In large cement operations, kiln availability defines plant performance.
The main drive motor runs continuously under extreme thermal and mechanical loads, where even gradual bearing degradation can trigger an unplanned shutdown and halt clinker production across thousands of tons per day.
For this cement producer, the challenge wasn’t lack of data or alarms, as they already alert monitoring solutions.
It was identifying which subtle deviations actually mattered early enough to act, before they escalated into forced downtime.
UptimeAI’s AI Reasoning Agent continuously reasoned across motor behavior, lubrication performance, and historical failure patterns to detect a developing risk that conventional monitoring systems would have treated as normal variation.
- By reasoning across asset context, historical patterns, and failure-mode knowledge, the system identified a developing lubrication-related risk well before traditional thresholds were crossed.
Guided by expert-grade recommendations, the plant prepared corrective action during a planned outage, avoiding a forced shutdown. The implementation was quite successful as this leading US Cement Producer saved
$500K in avoided issues caught in the first 4 weeks after deploying UptimeAI Reasoning Engine and a potential ~$550k in production impact.
Get a copy of the Customer Story: