Kohat Cement

Kohat Cement operated 8 manufacturing plants with hundreds of critical machines. Equipment maintenance was managed through paper logs, Excel sheets, and phone calls. When machines broke down, production stopped until technicians could diagnose and fix issues.

Plant managers tracked maintenance schedules manually, often missing preventive service windows. Technicians carried physical manuals for different equipment types. Finding spare parts meant searching through inventory logs. Each breakdown cost millions in lost production.

The team knew they needed a predictive maintenance system, but configuring one seemed impossible without months of IT work to map equipment hierarchies, maintenance protocols, and spare parts databases.

Kohat tried generic CMMS platforms. The implementations failed because cement manufacturing has unique requirements. Each plant had different equipment configurations. Maintenance protocols varied by machine age and production load. Spare parts had complex interdependencies.

Setting up equipment hierarchies for 8 plants would take 6 months. Configuring maintenance schedules for different machine types required constant IT changes. Creating part replacement workflows needed extensive customization. Every time equipment was upgraded, the whole system needed reconfiguration.

The operations team needed a system that understood cement plant operations, not a blank database they had to configure manually.