productivity excellence shree cement ltd. unit-5,...
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Productivity Excellence
Shree Cement Ltd.
Unit-5, Ras
National Awards for Cement Industry and Conclave on Sustainability
Excellence of Indian Cement Industry
15th & 16th Oct 2018 at Hyderabad
Shree Cement Profile
▪ Largest cement player of North India and has diversified into power business
including green power.
▪ Operations at eleven locations at Beawar, Ras, Raipur, Kodla, Khushkhera, Roorkee,
Jaipur, Suratgarh, Aurangabad, Panipat & Bulandshahar.
▪ Cement Production capacity of 41.9 MTPA and Power Generation Capacity of 646
MW.
▪ Awarded as ‘Asia’s Most Trusted Company’ 2018 by IBC InfoMedia Pvt. Ltd.
▪ World’s second best company in GHG Emission Management & Performance 2015,
by CDP London.
Shree Cement Profile
646
“Lead in Creating Prosperity & Happiness for all
Stakeholders through Innovation & Sustainable
Practices”
Our Vision
2006: 1 MTPA clinker
Energy Cons.- 86 Kwh/t Cement
Heat Cons.-759Kcal/Kg Clk
Capacity enhancement by up-gradation of Unit-5 from 1 MTPA
to 1.2 MTPA to 1.55 MTPA
2018: 15 MTPA clinker
Energy Cons.- 83 Kwh/t Cement
Heat Cons.-722 Kcal/Kg Clk.
Addition of 6 kilns of 1.55 MTPA each and 2 kilns of 2.85 MTPA each
One Unit
in
2006
Eight Units in
2018
Shree Cement’s Journey – Ras Plant
Systematic Approach for Manufacturing Sustainability
▪ Formulation of Corporate Policies
▪ Adoption of Management Systems
▪ Memberships with associations for knowledge sharing
▪ Management commitment
▪ Knowledge sharing within plant
▪ Small Group activities
▪ Preventive maintenance practices
▪ Process Optimization
▪ Technological modifications
Energy : Continuous reduction in GHG emission
Environment : Better climate & conservation of resources
Water : Conservation of water and water harvesting
CSR : Upliftment of social strata
Quality : Leading to consistent improvement
Health & Safety : Safe & healthy workplace
Human Resource : Empowering people
IT : System & transparency driven process
HIV/AIDS : Health management for stakeholders
Social Accountability : Welfare of stakeholders
Climate Change : Advancing towards Low Carbon Economy
Tax : Ethical & transparent business
A focused policy driven company for proper and systematic working through following policies.
Corporate Policies
SA- 8000 Social Accountability
ISO-9001 Quality Management System
ISO-14001 Environmental Management System
OHSAS - 18001 Occupational Health & Safety Assessment Series
ISO- 50001 Energy Management System
Management Systems
Knowledge Sharing: Memberships
▪ Cement Manufacturer's Association (CMA)
▪ National Council for Cement & Building Materials(NCCBM)
▪ Confederation of Indian Industries (CII)
▪ Bureau of Energy Efficiency (BEE)
▪ Federation of Indian Chambers of Commerce & Industry(FICCI)
▪ The Energy & Resource Institute (TERI)
▪ Cement Sustainability Initiative (CSI)
▪ Global Reporting Initiative (GRI)
First Indian cement company to join Cement Sustainability
Initiative of World Business Council for Sustainable Development
▪ Establishes a vision for the
employees.
▪ Sets standards for employees.
▪ Creating Awareness
▪ Defining areas including the
demands of the customer and the
content of the internal process.
▪ Helps direct the corporate
culture.
Management Commitment
Shree’s Approach to Achieve Productivity Excellence
Key process
best practices
Planning
&
schedulingTechnical
database
Engineering
interface with
Maintenance
Spare
Management
Predictive
Maintenance
Break down
analysis
Facilities, tools &
workshops
Skills
development
▪ Continual Skill Enrichment and job
enhancement
▪ Structured Job Rotation
▪ Participative Management
▪ Sustained high Promotion policy for establishing
happiness and knowledge enhancement
▪ Initiated People First Project to enhance our
people processes
▪ Introduced Mentorship process for new Joiners.
