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CTM data automation

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Compressive testing machine (CTM) measures an important physical property of cement. Here is a way to automate the lab equipment quality data of compressive strength, which is the need of the hour.

The compressive strength of cement; is a property viewed by the user of cement an important attribute for selecting a brand and to judge the superiority of a product. It is that property of cement which is tested at the age of three days, seven days and 28 days. One sample per hour and composite sample per shift and then one sample each for one full day of 24 hours is the minimum frequency of testing. Depending on the number of kilns, mills and packing plants, the number simply goes exponentially high. The samples such tested are huge and if automated can reduce considerable work load on the manpower of any plant.

Information Technology-based tools coupled with instrumentation can be used to automate the entire operation of laboratory physical and chemical testing. In case where there are multi-location plants like ACC, Ambuja, UltraTech and Shree, Dalmia Bharat, etc., monitoring the data of compressive strength from one central location is cumbersome, bit difficult and time consuming, mundane job but necessary. There an automated process for such monitoring is a boon.

Present scenario
Today the practice followed is that an operator in the laboratory generally undertakes the breaking of mortar cubes on analog / digital CTM machines. Some of the modern plants have installed digital machines but sizable number of plants have old analog machines. The operator checks the strength on the digital display or on dial. Then notes down the figure in the notebook or any register. Such data is kept as stated above for hourly, average sample per shift, average sample, per kiln, per mill per day, etc. It is a massive data that is handled by the laboratory personnel manually.

If the company is operated at several locations then the data is collected and send to one central place. At many of the units the entire operation is still manual or partially automated. In the present environment the operation can be fully automated using IT tools and instrumentation. The data, which is repeatedly entered manually in various registers, gives a chance for manipulation can be easily avoided. Use of excel spread sheets can provide a tool for various kind of analysis, which is a plus point.

Though the initial cost may be slightly higher but in the long run it is in the interest of the operating plant to have such kind of system. One such exercise has been successfully carried out by Drishti Software Solutions based at Kolhapur for a multinational large cement manufacturer in the country. The results are quite encouraging.

  • Limitations of a manual system
  • Data distributed across many systems/formats
  • Multiple environments/ multiple locations
  • No integrated reporting
  • Data volume is extremely high
  • Tedious to make some trend reports

Questions before top management:

  • What has been my strength and test results in different geographies/over a period of time?
  • Which are our high/low strength performer?
  • What is the real-time scenario?
  • How we can reduce time to prepare a report or to collect strength data?
  • On what time we were very low in strength and at what time we were best?
  • What are the areas of low strengths and how are they improving?

Automated system can provide:

  • Facility to record, the sample collection data with a unique Sample ID
  • Physical and chemical test register generation
  • Direct input of test data value to selected sample
  • Averaging of cube breaking data
  • Discarding or inconsideration of cube peak force facility
  • Pace or momentum capture facility
  • Report generation, alerts mechanism, analytical reporting Ranking – Top 10, Last 10
  • Aggregation – (Effective strengths, average value for a given samples, standard deviation, trend analysis)
  • Comparison – last batch v/s current batch
  • Access to detailed and aggregate data
  • Different departments gets to look at same data in different dimensions
  • Graphical representation of data

Business benefits

  • Fast decision making
  • Integration of data across all location
  • Summary of data has a real value to organisation
  • Historical data converted to information holds key to understanding the trend
  • Low maintenance cost

This information/article is based on the inputs given by Abhay Hukkeri of Drishti Software Solutions. He can be reached at drishtisv@gmail.com

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Steel: Shielded or Strengthened?

CW explores the impact of pro-steel policies on construction and infrastructure and identifies gaps that need to be addressed.

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Going forward, domestic steel mills are targeting capacity expansion
of nearly 40 per cent through till FY31, adding 80-85 mt, translating
into an investment pipeline of $ 45-50 billion. So, Jhunjhunwala points
out that continuing the safeguard duty will be vital to prevent a surge
in imports and protect domestic prices from external shocks. While in
FY26, the industry operating profit per tonne is expected to hold at
around $ 108, similar to last year, the industry’s earnings must
meaningfully improve from hereon to sustain large-scale investments.
Else, domestic mills could experience a significant spike in industry
leverage levels over the medium term, increasing their vulnerability to
external macroeconomic shocks.(~$ 60/tonne) over the past one month,
compressing the import parity discount to ~$ 23-25/tonne from previous
highs of ~$ 70-90/tonne, adds Jhunjhunwala. With this, he says, “the
industry can expect high resistance to further steel price increases.”

Domestic HRC prices have increased by ~Rs 5,000/tonne
“Aggressive
capacity additions (~15 mt commissioned in FY25, with 5 mt more by
FY26) have created a supply overhang, temporarily outpacing demand
growth of ~11-12 mt,” he says…

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Price hikes, drop in input costs help cement industry to post positive margins: Care Ratings

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Region-wise,the southern region comprises 35% of the total cement capacity, followed by thenorthern, eastern, western and central region comprising 20%, 18%, 14% and 13%of the capacity, respectively.

The cement industry is expected to post positive margins on decent price hikes over the months, falling raw material prices and marked drop in overall production costs, said an analysis of Care Ratings.

