CF Academy - RJM- Nov'12 Thane.pptx

7/28/2019 CF Academy - RJM- Nov'12 Thane.pptx

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09-04-07/SSA/DJ

Clinker factor Reduction

R J Modi

5thNov 2012


2/14

ACC Limited 1

Our journey towards moon ACC ACC - Sep YTDYTD Best performing plant

Baseline2011

ACC Moon

PPC clinkerfactor (Percent)

1

3100 2900

2926

Thermalenergy (Mj/tClinker)3

73.5 61.063.273.3Electricalenergy(kwh/t clinker)4

41.4 32.034.441.0Electricalenergy(kwh/t grind)5

60.0 85.082.158.3CPP PLF(Percent)

6

3081

67.0 60.065.5 62.0

PPC clinkerfactor (Percent)

2 46.3 40.044.18 41.1

Significantprogress inclinker factor,thermalenergy

But nosubstantialimprovementin electricaland CPP PLF

At monthlylevelperformance,

few plantshave alreadyachievedbreakthroughperformance

60.9

39.6

2918

60.5

33.9

82.5

Sep Best performing plant

Board Presentation


3/14


4/14

3

ACC-Q&PD,Thane 02.11-2012

Why SPC?

Appraisal Costs

Verification Quality Audits Inspection

Equipment Vendor rating

Failure Costs

Scrap Rework & rectification Re-inspection Downgrading Waste Failure analysis Customer complaints Warranty claims Liability Loss of goodwill

Prevention Costs

Quality planning Quality assurance Inspection Cost Training


5/14

4


Data Gathering

Raw Mix Pyro

Input

OutputCement

Grinding

Input

Output

Input

Process ControlVariables



Output

QualityAssuanran

ceInterface

Flow of Process

Quality Parameters for which Cpk value to be

measured

Raw Material

Preparation

LSF / TC

R90 Mic/ R212 Mic

Kiln FeedLSF / TC

R90 Mic / R212 Mic

MgO

ClinkerFree Lime

LSF

MgO

CementSO3

R45 Mic

Blaine (PSC)


6/14

5


Daily Weekly MonthlyEvery Shift

Review Mechanism

Process

EngineersShift Operators PPE Head - Production

Process Engineer to

update process control

chart . They should

discuss variations in

control charts with the

Operator during the shift

and log the corrective

action to be taken toeliminate assignable

causes

. The process

control charts to be

displayed inrespective control

room.

Analyze the charts

with the help of

process engineers.

Handover the charge

to the next shift

operator explaining

him about the

variations andcorrective action

taken.

On daily basis review

control charts and

plan for effective

corrective action in

the process and

equipments.

To hold weekly review

meetings with Process

engineers and operators

and ensure

implementation of the

acion plan. Development

of Control plan and

Preparation of SOPs isresponsibility of

Production Dept.

Plant Head

To review progress on

monthly basis with the

team and present status inregional monthly review

meetings.

0.35

0.45

0.55

0.65

0.75

0.85

0.95

1.05

1 3 5 7 9 11 13 15 17 19 21

ParameterValue

Value X avg UCL LCL

Signal


7/14 2012 Legal entity

Reading the heat maps performance snapshot (1/2)

SCCC EE EXAMPLE

6

Raw meal preparation

Clinker production

Cement grinding

Opportunities Reduce false air % Raise kiln NAI

Start tracking fanefficiency in S2 (PH,Baghouse, Coal mill)

Opportunities

Room to raise powerabsorption in mills and

pregrinder/roller-presses Raise MTBF PRI needs to be further

raised Start tracking false air and

fan efficiency in S2

SEEC

upto

Cement

grinding

SEEC

(raw

mate-

rial

prepara

tion)

SEEC

(raw

meal

prepa-

ration)

SEEC

(clinker

produc-

tion)

SEEC

(cement

grinding)

Plant name kWh/t

cementkWh/t

clinkerkWh/t

clinkerkWh/t

clinkerkWh/t

cement

Saraburi 1 - 1.20 - - 55.23

Saraburi 2 90.12 1.55 28.13 23.07 40.91

Saraburi 3 93.17 1.15 28.86 32.98 40.29

Raw

millsMTBF,

hPRI, % NAI,

%False

air, %Fan

eff, %

Power

factor

Sara 2 22.28 95.50 92.41 54.00

Sara 2 18.05 93.90 89.77 31.00

Sara 2 27.58 101.40 93.26 9.00

Sara 2 24.28 98.68 92.06 65.00

Sara 3 27.04 87.71 97.50 23.60 67.50 0.85

Kiln MTBF,

hPRI, % NAI,

%False

air, %

PH1 fan

eff, %

Sara 2 961.94 100.50 81.11 10.82

Sara 2 674.55 101.24 95.89 10.11

Sara 3 321.85 94.09 88.49 9.30 66.91

Cem-

ent

mills

Power

absor-

bed, %

MTBF,

hPRI,

%NAI,

%Power

absorbed

(PG/RP), %

Sara 1 82.50 124.54 90.14 96.33 88.00

Sara 2 84.70 157.18 80.34 98.23 57.90

Sara 2 83.80 96.41 77.59 98.04 56.90

Sara 2 81.30 74.09 73.55 97.65 45.20

Sara 3 80.70 138.41 84.11 92.33 71.00

L2 - Colour coding is based on ranking across all the plants inregion. Top 20% Green, Next 40% Yellow, Next 40% Red

