Cement kpi pdf production

The production of cement in india started in 1889 by company based in kolkata. Critical success factors for cement industry in india. Pdf key performance indicators for sustainable manufacturing. A unique set of kpis aimed at the manufacturing and engineering industries. Production volume 0 50 100 150 200 250 300 350 jan feb mar apr may jun jul aug sep oct nov dec21. Do you know all the kpis for a manufacturing operations manager.

The world consumption of cement is rising at an increasing rate creating significant levels of pollution and. Cement mixed with fine aggregate produces mortar for masonry, or with sand and gravel, produces concrete. This makes the service ideal for evaluating contaminated, lightweight, and foam cement slurries. They give manufacturers valuable business insights to meet their organizational goals. Integrity explorer cement evaluation service baker. This paper has developed a set of key performance indicators kpis for sustainable manufacturing evaluation in cement. The following data has been collated against the sustainable construction forum scf key performance indicators kpis and targets, and is compliant with the requirements of the building research establishment bre environmental and sustainability standard bes 6001, issue 3. As the worlds largest producer of variable frequency drives vital to modern cement production abb draws on its extensive cement industry knowledge to select the best drives to increase the through put, reliability and energy efficiency of your opera tions. Kpis and have semantic dependencies are excluded from the selection of kpi candidates. Csi key performance indicators data and coverage for fy 201617 issue key performance data coverage indicator kpi % of clinker production climate protection total co emissions gross million tons 11. Environmental sustainability decision requires a scientific approach of identifying and prioritization of kpis. Integrity explorer cement evaluation service baker hughes.

It is so simple with the industry compared to major industries, and depend on the availability of the necessary raw materials for it. Its size, rigid isolator and powerful transmitter allow robust operations. Key performance indicators kpi are performance assessment tools that identify the extent of achieving the desired parameters in the industrial production lines, which is of major importance for the success of the manufacturing company. Aug 15, 2014 capacity utilization capacity utilization of cement companies can be tracked to gauge their operating health. Key performance indicators for production monitoring. Key performance indicators identification and prioritization. Cement production and downtime management pims, mes for cement processing plants analyze your production and performance kpis. Cement is on the radar of all policy makers around the world. Kpi fy 201011 fy 201112 a climate protection excludes captive power without star cement co. Kpis for measuring performance of production systems for. Cement plant laboratories check each step in the manufacture of portland cement by frequent chemical and physical tests. Cement plant key performance indicators cement fuels scribd.

The cement industry is likely to use the ccs infrastructure developed for the power sector. Concrete is the most widely used material in existence and is only behind water as. Since cement is one of the largest consumed materials, it has to be produced in huge amount. Each of the life cycle phases is further broken down into individ. Here is the complete list of the most important manufacturing kpis and metrics, that we will discuss in this article in every. Key performance indicators for sustainable manufacturing. Lowcarbon roadmap for the egyptian cement industry 3 up until 2014, the egyptian cement industry principally used statesubsidised natural gas and heavy fuel oil to fire their kilns. Cement is seldom used on its own, but rather to bind sand and gravel together. The production of cement is a highly energy intensive process. There is a lack of quantitative kpis to measure performance at a strategic level. Weve assembled a list of key performance indicators kpis for the manufacturing industry. Informs webinar shows the relevance of key performance indicators in cement logistics and supply chain management register now.

Both of these materials are produced in portland cement manufacturing plants. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext. Weve assembled a collection of key performance indicators kpis and metrics. Manufacturing process lafarge in south africa cement. Despite varying concepts, each practice uses key performance indicators kpis to assess, analyze and track manufacturing processes. Cement evaluation radial bond tool baker hughes, a ge. However, a process of mentorship is one of the best motivators available. Performance management starts with figuring out what to measure. Capable of measuring the cement bond in any wellbore fluid environment, the integrity explorer service eliminates the need to unnecessarily add wellbore fluids for evaluation. You might think that participation incentives in any industry would primarily be based on financially rewarding employees. A diagram of the process, which encompasses production of both portland and masonry cement, is shown in figure 11.

