Pioneering Sustainable Manufacturing with Intelligent Asset Management
About
About Cemcor
Cemcor is one of Northern Ireland’s most prominent cement and quarrying specialists, operating a diverse network of facilities that includes a limestone quarry in Cookstown, a shale quarry in Dungannon, and an import/export terminal at Belfast Harbour. The company has a long-standing commitment to innovation and environmental responsibility, making regular investments to improve operational efficiency and reduce the environmental impact of its manufacturing processes.
To support this mission, Cemcor partnered with Naviam to implement IBM Maximo Application Suite (MAS). This cloud-based enterprise asset management solution empowers Cemcor to better monitor, maintain, and optimize its heavy industrial equipment — all while enabling data-driven decisions around sustainability performance.
Problem
Maintaining Control of Operational and Environmental Performance
Operating a heavy industrial site like Cemcor’s Cookstown plant requires a high degree of control over both operational and environmental performance. The facility contains an extensive range of heavy machinery, such as:
- Dumper trucks
- Stone crushers
- Conveyors and stone mills
- Granulators and drying kilns
Maintaining this complex asset base efficiently is essential for minimizing downtime, ensuring safety, and optimizing performance. However, Cemcor previously lacked a centralized digital system to coordinate asset management across sites, making it difficult to track equipment status in real time or plan proactive maintenance.
At the same time, the company was looking for better tools to quantify and reduce its carbon emissions. With mounting pressure to meet sustainability targets, Cemcor needed to bring environmental accountability into its day-to-day asset operations. This meant measuring energy use, monitoring emissions, and making informed adjustments based on accurate performance data — all of which required a new level of system integration and visibility.
Solution
Fast Implementation and Improved Workflows
To address both its operational and environmental challenges, Cemcor signed a three-year partnership with Naviam, one of the UK’s most experienced IBM Maximo implementation partners. Together, they rolled out IBM Maximo Application Suite at the Cookstown plant in what became one of the fastest MAS implementations in the UK.
MAS enabled Cemcor to consolidate maintenance, monitoring, and emissions management onto a single intelligent platform. The implementation included:
- Real-time tracking of all asset data across critical equipment
- Predictive maintenance tools to reduce downtime and optimize performance
- Dashboards for monitoring carbon emissions at the equipment and site level
- Scalable configuration to extend the system to other sites as needed
Naviam also tailored the solution to Cemcor’s industry context, ensuring the interface and workflows matched real-world plant operations. This meant faster user adoption, smoother change management, and immediate returns from day one.
Result
Operational Performance
With real-time asset visibility, Cemcor’s maintenance teams are now able to identify and resolve issues more quickly. Equipment uptime has improved, and unplanned outages have been significantly reduced. The predictive capabilities of MAS also help extend the life of critical machinery, minimizing capital expenditure and reducing overall operational risk.
Sustainability and Carbon Reduction
MAS provides Cemcor with deep insights into energy use and carbon emissions across its equipment fleet. For the first time, the company has accurate, actionable data to guide its carbon reduction strategy. This includes identifying energy-intensive processes, benchmarking performance, and prioritizing maintenance activities that yield environmental gains alongside operational ones.
Organizational Efficiency
The new system has streamlined communication between departments and established a single source of truth for asset data. Maintenance schedules, inventory levels, and environmental reports are now fully aligned — reducing administrative effort and empowering engineers and managers with the insights they need to take swift, informed action.
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