Operations

Machine Health

Predictive condition monitoring · 115 assets · live load dials · vibration & thermal trends

Fleet Health Index

74/100

+2.3

Assets At Risk

-12

Predictive Alerts

Avg MTBF

248d

+6.1 d

Maint. Compliance

92%

+3.4pp

Unplanned Downtime

1.8%

-0.6pp

Live Instrumentation

Asset Load Dials — Full Fleet

Modbus / OPC-UA · 1s poll

Asset Detail

Kiln 1

Critical

Rotary Kiln · Clinkerization

Next service: Overdue 3d

Runtime: 7,820 h · MTBF 142d

Load

108%

Vibration

4.8 mm/s

Temperature

412°C

Current

685 A

Predictive · 24h

Vibration Trend (mm/s)

Spectral

Vibration FFT — Cement Mill 1

Bearing defect freq detected

Thermal · 24h

Temperature Trend

Fleet

Health Distribution

Healthy (80-100)71

Watch (60-79)28

At Risk (<60)16

Condition Register

Asset Health Register

Asset	Type	Section	Health	Load	Vib	Temp	Runtime	Next Service	Status
Kiln 1	Rotary Kiln	Clinkerization	58	108%	4.8	412°	7.8k h	Overdue 3d	Critical
Kiln 2	Rotary Kiln	Clinkerization	88	91%	2.1	388°	6.4k h	in 41d	Good
Raw Mill A	Vertical Mill	Raw Grinding	71	97%	4.2	96°	5.1k h	in 6d	Warning
Raw Mill B	Vertical Mill	Raw Grinding	90	88%	1.8	88°	5.0k h	in 52d	Good
Cement Mill 1	Ball Mill	Grinding	52	112%	5.6	104°	8.2k h	Overdue 1d	Critical
Cement Mill 2	Ball Mill	Grinding	86	84%	2.4	92°	5.6k h	in 33d	Good
Compressor A1	Screw Compressor	Utilities	82	79%	2	74°	3.1k h	in 28d	Good
Compressor A2	Screw Compressor	Utilities	94	71%	1.4	68°	3.0k h	in 60d	Optimized
Chiller Unit 1	Centrifugal Chiller	Utilities	67	96%	3.1	12°	4.4k h	in 9d	Warning
Air Compressor	Recip Compressor	Utilities	64	99%	3.6	81°	6.7k h	in 4d	Warning

Work Orders

Upcoming Maintenance Schedule

Jul

Cement Mill 1 — Bearing replacement (DE side)

Team Mech-A · 6h

Critical

Jul

Kiln 1 — Refractory inspection + load re-trim

Team Process · 8h

Critical

Jul

Air Compressor — Valve plate + filter service

Team Utilities · 3h

Warning

Jul

Raw Mill A — Gearbox vibration analysis

Team Predictive · 2h

Warning

Jul

Chiller Unit 1 — Condenser tube cleaning (anti-fouling)

Team Utilities · 4h

Warning

Jul

Cement Mill 2 — Routine lubrication + alignment

Team Mech-B · 2h

Routine