This study is an attempt to set up a stochastic relationship between financial leverage and firms performance of cement industry operating in pakistan. The matrix classifies production systems for the production of multifamily residences along two dimensions. In addition to the traditional 3 ft amplitude and 5 ft vdl, the rbt has a radially. For archived information about the csi, please visit here. Sbt seal advanced cement bond analysis service baker hughes. Carbon costs will be a major production cost in the future. Driving supply chain improvement in the concrete industry martin clarke chief executive, british precast. Key performance indicators kpis are accessed from a smart database datapro, including configurable events such as. Specific heat consumption of clinker production mjtonne clinker. The diagrams illustrate the phases and apparatus to make cement and how cement is utilised in the production of concrete for construction. The labs also analyze and test the finished product to ensure that it complies with all industry specifications. A cement is a binder, a substance used for construction that sets, hardens, and adheres to other materials to bind them together. Figure 1 control pyramid of business objectives figure 2 cascaded objectives to achieve the business purpose. Key performance indicators for sustainable manufacturing evaluation in cement industry.

These kpis track performance in areas such as production costs, labour costs, production losses and cycle times. The cement dedicated to making a differencesustainability initiative howard klee ficem coprocessing forum coral gables, florida. Conclusions the cement industry is an intensive consumer of natural raw materials, fuels, energy, and high pollutant emitting industry. We discuss the construction kpis and critical metrics your company should be measuring to affect profits and productivity. Production and downtime management in cement manufacturing. In the cement production line, producing 1 ton of cement need grind at least 3 tons of materials including raw materials, fuel, clinker, mixed materials,gypsum. Key performance indicators need to be simple and focused 75% people trained to practitioner level. You will be redirected to the full text document in the repository in a few seconds, if not click here. The cement dedicated to making a difference sustainability. Jinsoo park haneul lee byungdu so yunbae kim department of management information systems department of industrial engineering yongin university sungkyunkwan university samgadong, cheoingu yuljeon, jangangu yonginsi, 449714, korea suwon, 440746, korea.

This paper proposes a set of key performance indicators kpis for evaluating the sustainable manufacturing believed to be appropriate to the cement industry. Specific heat consumption of clinker production mjtonne clinker 3540 alternative fuel rate incl. Dust emissions contribute about 6% of the pm 10 in greater cairo reaching as much as 30% in. Gcca sustainability guidelines for the monitoring and reporting of. Even if an organization does not employ formal continuous improvement initiatives, efficiency gains can still be realized by borrowing lessons learned through the visual. Models of future iea, csi, mckinsey, ccap, others all identify the same 4 levers for co2 control alternative fuels replacement of clinker. Essential construction kpis to improve profits and. Section 2 summarizes california cement industry statistics section 3 provides an overview of the cement production process. The bhge sbt seal advanced cement bond analysis service provides integrated assessment of cement seal quality for data acquired with the segmented bond tool sbt service. This paper proposes a set of key performance indicators kpis for evaluating the sustainable manufacturing believed to be appropriate to the cement industry based on the triple bottom line of sustainability. Example kpis for the manufacturing industry, updated for 2020. Egypt has increased cement production from 4 million tons in 1975 to 46 million tons in 2009, and now accounts for around 1. The cost of a new cement plant is equivalent to around 30 years of turnover, which ranks the cement industry among the most capital intensive industries.

History for 40 years, flsmidth has been a pioneer in highlevel expert control systems for cement applications. The sustainable concrete plant guidelines are organized according to the five life cycle phases of concrete construction as established in the nrmca sustainability initiatives. Global cement production top countries 2019 statista. The kpis are then used to develop an evaluation model of sustainable manufacturing. Due to the gradual phasing out of the subsidies and the scarcity of these fuels domestically, using natural gas. Thus, it is essential to evaluate the sustainable manufacturing in this industry.