Cement grinding metrics Based on technical standards

L3 Ball mills and vertical mills have different colour codingthresholds

Opportunities Raise MTBF with better

maintenance Monitor and raise power

factor Start tracking power factor

in S2 Lower false air % Monitor/ improve fan

efficiency

L3L2L1


8/14 2012 Legal entity 7

Reading the heat maps performance snapshot (2/2)

Short title, Department, Name/Function or Event/Creator, Date yymmdd, Classification

Opportunity to increase AF, AR consumption by increasing the design capacity of plants working at about 100% design capacity utilization (Ambujanagar 1)

High potential savings through sourcing and increasing AR utilization in plants having good design capacities (Darlaghat, Rauri)

Definition of the

parameterSpecific GAV TSR TEE

Capacity utilization - AF Capacity utilization - AR

OverallSpecific

stock -

AF

OverallSpecific

stock -

AR

Overal

l

Design

Capa-

city

Design

Capa-

city

utiliza-

tion

Planne

d

utiliza-

tion

wrt to

availa-

bility

in

region

Overal

l

Design

Capa-

city

Design

Capa-

city

utiliza-

tion

Planned

utiliza-

tion

wrt to

availa-

bility

in

region

Units Rank CHF/

tons of

Clk.

% % tons/

000' t

clk.

% % % tons/

000' t

clk.

% % % tons/

000' t

clk.

tons/

000' t

clk.

Plant name 4.78 30% 16% 137.81 404% 271% 883% 148.08 361% 132% 100% 5370.88 36705.00

Ambuja Nagar 1 11/26 0.34 4.3% 1.7% 22.02 78.0% 143.7% 26.4% 0.0 23.4%

Ambuja Nagar 2 14/26 0.23 1.0% 0.9% 8.54 13.9% 31.8% 4.8% 0.0 60.0%

Bhatapara 1 15/26 0.22 0.2% -0.1% 0.00 0.0

Bhatapara 2 13/26 0.33 0.6% 0.3% 0.00 0.0

Darlaghat 16/26 0.21 0.9% 0.7% 12.52 17.4% 270.8% 98.8% 83.5 7.5% 129.7% 17.5% 1.54 5.08

Maratha 23/26 0.06 1.3% 0.4% 0.00 122.2% 8.7% 0.0 20.8%

Rabriyawas 25/26 0.00 0.5% 112.1% 73.2%

Rauri 24/26 0.02 NA NA 0.00 68.6 3.0% 34.8% 34.8% 1.67

Performance 2012 Jun YTD data

ACL GEOCYCLE EXAMPLE


9/14 2012 Legal entity 8

Reading of heat maps Practices snapshot (2/2)

Quality of RM

Storage and

handling of

RM

Feeding

Grinding

Others

Oranization

Performance

management

Technology

Plant can

improve clinker

factor with little

capex by

improvingavailability and

storage of raw

materials

Technology can

be an important

lever to

increase clinker

factor, but will

need capex

Practice (L2) Score

Periodic assessment to improve availability of micro fine fly ash (dedicated

grinding mills for available fly ash, assessing new sources)

Minimize usage of aged raw material by using FIFO, traceability

No open storage of clinker, gypsum and other raw material with clear

demarcation for different types to avoid mixing

Maintain fly ash and cement homogeneity with blending arrangements

Monthly optimization of grinding aid dosing rate

Increase degree of automation for fly ash / slag / additive feeding system

using DCS to control dosing

Optimizing mill efficiency using periodical regrading or top ups of the grinding

media, longtitudinal sieving and circuit sampling every 15 days

Optimizing SO3 in cement using frequent sulphation tests

Ensure exhasutive SLAs between GU and mother plants to ensure quality of

clinker supply

Benchmarking of CF across products every quarter

Dedicated cross functional team with a champion on clinker factor

Separate team in the plant that is focused determine and developing alternate

sources of mineral components

Review of clinker factor such as in daily operations review, weekly by Head

Plant Operations, monthly by Plant Director

Training calendar and rewards and recognition mechanism

Plants spend time and resources to explore / study impact of technology

changes in mineral component drying, separate grinding of mineral

components, blending and mixing, flyash separation

Sample L3 practices (not exhasutive)