Involvement of People: Focusing on Development
▪ Financial resources
▪ Top-management
commitment
▪ External support
▪ Vendor
identification,
selection &
development
• Allow reasonable
timeframe for
implementation
• Set priorities
• Assure loops for
reflection and
interaction
▪ Cross functional
project teams
▪ Team members
from all Process,
Mechanical,
Electrical, R&D
departments
Define Project Team Set Timelines Allocate resources
Steps Towards Productivity Enhancement
Basic Idea : To develop work culture that is satisfying and fulfilling by raising
worker’s capabilities and making effective utilization of their abilities.
Form the Circle
Decide the Theme
Target & Plan
Evaluation of
AlternativesConfirm Effect
Revise Plan
Analysis
Implementation
Management
Approval
Project Proposal
Incorporate
managemen
t suggestion
No
Small Group Activities
Patrolling schedules
Stoppage Planning
Equipment Health Checks
RCFAs*
Preventive Maintenance to Ensure Equipment Availability
*RCFAs-Root Cause failure analysis
▪ Vibration Analysis
▪ Ferrography Analysis
▪ Ultrasonic Testing
▪ Daily round check list
• Outcome of
equipment health
check up report
• Why -Why Analysis
for any unexpected
stoppage
• Cross functional
team plant rounds
Stores management
▪ Inventory Reduction (Systematic sorting of spares, performance based
procurement, lead time reduction, min-max stock system)
▪ Cost Saving Techniques (Alternate vendors, Indigenous spares, in- house
fabrication/repairs, re-use after modification & life enhancement)
Engineering interface with maintenance
▪ Design, development & engineering
▪ Modifications
▪ Spare Management
▪ Co-ordination among departments
General Maintenance Strategy
Minimization of outsourcing through in-house
development of tools & workshop etc.
▪ Oil Ferrography Lab (First time in Cement Industry)
▪ Central tool room: Centralized storing & maintenance of all basic maintenance tools
▪ Idler maintenance department: Cost saving of Idlers by in- house maintenance
▪ Computerized Numeric Cutting Machine: Accurate fabrication of spare parts through CNC
▪ Vertical Turning Lathe machine: Fabrication of heavy / large machinery parts
▪ Roller Press roller refurbishment (First time in Cement Industry)
In- House Workshop Development
Installation of 3rd Cyclone in parallel to the existing twin cyclone at
the top stage (1st Stage) Preheater
Before the installation of triplet cyclone
Saving in Pressure Drop = 62 mm WG
After the installation of triplet cyclone
Pressure drop across preheater
= 749 mm WG
Pressure drop across preheater
= 687 mm WG
Saving in Power Consumption of PH fan = 86 kWh
Saving in Specific Power Consumption = 0.69 kWh / t Clinker
Reduction of CO2 Emission = 943 Ton / Annum
Case Study: 1Journey from 1 MTPA to 1.55 MTPA - Technological Modifications
Margin development in PH fan for increase in production
Modification in Vertical Raw Mill
Need:
Increase production capacity.
Reduce specific energy consumption.
Technological Intervention:
• Installation of more efficient classifier.
• Installation of new raw mill fan of higher efficiency.
• Installed third cyclone in parallel to two cyclones.
Key Benefits:
• Gain in production per day : 800 TPD
• Reduction in energy consumption by 0.32 Kwh / T
material
Journey from 1 MTPA to 1.55 MTPA - Technological Modifications Case Study: 2
Shree Cement was first in Indian Cement Industry to
install turbo blower
Compressed air was being utilized for conveying of coal
previously. Turbo blower was installed to reduce the
power consumption
Benefits:
Power Consumption by PD blowers :140 kW/hr
Power Consumption by turbo blower : 100 kW/hr
Power Saving :40kW/hr
Shree cement has now decided to install turbo blower in all the units in project phase
Barriers:
• Risk Management
• Safety
Journey from 1 MTPA to 1.55 MTPA - Technological Modifications Case Study: 3
Removed GCT from preheater tower
Gas conditioning tower (GCT) was installed to reduce the
temperature of preheater outlet gases.
Installed Waste Heat Recovery Boiler (WHRB) and removed
GCT to recover heat from preheater outlet gases.
Also to prevent false air in-gresment through GCT in system.
Journey from 1 MTPA to 1.55 MTPA - Technological Modifications Case Study: 4
Installed new preheater fan
Earlier we have installed preheater fan of 4,80,000m3/hr
which was under capacity and have to run the fan at full RPM.