Each kpi within the template has been selected by manufacturing professionals, providing a best of breed set of kpis to optimise for your own use. The analytical hierarchy process ahp methodology is. Llc i co 2 emissions gross tonnes 25,740,501 27,469,355 26,187,142 28,3,152 ii co 2. Flsmidth is a world leader in building and maintaining cement plants, and that firsthand experience plays an important role when developing innovative automation solutions that enhance the production capabilities of customers plants. The 75 kpis every manager needs to know published on.

The production of cement involves a 5 stage, linear process that begins with the mixing of raw materials and culminates in the packaging of new cement. Grinding operation consumes about 60% of total power in cement plants, raw material grinding more than 30%, while coal mill used in cement plant consumes 3%, cement grinding about 40%. With enhanced processing and intuitive graphical presentations. This statistic shows the worldwide cement production, by major producing countries, from 2015 to 2019. For this study 23cement producing firms working out of these 18 are consolidated in the. Physical asset management the purpose of most equipment in manufacturing is to support the production of product destined to downstream customers. Diversified and complicated manufacturing sites make optimal scheduling of production lines difficult. Driving supply chain improvement in the concrete industry. The cost of cement plants is usually above 150m per million tonnes of annual capacity, with correspondingly high costs for modifications. List of key performance indicators kpi cement co2 protocol. Capex plans capex plans of large industrial groups leads to a surge in demand. Key performance indicators kpis are a vital tool for measuring businesswide performance and are longestablished within sales, financial and operational departments. Net emissions from raw materials, kiln fuels and nonkiln fuels, excluding co2 from onsite power generation, divided by own clinker production. These kpis are further categorized into seven major groups.

Monitoring frequency and service modules are customizable so plants can match them to their own site requirements. Csi key performance indices cement operation only kpi fy 200809 fy 200910 a climate protection excludes captive power i co 2 emissions gross tonnes 23,546,758 25,950,920. Buy production kpi benchmarking dataasaservice products from opsdog. The bhge integrity explorer cement evaluation service provides accurate information that helps operators gain an understanding of the cement bondregardless of weight or contaminationto make critical downhole decisions with confidence. Cement provides the chemical bonds that hold the other materials together to form a dense rocklike substance. A manufacturing kpi or metric is a welldefined measurement to monitor, analyze and optimize production processes regarding their quantity, quality as well as different cost aspects. Cement plant performance optimization benchmarking. Csi additional key performance indicators 2016 lafargeholcim. The rbt allows the detection of poor cement conditions before perforating enabling proactive, measures to be taken. Pdf impact of financial leverage on firms performance. These kpis are grouped by both department and industry. Production planning kpis assist in effective evaluation of all aspects of the product life cycle right from product design and development, product management, employee training, product quality control, facility management, to product packaging and dispatch. Key performance indicators means factors by reference to which the development, performance or position of the business of the.

Cement plant key performance indicators free download as pdf file. Ecsprocessexpert is a development of ecsfuzzyexpert, which was the first expert system engineering platform in the cement industry. A hydraulic cement made by finely powderising the clinker produced by calcining to incipient fusion a mixture of argillaceous and calcareous materials. Cement plants performance levels to maintain smooth system operation. The kpi database helps you to find the right key performance indicators categorized by business framework, by industry and by process. The cement industry is considered of strategic industries. This paper examines the role of key performance indicators kpis that is believed to influence the environmental sustainability of cement production of pakistan. Kpi library key performance indicators kpi examples. Overview of cement production cement is an important construction ingredient around the world, and as a result, cement production is a significant source of global carbon dioxide co2 emissions, making up approximately 2.

From the limestone quarry to the delivery of the end product, follow every step in the cement manufacturing process. We have kpis for both common departments as well as all 20 of the us governments major industry. Key performance indicators for co2 and energy in cement. Our recommendation engine offers suggestions for performance indicators and measures based on your business process and interests. History for 40 years, flsmidth has been a pioneer in highlevel expert control. Identify how downtime is affecting your production targets, and get decision support on what actions to take for improving the performance. Cementitious sustainability responsible sourcing data 2015 kpi. Evaluates the widest range of cement weights in the industry. The most common way to manufacture portland cement.