A recursive plant-tree maps every asset from plant level to individual bearing. MTBF is tracked per component. Work orders are generated before failures happen — not after the kiln trips.
A cement plant is one of the most asset-intensive operations in any industry. A kiln has thousands of components — from the main drive gearbox to individual tyre riding ring bolts. A single bearing failure at the wrong time can halt production for 12–48 hours, costing crores. Traditional maintenance teams rely on experience and paper schedules. Titan ERP replaces intuition with data.
The recursive plant-tree structure allows unlimited depth: Plant Level → Production Line → Major Equipment → Sub-Assembly → Component → Part. MTBF is tracked for each node. Running hours are fed from the MES module automatically. When MTBF approaches, the system generates a predictive work order with spare parts list — before the failure.
The system calculates rolling MTBF from failure history. For Input Shaft Bearing #1 on the kiln main drive — if it has failed 3 times in 18,000 running hours, MTBF = 6,000 hours. At 5,500 hours, a predictive work order is raised. At 5,800 hours, an escalation alert fires.
Each workflow reduces unplanned downtime and extends equipment life through data-driven decisions.
Every asset in the plant is catalogued in a recursive tree structure. Each node carries: asset code, description, manufacturer, model, serial number, installation date, and criticality rating (A/B/C). Critical assets get enhanced monitoring — daily running hour updates and vibration/temperature log integration from SCADA. The plant tree is accessible via mobile for field engineers who can log observations against any asset on the spot.
For every component in the plant tree, the system maintains a failure history log. Using running hours (from MES) and the historical failure pattern, it calculates rolling MTBF. When current running hours reach the MTBF threshold (configurable at 80% of MTBF), a predictive work order is auto-generated, assigned to the relevant engineer, and spare parts are reserved from stores. The maintenance team acts before the failure — not during the crisis.
Calendar-based PM schedules are configured per equipment — daily, weekly, monthly, quarterly, annual. PM tasks are predefined with step-by-step instructions, estimated duration, required spares, and safety precautions. The system generates PM work orders 3–5 days before the due date and sends reminders to the maintenance engineer. Completed PM work orders include actual findings, parts consumed, and next PM date auto-updated.
When an equipment failure occurs, the Shift Supervisor raises an emergency breakdown work order directly from the mobile app. The system time-stamps the breakdown start. The assigned engineer logs findings, repair actions, parts consumed, and restoration time. Before the work order can be closed, a root cause must be selected from the standard taxonomy (Lubrication failure, Overload, Wear, Installation error, etc.). Downtime hours are automatically calculated and reported to the Plant Head and Finance for cost capture.
Built for the complexity of cement plant maintenance — from kiln main drive to conveyor idler bearings.
Data flows in from Production, decisions flow out to Stores, Finance, and Safety — automatically.
Running hours from MES automatically update equipment hour meters. Equipment downtime from breakdown WOs is captured as production loss hours.
Production ModuleWork orders reserve spare parts from stores. Consumed parts are deducted from inventory. Low spare stock triggers purchase requisition for critical components.
Procurement ModuleEvery work order closure captures labor and materials cost. Asset-level maintenance cost feeds depreciation schedules and maintenance budget reports for CFO.
Finance ModuleAI layer analyzes vibration trends, MTBF history, and environmental conditions to predict failures 14–21 days in advance with confidence scores.
AI Features