Improving plant performance through          Operational ExcellenceCement industries
If you’re in the Cement industries    you need the right strategy                                        Cement Industries...
Mattcons approach towards                                          Operational Excellence.                                ...
Pick our brains before Making your next move.                                  E-mail : dsahoo@mattcons.com If you are int...
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Cement plant catalog for operational excellence

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OE Catalog For Cement Plant

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Cement plant catalog for operational excellence

  1. 1. Improving plant performance through Operational ExcellenceCement industries
  2. 2. If you’re in the Cement industries you need the right strategy Cement Industries The Cement industry is a capital-intensive, high fixed cost proposition. The capital cost of a new Greenfield project could be about 3-5 years of revenue. On the demand side, the cement industry in India faces an oversupply scenario and is prone to high demand variability across months and across regions. This is so, since, cement consumption is impacted by several macro-economic factors like monsoon, industrial growth, savings rate, interest rate, governmental policies etc. The cement industry is teeming with competitors, the pie is getting smaller, big fish are eating the smaller ones, and there is no place for players who aren’t ready to innovate, change and look at the current economic downturn as an opportunity. The future looks good – it is the present that needs attention. The only way an organization can survive this turmoil is by adopting the right approach. This is the challenge most CEOs of well-run cement companies in India are facing today When companies go through testing times due to a market slowdown, the morale and energy levels of employees go down more than proportionally.Major Challenges & Opportunities Whereas, this also happens to be the time when these are needed the most to exploit improvement and cost reduction opportunities. Volatile Commodity Market. Utilizing Maximum plant efficiency. Fortunately, there are leaders who convert this threat into an opportunity and Faster time to market and Delivery. drive the organization to the next level of operational excellence. For such leaders, there is never a dearth of approaches. Higher Energy Consumption. Competition for self space. Unplanned down time of process and Survival of the fittestequipment was very high. Higher Level of Solid Wastes inOperation process. Performance Improvement through OE High demand variability across Operational excellence model helps achieve business goals while loweringmonths. costs and improving cycle times. It standardizes processes and integrates Shortage of Skilled Manpower in operations across multiple channels of supply and distribution, supportingOperation Process such as Engineering high-volume, low-margin business strategiesand Production. The Mattcons consulting team assists its clients to increase the value of their corporation, division, or individual facilities. Our consultants are focused Cement industries specialist and have developed cutting edge methodologies for the analysis and integration of business solutions that withstand market cycles, and aims to maximize the enterprise value to the shareholder.
  3. 3. Mattcons approach towards Operational Excellence. Value Proposition Increasing Profitability and Cash Flow Mattcons strategies, tools and techniques and our methodologies designed for improving business performance, improve equipment uptime (OEE), reduce scrap,Our Expertise improve yield, improve quality & productivity, accelerate set-up/change-over times, reduce lead times, optimize inventory.At Mattcons We look beyond costmanagement and focus on maximizing Driving Culture Changethe income-generating potential ofemployed capital. Our Consultants have Companies who successfully leverage operational excellence as part of a strategicdeep experience helping clients achieve platform for growth often achieve market performance well beyond their nearestand accelerate growth in their core competitors. We can help you how to expand continuous improvement into non-business and beyond. Combining manufacturing areas, how to enhance sales force productivity, how to optimize thecreativity and analytical insight with maintenance activities and enforcing the employees in all level.client engagement, our approach helps Supporting Growth Initiatives and New product developmentclients overcome both external andinternal barriers to growth. We will share best practices for applying process excellence to new product development and commercialization, Efficient product development processes closely integrated with the operational processes . You will gain important advantages, such as reduced lead time to market, improved quality and increased development capacity.Key Results Beyond the Basics Reduce Manufacturing Cost by 20 % Many manufacturing organizations need to expand continuous improvement Number of Breakdown reduced by 50% throughout the enterprise and seek training to expand capabilities into marketing, OEE improved by 30 % customer service, engineering ,new product development and quality control. Reduction Defective Products by 50% Supply Chain Management : The Real Improvement Customer Complain down by 60% Inventory down by 30% The complex and often costly internal supply chain processes is one area that manyMajor Accidents reduced by 100% businesses seek to improve. By “killing complexity” in the overall supply chain system,Improvement of Suggestion 10 times companies will experience better, faster delivery with lower costs . Improve 5S score by 80%Reduce Energy Consumption by 20% Focus on Maintenance : Key for enhancing Profitability . Proper maintenance of plant equipment can significantly reduce the overall operating cost, while boosting the productivity of the plant. Hence another perspective of looking at maintenance function is not only to maintain but also to enhance the process or the plant operation system as a result of turnaround planning.MethodologiesTPM, 5S and SMED It is a program Lean Manufacturing that is more than just worthwhile. Value Chain and Value added analysis Management SystemStrategic Alignment Return Over Investment (ROI) RCM and TQM 10 to 33+ Folds of investment in Consulting fees.
  4. 4. Pick our brains before Making your next move. E-mail : dsahoo@mattcons.com If you are interested in scheduling a no obligation 30 minute consultation to Phone : +91 - 902.900.5850 discuss any performance improvement. please contact:More About Mattcons MATTCONS Offering’s"We partner with clients in allsectors and regions to identify Management Consultingtheir highest-value opportunities, Lean Manufacturing Total Quality Managementaddress their most critical Reliabity centered Maintenance Supply Chain Managementchallenges, and transform their  Total Quality Management Operational Excellencebusinesses. Our winning  ISO Series Total Productive Maintenance.combination of local know-how,international orientation and Technical Consultingcustomized approach ensures that Vibration Analysis Motor Current Analysisour clients achieve sustainable IR - Thermography NDT techniquescompetitive advantage, build more Wear debris analysis Rotor balancingcapable organizations, and securelasting results. We seek to be Green Consultingagents of change—for our clients, Carbon Risk Management Carbon Pricingour people, and society broadly” Carbon Fund Management Carbon Neutrality Carbon Portfolio Valuation Carbon Rating (MATCARATS) Training and Certification Courses Public Seminar and Workshop Organization Development On -site Training (OST) Change Management On Job Training (OJT) Online Certification Courses Process improvement Certification Courses Projects Project Management Technical Support Pre project Engineering Services Decommissioning Contact Us Engineering Services Environmental services Construction and Field services +91-22-412-36302 Maintenance Products askus@mattcons.com CMMS - Computerized Maintenance management software . www.mattcons.com Operation Outsourcing  Operation Outsourcing  Manufacturing Outsourcing Mattcons Services Private Limited. Waghbill Naka, GB Road, Thane (West), Mumbai - 400607 Regd. Office – Kalyan Nagar, Pallahat, Khurda, Orissa, India – 752055

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