AssetStackAssetStack capability statement for cement producers
Engineering experience,
built into the platform.
AssetStack connects equipment, condition, maintenance and investment decisions in one operating platform, shaped by decades of engineering and asset-management experience.
Engineering context, not isolated data.
The experience behind the product
Lycopodium’s background spans engineering, project delivery, construction and asset management across the asset lifecycle.
What this means in AssetStack
The platform connects the asset hierarchy, technical documents, handover requirements and maintenance history. An equipment record is the starting point for understanding the asset, not just a row in a register.
Readiness and acceptance workflows help the plant team retain the knowledge that often gets lost between project delivery and operations.
A plant view, not a generic dashboard.
Cement-process understanding
SAXUM, 60% owned by Lycopodium, brings cement and lime experience across crushing, grinding, pyroprocessing, materials handling, storage and terminals.
What this means in AssetStack
Cement-specific workspaces put kiln and mill condition, electrical transition, quality release and production-margin exposure in their operating context.
The platform helps teams connect an asset concern to the process it supports, the evidence needed to investigate it and the decision that follows.
Maintenance logic that closes the loop.
Operational asset-management experience
The background includes CMMS implementation, criticality and FMEA-based maintenance, risk-based inspection, root cause analysis, critical spares and maintenance procedures.
What this means in AssetStack
- Condition evidence linked to assets and follow-up work.
- Maintenance priorities considered with spares and intervention windows.
- Decisions retained with ownership and supporting evidence.
- Outcome verification kept separate from projected savings.
Your plant team uses the workflows; engineering judgement and approval remain with accountable people.
Engineering heritage behind the platform · selected partner experience
Kwinana, Western Australia
Multidiscipline grinding-plant upgrade to Australian codes.
Brazil · 6,500 tpd line
Engineering delivered in 12 months, with Capex and Opex trade-off studies.
Houston · terminals & grinding
Storage, conveying and dispatch infrastructure.
Missouri & Utah, USA
Finish-mill engineering and kiln-upgrade experience.
Engineering heritage explains the product’s operational perspective; these projects are not AssetStack deployments or product certifications. Applicable local regulations, approved site designs and OEM limits govern plant decisions. *Scale figures supplied in the capability brief, not a product performance measure.
From the asset record to the workfront.
AssetStack connects engineering information, condition evidence and maintenance execution in one software platform. These six capabilities give plant teams a shared operating view and practical workflows.
Know what is installed
Asset register & technical knowledge
Structure equipment by site, system and asset. Bring together equipment details, O&M manuals, maintenance history and linked documents so engineering and operations work from the same asset context.
A usable hierarchy and asset dossier for existing lines and incoming electrical equipment.
Connect physical condition to the record
Digital twins, scans & field inspections
Review models, scan frames and inspection photographs. AI-assisted findings support anomaly classification and human review; evidence can be associated with assets and follow-up maintenance.
Traceable defect evidence rather than an isolated image or an unexplained score.
Detect and investigate deterioration
Condition monitoring & failure decision support
Trend timestamped sensor readings, inspect source records and identify missing or ageing evidence. Days to alarm and trip, 30-day failure probability and spare lead time are calculated for each critical asset and synced to the register.
A reviewable inspection or intervention priority, not an automatic plant-control instruction.
Make maintenance knowledge accessible
AssetMind engineering intelligence
Ask engineering questions using records and documents made available to the assistant. Explore equipment context, previous maintenance and related findings, then check material conclusions against their evidence.
A faster route from operational questions to informed engineering review.
Turn a concern into accountable work
Maintenance planning & execution
Plan preventive, predictive and corrective tasks; manage work orders, assignments and checklists. Retain labour, parts, findings and completion notes so the maintenance history supports the next decision.
A documented path from inspection request through completed work and follow-up.
Work within the available window
Shutdown & intervention planning
Build a critical-path schedule for each kiln stop from scope, dependencies and durations, with readiness gates and the value of the stop. Bring spare availability and intervention timing into the shutdown discussion before committing the production window.
A more explicit view of execution constraints and the consequences of deferral.
Readings, inspections and maintenance history support the decision. AI-generated findings and failure indications remain subject to engineering review; missing evidence is not replaced by a confident estimate.
Beyond maintenance. Across the lifecycle.
Connect spares, commissioning, assurance and investment to the same asset context, then retain the evidence needed to review the operational result.
Protect the intervention window
Critical spares & procurement exposure
Maintain spare-part records, equipment compatibility, suppliers and purchase orders. Review lead-time exposure against intervention needs, and use reservations and quantity confirmations where configured.
An actionable critical-spares list covering existing plant and new electrical assets.
Prepare to operate before commissioning
Operational readiness & asset handover
Track readiness requirements, supporting evidence, dependencies, competencies and materials. Handover reviews connect new assets to documents and acceptance requirements instead of treating delivery as operational readiness.