10/14

ACC Limited 9

Academy approach being used to drive performanceimprovement & capability building across plants

Dedicated COEchampions

Module &Handbook

Heat Maps

Facilitation of

plantexcellenceprojects

Model Plant

Key activities

8 full time (3 for EE, 3 for CF & 2 for CPP) has been nominated asCentre of Excellence (COE) Champions to drive improvement acrossplants

Module created for three critical areas EE, CF & CPP as guide book tohelp plants prepare road maps to reach aspiration values

Hand books for training of young engineers and plant teams

Critical performance & practice KPIs for the respective pillar at L1, L2and L3 levels

Plants to use this as a tool to identify opportunity areas

COE Champions to conduct plant visit & facilitate individual plant Observe performance and practices followed through plant walk-

aroundConducting workshop/ training in identified improvement areas

Training centre to be established in the respective model plants (e.g.,Chanda for EE & CPP, Tikaria for CF)

Model plants will also set example for break through performances forthe respective KPIs

1

4

3

2

5


11/14

ACC Limited 10

EAST

SOUTH-WEST

NORTH

Plant

PPC Clinker factorPercent

YTD

SEP

Q4

2012

Diff2011

ACC 65.5 63.767.0

KY1 62.062.064.0

G1 63.065.665.7

G2 63.065.765.2

LK 66.366.467.1

TK 62.062.865.4

SD ---

JL ---

DM ---

BG 70.572.174.5

CH 70.071.668.9

EN ---

W1 72.074.872.1W2 64.065.968.2

CD 64.264.468.9

BE ---

MK 73.076.974.4

KO 62.865.870.6

1.8

0.1

0.0

2.6

2.7

0.8

1.6

-

-

-

1.6

-

3.9

2.81.9

0.2

-

3.0

Q1

2013

Diff

Q1

2013

63.30.4

Q4

2012

63.7

1.8

YTD

Sep

65.5

2011

67.0

ACC PPC Clinker factor

Percent

My

Moon

63.3

61.5

63.0

63.0

66.3

62.0

-

-

-

70.0

67

-

72.064.0

63.5

-

68.0

62.2

0.4

0.0

0.5

0.0

0.0

0.0

03

-

-

-

0.5

-

5.0

0.00.0

0.7

-

0.6

60.0

60.0

64.0

64.0

60.0

62.0

-

-

-

65.5

63.0

-

69.160.0

63.0

-

69.0

60.0

Recommitment towards our aspiration andmini-moons (1/6) x

Difference betweenQ412 YTD 2012 /Q113 - Q412


12/14

ACC Limited 11

EAST

SOUTH-WEST

NORTH

Plant

PSC Clinker factorPercent

YTD

SEP

Q4

2012

Diff2011

ACC 44.2 42.846.3

KY1 ---

G1 ---

G2 ---

LK ---

TK ---

SD 42.742.744.3

JL 42.543.444.6

DM 43.045.150.2

BG 40.041.144.7

CH 44.047.047.5

EN 39.045.049.2

W1 ---W2 ---

CD ---

BE 47.047.249.4

MK 50.053.155.0

KO ---

1.4

-

-

-

-

-

3.0

0.0

0.9

2.1

1.1

6.0

3.1

--

-

0.2

-

Q1

2013

Diff

Q4

2012

42.8

1.4

YTD

Sep

44.2

Q1

2013

41.90.9

2011

46.3

ACC PSC Clinker factor

Percent

My

Moon

41.9

-

-

-

-

-

42.5

42.0

42.0

39.0

42.0

38.0

--

-

46.0

47.0

-

0.9

-

-

-

-

-

2.0

0.2

0.5

1.0

1.0

1.0

3.0

--

-

1.0

-

39.6

-

-

-

-

-

40.0

40.0

40.0

38.0

40.0

40.0

--

-

40.0

40.0

-

Recommitment towards our aspiration andmini-moons (2/6) x

Difference betweenQ412 YTD 2012 /Q113 - Q412


13/14

ACC Limited 12

Two way approach for achieving our aspirations...

ContinuousImprovement

Breakthroughprojects

Use of micro fine fly ash from last field of ESPBeneficiation of fly ash by removing carbon particles by using

latest technologySeparate grinding of fly ash / slagTransfer of surplus mills from Chanda to different locationsOutsourcing of blending of grinding aid for PSCUse of a combination of accelerators and grinding aidUse of modified gypsum / low purity gypsum

Breakthrough activities


14/14

ACC Limited

Lets work rigorously for next four days to prepare a

way out for achieving our aspirations

CF Academy - RJM- Nov'12 Thane.pptx

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