Cement workflows and their owners

Configure TwoSuns around the work a plant needs to advance.

TwoSuns combines capabilities from Horizon and Pulse around practical cement workflows. The workflows below are drawn from the work a producer already does each week, from the quarry face to cash collected. Further workflows can be configured as the deployment expands.

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The chain

Where the workflows sit

The workflows below are listed in the order of this chain. Each one acts on one or two of these stages, and a decision taken at one stage sets the options available at the next: the face selected moves what the raw mill has to correct, just as the silo released decides what dispatch can load.

Quarry and raw materials
Crushing and raw material storage
Raw mill and raw mix correction
Preheater, kiln, cooler and clinker
Cement mill and product
Storage, packing and loading
Dispatch and logistics
Sales, orders and contracts
Credit and collection

Workflows

Cement workflows

Each workflow states the function that owns it, the platform surfaces it uses, the work itself and what changes once the workflow runs in one enterprise context.

Quarry plan against the reserve model and blending

Function that owns it: Mining and quarry operations
Platform surfaces: Pulse Quarry and Materials and Supply, with the shared Digital Twin facility, the plant basis in Core and Ray
Configured workflow: Sequence faces and benches against the reserve model so the chemistry reaching the crusher holds the raw mix window without unplanned corrective purchases.
What changes: Face selection is agreed against reserves, chemistry and corrective material cost at the same time, before the face is opened.

Raw mix control and correction

Function that owns it: Process and quality
Platform surfaces: Pulse Crushing and Raw Mix, with the shared Product Quality facility and the limits held in Core
Configured workflow: Correct the raw mix from XRF and hourly composites against the lime saturation factor, the silica and alumina moduli and the targets the plant's engineers define and own.
What changes: Every correction is made against the band in force, with its corrective material cost and its effect on clinker quality stated beside it.

Fuel procurement and stock cover

Function that owns it: Procurement, with the pyro process lead
Platform surfaces: Pulse Materials and Supply, with the shared Energy and Resources facility and Horizon Finance
Configured workflow: Buy coal, petcoke and alternative streams against NCV as received, sulphur, chlorine and ash, delivered cost per kcal on an NCV basis, and the days of cover at the current kiln feed rate.
What changes: A fuel purchase is decided against its effect on heat cost, clinker quality and permit limits, with the days of cover visible.

Kiln thermal performance and fuel mix

Function that owns it: Process and production
Platform surfaces: Pulse Pyro Process and Cooling, with the shared Energy and Resources and Optimization and Scenarios facilities, and Ray
Configured workflow: Hold specific heat consumption and the fired fuel mix against kiln stability, clinker quality and the fuel prices and availability in force.
What changes: A move in kcal per kg of clinker is costed as exposure per day and taken to the named owner with the kiln process values and the laboratory results behind it.

Alternative fuels and co-processing

Function that owns it: Environment and permits
Platform surfaces: Pulse Pyro Process and Cooling, Sustainability and Materials and Supply, with permits and approvals held in Core
Configured workflow: Raise the thermal substitution rate within sulphur, chlorine, stack permit and clinker quality limits, and against the delivered cost of each stream.
What changes: Substitution is planned against the binding limit rather than the fuel price alone, and the permit position behind each decision stays on the record.

Cement designation, clinker factor and additions

Function that owns it: Quality assurance and production
Platform surfaces: Pulse Grinding and Product and Sustainability, with the shared Product Quality and Inventory facilities
Configured workflow: Set the cement designation, the clinker factor and the addition rate for each product within the constituent limits the standard allows for that designation, against strength results, supplementary material availability and reported CO2 per tonne.
What changes: The clinker factor is set per product with the strength margin, the material supply position and the CO2 effect visible in one view.

Cement mill scheduling against the order book

Function that owns it: Production planning and scheduling
Platform surfaces: Pulse Grinding and Product with Horizon Order Management and Invoicing, and the shared Inventory and Calendars facilities
Configured workflow: Sequence cement mills, product changes and silo allocation against confirmed orders, class mix, silo stock and power tariff periods.
What changes: The mill schedule is built from the order book and the silo position together, so product changes and grinding power are planned rather than reacted to.

Preventive and predictive maintenance around a kiln stoppage

Function that owns it: Maintenance and reliability
Platform surfaces: Pulse Pyro Process and Cooling and Materials and Supply, with the shared Calendars and Optimization and Scenarios facilities and the decision history in Core
Configured workflow: Plan the stoppage window, the work list and the spare parts against operating readings, work history and the clinker stock that has to cover the outage.
What changes: Stoppage timing is decided against clinker cover, spares readiness and commercial commitments, and the work history stays with the asset.

Silo release and consignment test reports

Function that owns it: Quality assurance and the laboratory
Platform surfaces: The shared Product Quality facility with Pulse Packing and Dispatch, and the business rules and approval chains held in Core
Configured workflow: Release each silo against the plant's own early-age release limits, assemble the supporting results, and issue the test report for each consignment, while conformity over the control period is assessed statistically as later-age results arrive.
What changes: Release follows one approval chain with the early-age record attached, later-age results attach back to the consignments already shipped, and a held silo is visible to dispatch and sales as soon as it is held.

Bulk dispatch and tanker turnaround

Function that owns it: Dispatch and logistics
Platform surfaces: Pulse Packing and Dispatch with the shared Logistics and Inventory facilities and Horizon Order Management and Invoicing
Configured workflow: Plan loading slots, bay allocation and tanker turnaround against released stock, confirmed orders and haulier availability.
What changes: Loading is planned against released tonnes rather than nominal stock, and turnaround time and waiting cost are measured per bay and per haulier.

Bagged dispatch, packing and weight control

Function that owns it: Packing plant operations
Platform surfaces: Pulse Packing and Dispatch with the shared Product Quality, Inventory and Dashboards facilities
Configured workflow: Run the packers against the bagged order book while holding bag weight distribution, giveaway and reject rates inside the declared tolerance.
What changes: Weight giveaway and packer losses are costed per tonne packed and sit beside the maintenance and order decisions that cause them.

Dealer allocation against available tonnes

Function that owns it: Commercial management, with credit and finance
Platform surfaces: Horizon Order Management and Invoicing, Finance and Contracts and Offers, with approval chains held in Core
Configured workflow: Allocate available tonnes across dealers and distributors against agreed terms, the credit position in force and the tonnes packing can release.
What changes: An allocation is made against released tonnes and the terms that apply, and a release beyond those terms needs its named approval.

Tender and bulk supply contract pricing

Function that owns it: Commercial leadership and finance
Platform surfaces: Horizon Contracts and Offers, Omni Signals and Finance, with cost and capacity from Pulse and the shared Logistics facility
Configured workflow: Price a tender or bulk supply contract against production cost, available capacity, freight to destination, competitor activity and the margin floor.
What changes: A price is committed against the plant's own cost per tonne and the tonnes it can still supply, and the assumptions behind it stay on the record for the contract term.

These are representative, not exhaustive.

Your workflow

Bring us the workflow

Every producer combines its own reserves, fuels, products, people, inputs, systems and operating practices differently. Two plants with the same kiln can need different decisions on the same day. TwoSuns can be configured around a workflow described here or another one that matters at your plant.

A selected workflow can be shown as a short platform demonstration against your own reports, with the process, quality and commercial leads who would own it.

Start from one workflow

Choose a workflow described here or bring us one of your own, and the team will show how it would be configured on a cement value chain.

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