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Shaping Manpower Development

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Unless the different ranks of technicians and other staff working in cement plants keep themselves updated with innovations, it will be difficult for them to continue in their jobs. BHASKAR AGATE shares his views.

Cement automation and process control have now considerably advanced, and cement plants have been well-equipped with a number of capital-intensive expert systems.

The FLS Advanced process control for the cement industry ensures that cement plants perform better, resulting in increased stability and higher profitability. A few direct and indirect benefits are enumerated below.

Direct Benefits: Up to 8 per higher production; up to 6 per cent lower fuel/energy consumption, up to 30 per cent lower standard deviation of quality, Payback of investment in less than a year (depending on specific applications); Indirect Benefits: Long-term stability ? Reduced equipment wear; minimised downtime and reduced maintenance costs.

Similarly, Siemens offers CEMAT, a process-control system for the cement industry. ABB also uses process control and automation solutions for cement plants.

However, in the current competitive environment, plant managements have been forced to downsise and restructure their technical staff; and also to make them ready to operate the aforesaid costly systems effectively.

When it comes to enhancing competitiveness, the management focus is on the 4 ?M?s (Men, Materials, Machines and Money). As far as developing technical staff, normally Human Resource Heads of the cement plants or corporates look for a low-cost trainer who can give quality training input to their technical staff. It is well understood that training is an investment that is very much essential to upgrade employees.

In fact, it has been experienced that these technical people who are either rotated within the various sections of the plant during restructuring or directly operate from the Central Control Room (CCR), are seldom exposed to structured input on cement quality and process control measures. Monitoring the number of processes and quality parameters together; and to take verities of operational & process control corrective actions is a challenging task for technical staff, as well quality control staff of the laboratory, but nevertheless, expert systems robots have been provided to them.

The middle and the higher level of management get comparatively better exposure but they do not have these expert systems at their fingertips. Seasoned cement engineers would recall during age old times, cement quality used to be secret and the process function was totally camouflaged or at infancy stage. Perhaps the only higher level of management was knowledge upgradation and they used to keep everything up their sleeves. Now the scenario has changed and everything is available to learn and apply with a touch of finger.

The first line technical staff – including artisans – need to be told in simple language, what important role they play on the shop floor, to impart them sound theoretical and practical understanding of basic knowledge on cement quality and process control activity and its real application in enhancing their skills as well as process effectiveness. This would certainly help the organisations in achieving their goals and objectives in the long run.

Appreciating the stated need, it is better to customise programmes for these categories of technicians to help them as well as the plant management. Some of the key subject initiatives to be covered are as under.

Cement Quality & Process Control
The efficiency of pyro-processing (kiln section) is adjudged by its most important parameter i.e., specific fuel consumption expressed in terms of Kg.cal.per Kg . clinker. Different types of world-class pyro-processing systems that are operating in India are provided with computer-based systems for efficient operation; however, the lack of knowledge, clarity in understanding and poor way of monitoring the process results in lower production at higher cost and higher power consumption as well. This is not acceptable to any organisation in the present era of competitive market.

There are a number of process and operating parameters and equipment in the overall upstream & downstream of a Pyro-processing System including raw material and cement quality, and process parameters which are required to be monitored and optimised for the stable running of a cement plant and its profitability.

In fact, everyone working in cement plant need to be aware of this aspect and develop sensitivity towards these parameters.

Why attend?
Artisans (fitters, welders, HEOs, diesel mechanics, MTOs, testing boys, testers) and 1st line supervisors of cements plant have got the necessary skill, but because of thr circumstances, they are required to be relocated during restructuring; however, it is essential to upgrade them with basic cement technology and bring to their attention what role an individual artisan plays in their respective skill while performing maintenance jobs and also in turn maintaining cement quality and process efficiency at its peak operational level with the process control parameters.

