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Reliability Audit for Cement Plant

Cement plant Reliability Audit identifies the core issues which are compromising KPI and prevent plants from increasing capacity and maximizing productivity.

Our Reliability Audit is focused at all aspects of reliability improvement in the cement plant covering the Process, Equipment and Human Resources. We provide recommendations and action plans for corrective steps and also assist to develop reliability team for planning, monitoring and measurement of equipment reliability.

Poor equipment reliability is one of the greatest causes of loss of production, profitability and safety performance for a cement manufacturer. Moreover, poor plant reliability leads to higher production and maintenance costs along with compromised quality of final product. Reliability audit report help to bridge the gaps between existing plant performance and the reliability requirements.

Reliability Audit Cement Plant Audit

Stages of Cement Plant Reliability Audit

Plant Audit Execution

We offer a comprehensive reliability improvement program to improve the reliability and profitability of the cement plant and at the same time achieving reduced stoppages and costs.

The first stage of the Reliability Audit is to collect necessary data of stoppages and incidents of certain period to assess the current performance of the plant. We also assess the methodology and tools being used to monitor the equipment condition and the structure of the allocated human resources.

The second stage is to finalize corrective steps for Reliability Improvement Action Plan, providing the customer with specific actions to improve the reliability of the plant.

Once the customer implements the Reliability Improvement Action Plan, we provide support to the customer in areas such as Root Cause Analysis plan, development of the skills of technicians in the methodology for developing equipment specific maintenance.

We also benchmark and rate your operational conditions against industry’s Best Practice standards. Best Practices enhance equipment reliability and realized capacity by avoiding unnecessary production interruptions. We make appropriate recommendations for improvements, with follow-up audits.

Our Team

Our Experts have years of experience working on different cement technologies with exposure to local industrial working conditions. This specialist knowledge combined with many years of experience led into the highest quality of services we offer. Our experts listen before they speak, which means they are focused on Your needs and open to technical discussions to give You the best solution to the problems. Instead of bringing new components catalogues and recommending expensive replacements, we prefer finding smarter and easier ways to resolve problems.

We are not attached to any plant supplier because our goal is to find the best solution that works for You without taking any unnecessary expensive moves. That is why You can be absolutely sure that our recommendations are based on unbiased motivation to best serve Your needs.


We will undertake the reliability audit study focusing on the following key areas:

  • Reliability of each process stage from crusher through to packer covering planned and unplanned stops, mean time between stops and mean time to repair. We will also review the Pareto analysis of stops in order to identify the main causes for stops.
  • Maintenance department metrics i.e. how the performance of the department is measured.
  • Cost effective solutions for the global cement industry
  • Review the use of Root Cause Analysis in identifying the cause of stops and how to improve maintenance over the long term.
  • Age of equipment and overall maintenance strategy for the plant – for example, the degree to which the strategy is reactive compared to proactive.
  • Annual repair planning.
  • Use of reliability tools such as condition-based monitoring, oil analysis, thermography etc.
  • Use of equipment inspections for reliability improvement.
  • Use of lubrication for reliability improvement.
  • Plant maintenance department structure and how the plant is organised to improve the reliability of the plant as well as the scope of each of the maintenance functions.
  • The use of any existing Computerized Maintenance Management System (such as Maximo, Oracle, SAP etc) and the suitability for improving reliability in the target company.
  • Purchasing strategy and performance including spare parts policy and spare parts stockholding.
  • Maintenance planning and use of Human Resources including manpower requirements, availability and utilization.
  • Review skill levels of maintenance/reliability personnel.
  • Once all the above information has been reviewed by us, we would submit a detailed report and also meeting with customer to discuss the issue in more detail.


Reliability Audit Report

We will provide a report on the findings covering the following areas:

  • Current reliability of the plant compared to expected benchmark levels and an assessment of the types and nature of stops based on the Pareto analysis.
  • The extent of the use of data and techniques for the improvement of reliability.
  • The overall maintenance strategy in terms of proactive maintenance compared to reactive maintenance.
  • The use of reliability tools such as inspections, oil analysis, thermography, vibration analysis etc.
  • An assessment of the number of personnel in the maintenance department and a comparison of the structure with what would be considered to be a reliability department with inspection and planning as core functions.
  • Provide an action plan and methodology to develop a maintenance strategy if this does not already exist. This would include how the current structure could be changed to include the functions normally found within a Reliability Department (Inspection and Planning), the tools that should be more frequently used to assist in improving reliability, implementation of the use of Computerized Maintenance Management Systems etc.
  • Along with the above analysis, we will provide recommendations on how to improve reliability including short term, medium term and long-term actions. This includes an example of how the maintenance department could be adjusted to be a more effective reliability department with different roles and responsibilities for the personnel.

Optimization & Performance Improvement:

  • Analysis of raw mix to reduce Raw material cost
  • Design of Raw mix to utilize pet coke /local coal for fuel cost reduction.
  • Analysis of breakdown and suggestion for reduction of maintenance.
  • Investigation for higher power consumption root causes.
  • HR Cost reduction by optimization.
  • Pack cost reduction
  • To improve clinker quality for PI additive addition.
  • Cement mill performance improvement by grinding aid.
  • Cooler operation optimization for specific heat consumption and waste heat recovery.