Optimizing Production and Maintenance Processes in the Cement Industry

I am presently working in a cement production plant. We face a lot of problems with transportation regarding diesel expenses and maintenance expenses of our trucks. I want to create a weekly or monthly format to control this issue.

Also, I need a format for production in my cement plant. This includes an hourly production format on a weekly basis, as well as an output format for machinery and equipment maintenance.

I would greatly appreciate it if anyone with this knowledge could help me. Thank you.

Dear Deepti,

Your post is a little confusing. The confusion stems from the fact that the cement industry is one of the core industries. However, the queries that you are posing are quite basic. There is nothing more 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, concerning the maintenance of the production schedule or production format in your factory, the production manager is responsible.

Why are these people not working according to the industry requirements? Any production format, whether standard or otherwise, has to be devised on your own, and there is no "copy and paste" solution.

By the way, what is your role there? Are you an employee, or is this your own company?

Ok...

DVD

I have just joined this company. I am working as an administrative head. This plant needs a lot of professionalism. It's a very old plant and now its production output has also decreased.

I need these formats to make this plant run on a system. We are not finding the right people to run our plant. We do not have a logistics department. Everything is done by a 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,

I am a little appalled by what you have written. If no proper controls are in place, the amount of revenue leakage that may have occurred is unimaginable.

Why did your internal auditors not raise objections on various counts? Recently, I conducted a training program on "Warehouse Management" in Bangalore. Two Chartered Accountants flew all the way from Kolkata to attend, even though they were not warehouse managers. They mentioned wanting to enhance internal controls in warehouse operations, hence their attendance to gain subject knowledge.

Operations in the cement industry are driven by a "pull" factor. I recommend engaging an SCM consultant for improving systems and processes in logistics, inventory management, and production.

At this point, a complete overhaul of your working procedures and the establishment of proper systems and processes are necessary. Simply introducing a few formats may not halt the invisible revenue leakage.

Where is your plant located? I can suggest a highly competent SCM consultant, although he is an IITian, so your company should be prepared for the associated costs. Do you have approval from your top management for the actions you are taking?

Thank you,

Dinesh V Divekar

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

Dear Deepti,

I have been in the cement industry for many years. Just having formats to fill up will not help in improving productivity or controlling losses. Benchmarking is essential for comparing data, and it depends on the type of equipment used and the training of operators for best practices. An extensive study by experts is necessary to determine root causes and areas for improvement.

Feel free to contact me for guidance if you find it necessary.

Best Wishes,
Daljit Singh
95555 30663
[singh.daljit@indiatimes.com](mailto:singh.daljit@indiatimes.com)