MSR Kaliprasad, Chief Digital and Information Officer, Shree Cement, shares his ideas about digitalisation with Kanika Mathur.
Digitalisation is revolutionising the cement manufacturing process, driving efficiency, sustainability, and innovation across operations. Understanding the impact of digitalisation on plant performance and efficiency involves getting an insider’s perspective. Through this interview, we endeavour to bring various aspects of technology that are affecting the march towards Net Zero.
How has digitalisation transformed operational efficiency and productivity in the cement manufacturing process?
Digitalisation has revolutionised our operational efficiency and productivity by centralising control and enhancing real-time decision making . Each of our plants has a central control room equipped with SCADA and PLC systems that manage the entire manufacturing process. Key parameters captured from numerous sensors are stored in our IIoT historian, providing a comprehensive view of operations from limestone mining to cement dispatch. This integration has minimised manual interventions and enabled near real-time operational insights through BI dashboards accessible at all management levels. As a result, we have seen significant improvements in process optimisation, resource utilisation and overall productivity, ensuring we consistently meet production targets and deliver high-quality cement to our customers.
Can you share examples of advanced technologies currently being adopted in cement manufacturing, such as AI, IoT, or machine learning?
We are actively integrating advanced technologies to enhance our manufacturing processes. Our platform leverages IoT to collect and store data from various sensors across the plant. Additionally, robotic systems are employed for sample collection, preparation and testing using XRF and XRD machines, ensuring precise quality control. Machine learning and AI are being utilised for predictive maintenance, where models predict equipment failures before they occur, reducing downtime and maintenance costs. Automated process control and blending optimisation technologies deployed in our cement and raw mills enhance efficiency and consistency.
What role does automation play in improving the accuracy and speed of processes across cement production?
Automation plays a critical role in improving both accuracy and speed across our production processes. By automating operations through SCADA systems and PLCs, we ensure precise control over key manufacturing parameters, reducing human error and increasing consistency. Robotic systems used for sample handling and automated testing accelerate quality assurance while providing reliable data. Automated process control further streamlines production, enabling faster adjustments and minimising downtime while maintaining high-quality standards.
How has digitization helped in predictive maintenance for critical equipment in cement plants, and what benefits have you observed?
Digitalisation has been pivotal in shifting our maintenance strategy to a predictive approach. By capturing granular data on key parameters and equipment vibrations, we are building AI/ML models that predict potential failures before they occur. This proactive approach reduces maintenance costs and improves equipment uptime and availability. Predictive models address issues in critical machinery
before they lead to costly breakdowns, enhancing operational reliability.
Could you discuss the impact of digital tools on quality control and consistency in cement production?
Digital tools have significantly improved quality control and consistency in cement production. All quality data, including results from bomb calorimeters, compression strength testing machinery and other equipment, are centrally stored in our historian. This centralised repository enables seamless analysis and reporting, ensuring consistent quality standards across all production stages. Automated testing and
robotic sample handling minimise human error, further enhancing the accuracy and reliability of our quality assessments.
How does your company use digital technology to monitor and reduce environmental impact and emissions?
Our commitment to sustainability is deeply embedded in our digital strategy. We integrate power and production data captured through sensors with SAP S4 HANA, enabling real-time tracking of power efficiency and consumption, optimising energy use across operations. Renewable energy projects, such as the solar plant in Beawar (Rajasthan) and wind plants in Kushtagi and Jath, are monitored digitally to ensure optimal performance. Digital tools effectively help monitor, manage and reduce our environmental footprint, aligning with our sustainability goals.
What challenges have you faced in implementing digital solutions in cement manufacturing, and how have these been overcome?
Implementing digital solutions in cement manufacturing necessitates change management. Transitioning to a digitalised environment required a significant shift in organisational culture and employee mindset. To address this, we launched a capability-building programme to train our workforce at all levels on new technologies and ways of working. Additionally, integrating diverse digital systems like IIoT historian and SAP S4 HANA require meticulous planning and a robust IT infrastructure. We are fostering a culture of continuous learning and investing in our technology backbone with future-ready cloud computing tools that support advanced analytics and AI/ML.
How has digitalisation improved the supply chain and logistics in cement distribution?
Digitalisation has significantly enhanced supply chain and logistics operations. GPS tracking across our truck fleet provides real-time visibility to both our supply chain team and customers via our apps. This track-and-trace capability ensures timely deliveries and improves customer satisfaction. Our ongoing supply chain transformation project leverages digital tools to implement a robust Sales and Operations Planning (S&OP) process. This initiative helps us optimise logistics costs and increase reach while meeting our EBITDA goals. Advanced
network optimisation tools alongside an intelligent GIS platform and a prescriptive order management solution for trade customers ensure effective service at optimised costs.
What impact has technology had on enhancing workplace safety in high-risk areas of cement production?
Technology has played a crucial role in enhancing workplace safety across high-risk areas in cement production. Our Hazard Identification and Risk Assessment (HIRA) system proactively identifies and mitigates potential risks before an incident occurs. Regular safety inspections, mock drills and ongoing training ensure consistency and effectiveness. Our mobile-first ‘boots on ground’ tool empowers frontline personnel to report safety issues directly from the field. The SAP PM module further enhances safety by tracking walk-by inspections, breakdowns and remedial actions in real time. These technologies foster a ‘zero-injury’ culture by ensuring safety protocols are rigorously followed.
Looking forward, which digital or technological advancements do you see as having the greatest potential to shape the future of the cement industry?
Several digital and technological advancements hold immense potential to shape the cement industry’s future. GenAI will scale AI/ML across the value chain, enabling foundation models to be leveraged at all locations without specific ML models. Use cases like cement strength prediction, fineness optimisation and cyclone jamming prediction will further enhance efficiency and quality. Advanced pricing analytics will enable targeted customer strategies to ensure profitability. These advancements, coupled with a customer-centric approach and a future-ready workforce, will keep us at the forefront of innovation in the cement industry.
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