Wholesale and retail prices of cement have increased 11.9% and 12.4%, respectively, in the current financial year. As whole prices have remained elevated in most of the markets in the months of FY20, against the corresponding period of the previous year.

Similarly, electricity and fuel cost have declined 11.9% during 9M FY20 due to drop in crude oil prices. Logistics costs, the biggest cost for cement industry, has also dropped 7.7% (selling and distribution) as the Railways extended the benefit of exemption from busy season surcharge. Moreover, the cost of raw materials, too, declined 5.1% given the price of limestone had fallen 11.3% in the same aforementioned period, the analysis said.

According to Care Ratings, though the overall sales revenue has increased only 1.3%, against 16% growth in the year-ago period, the overall expenditure has declined 3.2% which has benefited the industry largely given the moderation in sales.

Even though FY20 has been subdued in terms of production and demand, the fall in cost of production has still supported the cement industry by clocking in positive margins, the rating agency said.

Cement demand is closely linked to the overall economic growth, particularly the housing and infrastructure sector. The cement sector will be seeing a sharp growth in volumes mainly due to increasing demand from affordable housing and other government infrastructure projects like roads, metros, airports, irrigation.

The government’s newly introduced National Infrastructure Pipeline (NIP), with its target of becoming a $5-trillion economy by 2025, is a detailed road map focused on economic revival through infrastructure development.

The NIP covers a gamut of sectors; rural and urban infrastructure and entails investments of Rs.102 lakh crore to be undertaken by the central government, state governments and the private sector. Of the total projects of the NIP, 42% are under implementation while 19% are under development, 31% are at the conceptual stage and 8% are yet to be classified.

The sectors that will be of focus will be roads, railways, power (renewable and conventional), irrigation and urban infrastructure. These sectors together account for 79% of the proposed investments in six years to 2025. Given the government’s thrust on infrastructure creation, it is likely to benefit the cement industry going forward.

Similarly, the Pradhan Mantri Awaas Yojana, aimed at providing affordable housing, will be a strong driver to lift cement demand. Prices have started correcting Q4 FY20 onwards due to revival in demand of the commodity, the agency said in its analysis.

Industry’s sales revenue has grown at a CAGR of 7.3% during FY15-19 but has grown only 1.3% in the current financial year. Tepid demand throughout the country in the first half of the year has led to the contraction of sales revenue. Fall in the total expenditure of cement firms had aided in improving the operating profit and net profit margins of the industry (OPM was 15.2 during 9M FY19 and NPM was 3.1 during 9M FY19). Interest coverage ratio, too, has improved on an overall basis (ICR was 3.3 during 9M FY19).

According to Cement Manufacturers Association, India accounts for over 8% of the overall global installed capacity. Region-wise, the southern region comprises 35% of the total cement capacity, followed by the northern, eastern, western and central region comprising 20%, 18%, 14% and 13% of the capacity, respectively.

Installed capacity of domestic cement makers has increased at a CAGR of 4.9% during FY16-20. Manufacturers have been able to maintain a capacity utilisation rate above 65% in the past quinquennium. In the current financial year due to the prolonged rains in many parts of the country, the capacity utilisation rate has fallen from 70% during FY19 to 66% currently (YTD).

Source:moneycontrol.com

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Wonder Cement shows journey of cement with new campaign

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The campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV…

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Cement manufacturing company Wonder Cement, has announced the launch of a digital campaign ‘Har Raah Mein Wonder Hai’. The campaign has been designed specifically to run on platforms such as Instagram, Facebook and YouTube.

#HarRaahMeinWonderHai is a one-minute video, designed and conceptualised by its digital media partner Triature Digital Marketing and Technologies Pvt Ltd. The entire journey of the cement brand from leaving the factory, going through various weather conditions and witnessing the beauty of nature and wonders through the way until it reaches the destination i.e., to the consumer is very intriguing and the brand has tried to showcase the same with the film.

Sanjay Joshi, executive director, Wonder Cement, said, "Cement as a product poses a unique marketing challenge. Most consumers will build their homes once and therefore buy cement once in a lifetime. It is critical for a cement company to connect with their consumers emotionally. As a part of our communication strategy, it is our endeavor to reach out to a large audience of this country through digital. Wonder Cement always a pioneer in digital, with the launch of our IGTV campaign #HarRahMeinWonderHai, is the first brand in the cement category to venture into this space. Through this campaign, we have captured the emotional journey of a cement bag through its own perspective and depicted what it takes to lay the foundation of one’s dreams and turn them into reality."

The story begins with a family performing the bhoomi poojan of their new plot. It is the place where they are investing their life-long earnings; and planning to build a dream house for the family and children. The family believes in the tradition of having a ‘perfect shuruaat’ (perfect beginning) for their future dream house. The video later highlights the process of construction and in sequence it is emphasising the value of ‘Perfect Shuruaat’ through the eyes of a cement bag.

Tarun Singh Chauhan, management advisor and brand consultant, Wonder Cement, said, "Our objective with this campaign was to show that the cement produced at the Wonder Cement plant speaks for itself, its quality, trust and most of all perfection. The only way this was possible was to take the perspective of a cement bag and showing its journey of perfection from beginning till the end."

According to the company, the campaign also marks Wonder Cement being the first ever cement brand to enter the world of IGTV. No other brand in this category has created content specific to the platform.

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