Running fan on full RPM some time lead to vibration & PH
fan tripping.
Installed new preheater fan of 6,00,000m3/hr air flow with
MVD.
.
Journey from 1 MTPA to 1.55 MTPA - Technological Modifications Case Study: 5
Modification in Coal Mill
Need:
Increase production capacity.
Reduce specific energy consumption.
Technological Intervention:
• Installation of more efficient classifier.
• Installation of new coal mill fan of higher capacity.
• Increase the bag house area
Key Benefits:
• Gain in coal mill production by 25%
• Reduction in energy consumption by 5 %
• Overcome the problem of mill stopage due to high
bag house DP
Journey from 1 MTPA to 1.55 MTPA - Technological Modifications Case Study: 6
Installation of hot air recirculation system with modifications in cooler fans
Benefits- Resulted in increase of WHRB generation
Kiln inlet area increased
Benefits- Resulted in increase in production.
Kiln inlet and outlet seal replaced with new in -house made graphite seal
Benefits- Resulted in reduction of false air and thermal energy consumption.
Tertiary Air duct (TA duct) dia increased.
Benefits- Resulted in increase of production
Technological Modifications
Process Optimization- Other improvements
Raw mix design optimized
Benefits- Resulted in increase of production and clinker quality improvement
Burner flame momentum increased
Benefits- Resulted in better flame and low oxygen level at kiln inlet
Kiln RPM increased by 1.0 RPM in steps
Benefits- Resulted in increase in production.
Impacts:
Continuous management support and commitment of R&D team led
by young and experienced leaders has resulted in following operational
achievements:
▪Specific heat consumption reduced from 759 to 722 kcal/kg-clinker
▪Specific energy consumption up to clinckerization decreases from 60 to 53
KWh/T-clinker
▪WHRB generation increases by 20 % /ton.clk
Productivity Enhancement
RPO Obligation
Ras (2017-18)
RPO Obligation 14.25%
Measures taken to fulfill RPOMeeting RPO from WHR
Power
Share of WHR Power in captive
power consumption subject to RPO42.50% (51,435.84 Mwh)
Excess / Shortfall over RPO Excess
Meeting RPO requirement of State
RegulatorYes
Certificates procured Not Required
PAT Performance
0.489
0.465
0.409
0.36
0.38
0.4
0.42
0.44
0.46
0.48
0.5
Present Target Achieved
En
erg
y C
on
su
mp
tio
n (
MT
OE
)
SCL Ras Performance
• Energy reduction target = 5.06%
• Target achieved = 20.58%
• Target overachieved = 15.52%
• ESCerts Issued = 72140Nos.
Entrepreneur for the Year Award 2017 to Shri H.M.
Bangur, Managing Director of the Company
Best Energy Performance Award National Awards for Energy Efficiency and Quality Excellence by NCCBM
Awards & Recognitions
▪ Asia’s Most Trusted Company 2018 by
International Brand Consulting Corporation,
USA
▪ Best Performer in terms of energy saving
under Perform, Achieve and Trade Scheme by
Bureau of Energy Efficiency for Beawar and
Ras units.
▪ First prize in Cement Sector in “Rajasthan
Energy Conservation Award 2017” instituted
by Rajasthan Renewable Energy Corporation
Limited
▪ NCCBM Award for Best improvement in
thermal energy performance (Ras, Rajasthan)
2015-16
▪ NCCBM Award for Best Quality Excellence
for the year 2016-17
▪ NCCBM Award for Best Quality Excellence
for the year 2015-16
Awards & Recognitions
▪ Best Employer 2016 Award by the
Employers Association of Rajasthan
▪ Forbes India Magazine Entrepreneur of
the year award to Syt. H.M. Bangur, MD
▪ Second Rank for Excellence in Community
Impact by Society of Human Resource
Management
▪ Global Sustainability Awards in Platinum
Category by Energy & Environment
Foundation,New Delhi.
▪ National award for Cost Management 2016
by Institute of Cost Accountants of India
▪ India’s top 5 companies to work for in the
Manufacturing and Production sector and
ranked 65th among India’s top 100
companies to work for by Great Place to
Work.
Awards & Recognitions
You Green
Company Green
Globe Green
Thanks !
www.shreecement.in