The document discusses strategies for improving operational excellence in cement industries. It outlines major challenges like volatile commodity markets and high energy consumption. Adopting an operational excellence model can help standardize processes, integrate operations, and support business strategies. Mattcons consultants can assist with increasing value through strategies to improve equipment uptime, reduce costs, drive culture change, and support growth initiatives. Their approach aims to maximize profitability and cash flow through techniques like Lean Manufacturing, TPM, and supply chain management.

1. Improving plant performance through
Operational Excellence
Cement industries

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 fittest
equipment was very high.
 Higher Level of Solid Wastes in
Operation process.
Performance Improvement through OE
 High demand variability across
Operational excellence model helps achieve business goals while lowering
months.
costs and improving cycle times. It standardizes processes and integrates
 Shortage of Skilled Manpower in operations across multiple channels of supply and distribution, supporting
Operation Process such as Engineering high-volume, low-margin business strategies
and 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. 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 cost
management and focus on maximizing Driving Culture Change
the income-generating potential of
employed capital. Our Consultants have Companies who successfully leverage operational excellence as part of a strategic
deep experience helping clients achieve platform for growth often achieve market performance well beyond their nearest
and 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 the
creativity and analytical insight with maintenance activities and enforcing the employees in all level.
client engagement, our approach helps
Supporting Growth Initiatives and New product development
clients overcome both external and
internal 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. 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 all
sectors and regions to identify Management Consulting
their highest-value opportunities, Lean Manufacturing Total Quality Management
address their most critical Reliabity centered Maintenance Supply Chain Management
challenges, and transform their  Total Quality Management Operational Excellence
businesses. Our winning  ISO Series Total Productive Maintenance.
combination of local know-how,
international orientation and Technical Consulting
customized approach ensures that Vibration Analysis Motor Current Analysis
our clients achieve sustainable IR - Thermography NDT techniques
competitive advantage, build more Wear debris analysis Rotor balancing
capable organizations, and secure
lasting results. We seek to be Green Consulting
agents of change—for our clients, Carbon Risk Management Carbon Pricing
our 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
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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 .
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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