Cement Manufacturing
Cement Plant Operations
Cement Factory Maintenance and Optimisation
Maintaining a cement plant for availability, and finding the optimisation that maintenance work makes possible.
- Duration
- 5 days
- Contact hours
- 30
- Level
- Intermediate
- Fee from
- On enquiry
Overview
Cement plants run continuously, so maintenance is a negotiation with production over a fixed amount of downtime. This week covers the strategy behind that negotiation: criticality assessment, the right maintenance approach for each asset class, condition monitoring, and shutdown planning and execution. Optimisation is treated as part of maintenance rather than separate from it, since a shutdown is usually the only opportunity to change anything physical.
Who should attend
Maintenance managers, engineers and planners, reliability engineers, production managers negotiating downtime, and shutdown coordinators.
What you will be able to do
- Assess criticality and assign a maintenance strategy accordingly.
- Build a condition monitoring programme that catches failures early.
- Plan and execute a shutdown that finishes on time.
- Combine maintenance and optimisation work in one window.
- Measure maintenance on availability rather than activity.
How it is taught
Short input, then work, across 5 days of roughly 6 teaching hours each. Exercises run on situations delegates bring rather than on a case study written for a different organisation. Cohorts are capped so that everybody is asked something.
Available as classroom, live online, in house.
Programme outline
Day 1
Strategy
- Criticality assessment
- Preventive, predictive and run to failure
- Spares policy against criticality
Day 2
Condition monitoring
- Vibration on mills, fans and crushers
- Thermography and shell scanning
- Oil analysis and wear debris
Day 3
Major equipment
- Kiln mechanical condition and alignment
- Mill and crusher maintenance
- Fans, conveyors and dedusting
Day 4
Shutdowns
- Scope development and freezing it
- Sequencing and resource levelling
- Execution, contractors and handback
Day 5
Optimisation in the window
- Identifying improvements only a shutdown allows
- Justifying them alongside maintenance scope
- Verifying the gain after start up
What you leave with
- A criticality assessment for one plant section.
- A condition monitoring plan.
- A shutdown plan with scope frozen and sequenced.
Dates and fees
| Dates | Location | Format | Fee |
|---|---|---|---|
| 23 to 27 November 2026 | Dubai, United Arab Emirates | Classroom | US$1,500 |
| 30 November 2026 to 4 December 2026 | Windhoek, Namibia | Classroom | R15,000 |
| 7 to 11 December 2026 | Accra, Ghana | Classroom | US$1,500 |
| 14 to 18 December 2026 | Maseru, Lesotho | Classroom | R15,000 |
Fees are per delegate and cover tuition, all programme materials and the certificate. Travel, accommodation and visas are arranged by the delegate. Registration closes two weeks before a programme starts.
Certificate
A GATI certificate recording what was attended, issued after the programme has run and attendance has been taken. Attending at least 80 per cent of the days earns a certificate of completion; attending less earns a certificate of attendance stating exactly what was attended. Every certificate carries a code that anybody can check against GATI's own record.
It records participation. and GATI does not claim one it does not hold.