A structured acceptance package with explicit outstanding requirements and ownership.
Keep engineering duties visible
Obligations & critical-control assurance
Map environmental, electrical and product-standard obligations and certificates to asset scope, with a due-date calendar and stack emissions headroom. Maintain safety-critical elements, performance standards and verification records; review overdue assurance and evidence gaps against approved site requirements.
A reviewable obligations and control-verification record, not an automatic compliance certificate.
Connect reliability to the product
Cement quality, dispatch & energy
Manage cement batch release and shipment records, conformity evidence and carbon-accounting assumptions. Review grid-transition milestones and energy economics alongside the production assets they support.
Connected quality-release and transition evidence, subject to laboratory and engineering sign-off.
Prioritise investment across old and new
Lifecycle capital & project delivery
Capture replacement timing, condition, risk and estimated cost in the capital plan. Use project budgets, phases, risks, work orders and sign-offs to follow the delivery of approved interventions.
A coordinated replacement and delivery view, with assumptions visible to decision-makers.
Close the loop on the outcome
Governed decisions & verified value
Keep proposals, execution evidence and outcome reviews in the decision workflow, with the value flow visible from proposal to verified result. Record projected and verified savings separately, check each value chain for missing links, and lead the board pack with the cement plant section.
An accountable decision trail and a clear distinction between expected and evidenced results.
Structure the register first; use criticality and FMEA to define strategies; accept complete handover data; link work instructions; use failure feedback and KPIs to refine maintenance; feed lifecycle cost and critical-spares reviews into the capital plan.
One engine. Every screen tells the plant's story.
A cement intelligence engine reads kiln, mill, laboratory, energy, emissions and condition data, then prices each finding. Its results flow into every AssetStack screen, from the asset register to the board pack.
See the kiln before it stops you
Kiln & pyroprocessing intelligence
A 3D kiln twin overlaid with the shell-scanner heat map, refractory wear and days-to-minimum-lining by zone, ring and build-up risk, a free-lime soft sensor and a daily heat balance in kcal/kg.
Hot spots, lining life and ring risk turned into dated actions with value at stake.
Find the kWh/t that is leaking
Mills & grinding efficiency
Raw mill and cement mill throughput, specific power, Blaine, residue and vibration trends against each mill’s own baseline, with the excess energy priced per year.
A ranked list of grinding losses and the mill condition behind them.
Stop giving strength away
Quality AI
SPC on free lime, LSF and C3S; a 28-day strength model from early tests; and the over-design and clinker-factor margin it releases, with raw-mix guidance toward the LSF target.
Safe clinker-factor reductions and early warning on at-risk batches.
Price every kcal and every trip
Energy, CO₂ & grid
Fuel mix and thermal substitution, CO₂ per tonne split into process, fuel and power, stack emissions headroom against permit limits, and grid events traced to kiln trips and lost clinker.
An energy and carbon view linked to the assets and the grid transition.
Know what fails first, and whether the spare arrives
Predictive reliability
Days to alarm and trip for every critical asset from its condition trend, 30-day failure probability, and spare lead time set against remaining life. Results sync to the asset register.
Spares that will arrive too late, flagged while there is still time to act.
Ask the plant a question
CementMind agent
An AI agent that answers from the cement engine and plant records: what to fix first, how many lining days remain, what a raw mill trip costs. Findings can be raised as decisions or work orders in one click.
A plant manager briefing in seconds, with the evidence behind each answer.
Built into every platform screen
Decisions & value
Decision value flow from proposal to verified outcome, a savings waterfall, return on each intervention, and an evidence-chain check on every value claim.
Assets & maintenance
Health against failure probability, remaining useful life, backlog and planned hours, margin at risk by process stage, and a critical-path schedule for each kiln stop.
Assurance
Environmental, electrical and product-standard obligations on a due-date calendar, stack headroom, barrier verification status, change and bypass timelines, and a regulator-ready evidence pack.
Supply & capital
Spare lead time against remaining life, stock cover, supplier delivery and quality, capital spend and risk matrix, and project schedule and cost.
Findings carry their evidence and value basis. Savings count as proven only when evidence, approval, execution, independent verification and a measured result are all on record.
From insight to an approved action.
The intelligence layer does more than report. It drafts the day’s actions for a person to approve, explains every number it shows, recommends set points for the shift and tests an event before the plant lives through it.
The agent drafts. A person approves.
Agent Desk
A morning scan checks the whole plant and drafts the day’s actions: decisions, work orders and purchase requests to expedite late spares. Each one carries its reason and the value at stake. Approving creates the record and logs who approved it. Role briefings give the plant manager, kiln operator, planner, quality, finance and energy leads their three actions for the shift.
A prioritised approval queue each morning, and one page per role, without anyone building a report.
Count only the savings that are proven
Value Ledger
Every finding is tracked from identified to approved, executed and verified, valued in money. Delivered value is set against value still at stake, by area and by owner.
