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I am presently working in a cement production plant. We face a lot of problem with transportation with regards to diesel expense, maintainence expense of our trucks. I want to make a weekly or monthly format to control this problem.
Also I need a format for production in my cement plant. Hourly production format,weekly.
Output format.
Machinery and equipment maintainence formats.
I would really appreciate if anyone with this knowledge can help me.
Thank you

Dear Deepti,
Your post is little confusing. Confusion is because cement industry is one of the core industry. However, the queries that you are asking are quite basic. Nothing is basic than this.
For maintaining the expense sheet on trucks or diesel etc, your logistic manager is responsible. Why is he not able to do this?
Secondly, as far as maintaining production schedule or production format in your factory is concerned, production manager is responsible.
Why these people are not working according to the industry requirements? Any format production or otherwise has to be devised on your own and there is no "copy and paste" solution.
By the way you work there as what or is this your own company?

I have just joined this company. I am working as an administrative head. This plant needs a lot of professionalism. It's very old plant and now it's production output has also decreased.
I need these formats to make this plant run on a system. We are not finding right people to run our plant. We do not have a logistics department. Everything is done by few people. The cement plant needs a systematic approach. These formats may be basic but as of now I really need them.
Please help....

Dear Deepti,

Going by what you have written I am little appalled. If no proper controls are there then how much amount of revenue leakage that must have taken place that cannot be imagined.

How come your internal auditors also did not raise their objections on various counts? Recently I conducted training programme on "Warehouse Management". Though the programme was at Bangalore, two Chartered Accounts had flown all the way from Kolkata to attend my training. They attended this training though they were not warehouse managers. Later they told that they wanted to improve internal controls in warehouse operations hence they attended training to acquire subject knowledge.

Operations in cement industry happen through "pull" factor. Therefore, I recommend you approaching some SCM consultant. He will suggest improvement in the systems and process of your logistics, inventory management and above all production.

At this stage you need complete overhaul of your working procedure and establishment of proper systems and processes. By mere introducing few formats your revenue leakage that is invisible may not stop.

Where is your plant located? I will suggest name of one very good SCM consultant. However, he is IITian and your company should be able to afford that person But then for whatever you are doing, do you have sanction of your top management?


Dinesh V Divekar

Beware of false knowledge; it is more dangerous than ignorance.

Dear Deepti,
I have been in the Cement Industry for many many years.
Just getting formats to be filled up shall not help in improving productivity or controlling losses.
Bench marking is essential for comparing data and it depends on type of equipment used and training of operators for Best Practices. An extensive study by experts is necessary to determinr Root Causes and areas for improvement.
Do contact me for guidance if you feel the necessity.
Best Wishes,
Daljit Singh
95555 30663:

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