for indoor...

A cement plant in Vietnam reduced unplanned downtime by 34% after implementing IoT analytics dashboards that transformed 2.3 million daily sensor readings into actionable maintenance insights. Before the...

A cement plant in Arizona struggled with IoT connectivity across their 2-mile quarry-to-plant operation. WiFi coverage gaps left mobile crushers and conveyor transfer points without monitoring. Cellular IoT...

A cement plant in Rajasthan had 47 vibration sensors installed across their kiln and grinding sections—but technicians still missed critical bearing failures because sensor alerts went to...

A cement plant in Morocco saved $1.4 million in emergency repairs when their IoT alert system notified the maintenance supervisor of abnormal kiln shell temperatures at 2:47 AM—while the operator on shift had...

A cement plant in Ohio ran SAP for materials management but struggled with maintenance spare parts coordination. Technicians couldn't see real-time stock availability from their CMMS—they'd create work orders...

A cement plant in Gujarat lost 47 hours of production data when their consumer-grade WiFi network failed under kiln area temperatures exceeding 65°C. The plant had deployed sensors on...

A cement plant in Turkey prevented a $1.8 million refractory replacement when their IoT sensor network detected a developing hot spot 23 days before visible shell deformation occurred. The thermal imaging...

A cement plant in Pennsylvania deployed 340 IoT sensors across their kiln, mills, and conveyor systems—then struggled to extract value from the data. Sensors from four different vendors fed into separate...

A cement plant in Kentucky learned the cost of robot spare parts stockouts when their primary inspection drone required propeller replacement during their annual kiln shutdown—but no replacement propellers...

A cement plant in Germany discovered unauthorized access attempts on their kiln control DCS after deploying inspection robots with default network credentials—the same robots transmitting quality control data...

A cement producer in Germany reduced unplanned downtime by 42% and cut shutdown planning time from 6 weeks to 10 days after implementing a digital twin platform that simulates their entire production line from...

A cement plant in Alabama experienced catastrophic kiln shell failure when undetected refractory damage allowed shell temperatures to exceed 400°C—warping the steel shell and requiring 45 days of emergency...

A cement plant in Turkey lost $1.2 million in production revenue when their kiln inspection robot failed mid-shutdown—bearing seizure from cement dust infiltration that vibration sensors would have flagged...

A cement plant in India detected 47 developing crusher component failures during a single quarter after deploying quadruped robots for continuous patrol of their primary and secondary crushing stations. Their...

A cement plant in Egypt extended their vertical roller mill campaign from 8,000 to 11,500 hours by deploying inspection robots during scheduled outages—the drone-captured wear measurements identified uneven...

A cement plant in Brazil eliminated 94% of packaging department injuries and reduced worker turnover from 45% to 8% annually after deploying collaborative robots and automated palletizers across their bag...

A cement plant in Georgia faced 340% annual turnover in their packaging department—workers couldn't sustain the physical demands of stacking 50-lb cement bags onto pallets for entire shifts. Workers'...

A cement plant in Ohio lost $180,000 in a single shift when a failed idler roller on their limestone conveyor caused belt damage that halted raw material feed to the mill. The roller had been running hot...

A cement plant in Morocco eliminated rope access inspections entirely after deploying specialized drones for their 85-meter kiln stack assessment. Their previous inspection approach required a 4-person rope...

A cement plant in Texas experienced unexpected grate plate failures that caused 72 hours of unplanned downtime—$540,000 in lost production plus emergency repair costs. Post-incident analysis revealed that...

A cement plant in Texas achieved 100% EPA NESHAP compliance and reduced worker exposure to respirable silica by 85% after deploying quadruped robots equipped with multi-gas detection arrays across their...

A cement producer in Germany achieved 99.2% sample analysis accuracy and reduced clinker factor by 3.5% after deploying Fuller Technologies QCX RoboLab automation across their quality control laboratory. Their...

A cement plant in Indiana faced a 21-day annual shutdown for preheater tower relining—with 8 days consumed waiting for safe entry temperatures and manual demolition of existing refractory. After deploying...

A cement manufacturer in Pennsylvania spent $45,000 annually on scaffold-based silo inspections—each requiring 3-day shutdowns, confined space permits, rescue teams on standby, and workers exposed to...

A cement plant in Turkey eliminated all confined space entries for preheater cyclone inspections after deploying cage-protected inspection drones. Their four-stage preheater tower required 18 workers, 3 days of...

Rotary kiln inspections have traditionally required full cooldown periods lasting 3-5 days, scaffold installation inside 4-meter diameter vessels, and confined space entry protocols that expose workers to...

CRH's Ash Grove Spot robot deployment in Washington State represents one of the most successful implementations of quadruped robot cement plant inspection in North America....

Cement plants represent some of the most challenging environments for maintenance operations—extreme temperatures exceeding 1400°C in kilns, abrasive clinker dust that destroys equipment, confined spaces...

This real-world case study documents how a 2.4 million ton per year cement plant in Indonesia transformed their maintenance operations through robotic inspections and CMMS...