Bridges your SCADA layer to your business systems. Every kiln slot, mill hour, and packing run logged, planned, and analyzed — in real time, shift by shift.
A cement plant generates enormous process data — from kiln inlet temperatures to mill feed rates — but most of it stays locked in SCADA systems and shift logbooks. The Production & MES module bridges this gap, bringing operational data into the business layer where it drives decisions on cost, quality, scheduling, and maintenance.
The Plant Head sees production vs. plan in real time. The Finance team sees energy cost per tonne as it accumulates. The Quality team gets batch identifiers the moment clinker is produced. And the Sales team can see real-time production capacity before confirming new orders.
Specific heat consumption per tonne of clinker and mill kWh per tonne are tracked per shift. Trends are plotted and compared against norms. Deviations trigger automatic alerts to the Plant Head and are included in shift handover records.
From kiln scheduling to digital shift handover — every production activity governed and logged.
The Plant Planner allocates kiln capacity on a weekly calendar, aligned to confirmed sales orders and raw material availability. Each shift's actual kiln feed rate (t/hr), kiln outlet temperature, specific heat consumption (kcal/kg clinker), and clinker production (MT) are logged — by CCR operators via tablet or automatically via SCADA bridge. Deviations from plan are flagged instantly.
Mill scheduling ensures the right cement grade (OPC 53, PPC, PSC, OPC 43) is produced at the right time to meet order queues. TPH (tonnes per hour) is logged per mill per shift. Blending ratios (clinker, gypsum, fly ash, slag percentages) are recorded and linked to the batch. Mill kWh per tonne is computed and compared against benchmark.
Titan ERP connects to your existing DCS/SCADA via OPC-UA or MQTT protocols. Selected tags (kiln feed, temperatures, mill current, power meters) are mapped to ERP parameters. Data flows automatically every 5 minutes — no manual re-entry. Process data is given business context: cost, batch ID, and shift ownership — making it actionable, not just historical.
Before a shift change, the outgoing Shift Supervisor must complete a digital handover form capturing: kiln and mill operational status, any active alarms, equipment under breakdown, maintenance activities in progress, pending quality samples, and any safety incidents. The incoming supervisor reviews and countersigns digitally. The system blocks shift change completion if critical fields are blank.
Every feature designed for the realities of a cement plant — from CCR cabin to board room.
Every department's data flows through Production — and Production data flows back into every department.
Every clinker and cement batch triggers quality sample collection. Production batch is on hold until QC releases it for dispatch.
Quality ModuleProduction consumption triggers material issue from stores. When stock hits reorder level, auto-PR is generated for procurement to act on.
Procurement ModuleRunning hours from MES feed into predictive maintenance MTBF calculations. Equipment downtime logged in Production flows into maintenance cost tracking.
Maintenance ModuleReal-time production capacity and finished goods inventory are visible to Sales at the point of order — no more overpromising delivery dates.
Sales Module