A board-ready view of value delivered, with the evidence chain behind each saving.
Know which numbers you can rely on
Trust & Data
A trust score for every key tag from freshness, completeness, flat-lining and range checks, and an “explain this number” register: tap any headline figure for its formula, sources, assumptions and confidence.
Confidence in the figures before they reach a decision, and a list of instruments to fix first.
Set points for this shift, with the reason
Process Optimiser
Recommended kiln and mill set points (burner fuel, O₂, kiln feed, LSF, cooler grate, mill pressure and separator speed), each with its saving per day and the constraint checks it passed. An alternative-fuel planner sets RDF, tyre and biomass rates against chlorine, sulphur and heat limits.
Advice the shift can accept or reject, logged with the operator’s decision.
Release strength you are giving away
Clinker & Quality
The safe clinker-factor reduction by cement type against the 28-day strength risk, raw-mix correction towards the LSF target, and release decisions that flag at-risk silos before dispatch.
Lower clinker per tonne without missing the strength class, priced in cost and CO₂.
Test the event before the plant does
What-if Simulator
Type a question such as “raw mill down 30 h” or “lose the grid feed for 2 h”. The simulator runs the line hour by hour for 72 hours through silos, kiln, mills and dispatch, and shows the lost clinker, missed orders, kiln stops and the cost.
A priced answer in seconds, and the buffer levels that would avoid a kiln stop.
Every drafted action shows its reason and value; approval creates the work order, decision or purchase request; the value ledger counts the saving only once it is executed and verified.
Plan the stop, sell the tonne, price the carbon.
The same engine plans maintenance and kiln stops, schedules mills around demand and the tariff, and sets the plant against the world’s best plants and a rising carbon price, all priced.
The right task for each failure mode
Reliability Strategy
FMEA with risk priority for every critical asset, P-F intervals from live degradation rates, and the strategy that fits: condition monitoring, scheduled overhaul or run to failure. A refractory planner forecasts each kiln zone’s lining life under hot-spot load.
A maintenance strategy priced by risk avoided against task cost, and a reline plan by zone.
The shortest safe kiln stop
Shutdown Planner
Builds the stop scope from findings, asset condition, the ring and the refractory campaign, sequences it on the critical path, and checks every spare against its lead time. Saves straight into a turnaround scope with readiness gates.
A window in hours, the lost clinker it costs, and the spares to expedite now.
Field readings on a phone
Operator Rounds
Mobile rounds for each shift with limits shown as the operator types. An out-of-limit reading raises a fault straight onto the Agent Desk for approval.
Field evidence in the same record as the sensors, the same shift it is taken.
Grind the right cement at the right hour
Demand, Dispatch & Energy
A 30-day dispatch forecast with its range, split by cement type and market and matched to silo cover. Mill hours are scheduled out of the peak tariff and onto on-site solar, cutting peak load on the grid feed.
Which cement to grind next, and the energy saving per day and per year.
The gap to the best, in cost and CO₂
Benchmark & Carbon
Your plant against median and top-quartile plants on clinker factor, OEE, heat, power, CO₂ and alternative fuel. A marginal abatement cost curve puts the cheapest tonne of CO₂ first, with a 10-year path under a rising carbon price and the EU CBAM cost.
A decarbonisation plan ranked by cost per tonne, tied to the plant’s own levers.
Each planner lists the assumptions behind its numbers and lets the team change prices, limits and dates, so the answer can be checked against the plant’s own figures before it is used.
Capture the transition. Keep the knowledge.
Use AssetStack to keep new electrical assets, existing production lines and retiring generation equipment in one connected operating record. The knowledge stays with your team as the plant changes.
Why now
A changing power system needs a complete asset record.
Many cement producers are moving from on-site thermal generation to grid interconnection, adding new transformers, switchgear and protection alongside existing kilns and mills.
Fuel displacement programmes target better energy efficiency, lower generation emissions and improved operational reliability.
Many plants are also adding on-site solar and new transmission capacity, which changes how power, assets and risk are managed.
The client value
Assets enter operations with context.
Equipment identities, documents, responsibilities and maintenance requirements stay connected.
Earlier, better-supported decisions.
Teams can review condition trends and maintenance history before committing to an intervention.
A plan that sees both old and new.
Critical spares, lifecycle needs and replacement priorities are considered together, not as separate projects.
Put the platform to work
Start with one connected asset group in AssetStack.
Capture the interconnection
Load transformers, switchgear, cabling and protection into a structured register at handover.
First action: Agree hierarchy, document requirements and ownership with the electrical lead and project team.
Trend the existing lines
Start with kiln and mill readings on the operating production lines.
First action: Confirm sensor provenance, approved limits and the engineer responsible for reviewing concerns.
Build the first investment view
Use AssetStack’s spare-parts and capital-planning workflows across new and existing assets.
First action: Confirm BOMs, lead times, replacement priorities and how retired generation assets will be closed out.