Besides the above, the following initiatives are also useful for cement technical staff:
Techno-communication Skill
In various sections of a cement plant, a lot of data is normally generated and analysed so that technical staff are equipped with the analytical tools. To meet this objective analytical tools like Juran Quality Improvement Tools are learnt through:
a)Basic Communication
b)Juran Triology and Introduction to Problem solving.
With this, technical staff can present their findings before the management while problem solving.

Course Methodology
The initiatives indicated abroad should be preferably designed by a well experienced cement engineer who has risen up from the ranks. This would facilitate in healthy interaction with the 1st line technical staff, and overall better learning and sharing. Participants have to work hard and enjoy hands-on work experience by taking down their own notes manually in exercise books and interacting with the Cement Engineer. On completion of such initiatives the technical groups (TGs) should take up small projects under SGA (Small Group Activity) of TPM (Total Productivity Maintenance) and present these projects before their Chief Executive in a monthly meeting. This will ensure their learning and also enhance the confidence level of individuals from their learning stage to become independent teachers and trainers based on their individual potential.

Out of the Box
The initiatives given below may look to be out of the box thinking, but are certainly useful to fresh technicians, school teachers and social club members of a cement plant.

Soft Skills /Skill building Programme
(a)Confidence building through Personality Development Many cement plants are located in isolated areas where they have not got schools as well as ladies? clubs. The school teachers, and members of ladies clubs also need good quality input in soft skills. This in turn would help them impart education to their children.

All the above initiatives have already been implemented in some of the cement plants in India, and the trend is likely expand, as more cement companies carry out their CSR (Corporate Social Responsibility).

About the author:
Bhaskar Agate,
currently based at Pune, was Dy Gen Manager (Tech) at ACC Ltd. He is presently a professional trainer and technical adviser to AIMIL Ltd (New Delhi), and a Process Expert (GSH) at Chennai for PAT (Perform, Achieve and Trade) Audit.

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Process

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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Process

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…

ETBrandEquity

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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Process

In spite of company’s optimism, demand weakness in cement is seen in the 4% y-o-y drop in sales volume. (Reuters)

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Cost cuts and better realizations save? the ?day ?for ?UltraTech Cement, Updated: 27 Jan 2020, Vatsala Kamat from Live Mint

Lower cost of energy and logistics helped Ebitda per tonne rise by about 29% in Q3
Premiumization of acquired brands, synergistic?operations hold promise for future profit growth Topics

UltraTech Cement
India’s largest cement producer UltraTech Cement Ltd turned out a bittersweet show in the December quarter. A sharp drop in fuel costs and higher realizations helped drive profit growth. But the inherent demand weakness was evident in the sales volumes drop during the quarter.

Better realizations during the December quarter, in spite of the 4% year-on-year volume decline, minimized the pain. Net stand-alone revenue fell by 2.6% to ?9,981.8 crore.

But as pointed out earlier, lower costs on most fronts helped profitability. The chart alongside shows the sharp drop in energy costs led by lower petcoke prices, lower fuel consumption and higher use of green power. Logistics costs, too, fell due to lower railway freight charges and synergies from the acquired assets. These savings helped offset the increase in raw material costs.

The upshot: Q3 Ebitda (earnings before interest, tax, depreciation and amortization) of about ?990 per tonne was 29% higher from a year ago. The jump in profit on a per tonne basis was more or less along expected lines, given the increase in realizations. "Besides, the reduction in net debt by about ?2,000 crore is a key positive," said Binod Modi, analyst at Reliance Securities Ltd.

Graphic by Santosh Sharma/Mint
What also impressed analysts is the nimble-footed integration of the recently merged cement assets of Nathdwara and Century, which was a concern on the Street.

Kunal Shah, analyst (institutional equities) at Yes Securities (India) Ltd, said: "The company has proved its ability of asset integration. Century’s cement assets were ramped up to 79% capacity utilization in December, even as they operated Nathdwara generating an Ebitda of ?1,500 per tonne."

Looks like the demand weakness mirrored in weak sales during the quarter was masked by the deft integration and synergies derived from these acquired assets. This drove UltraTech’s stock up by 2.6% to ?4,643 after the Q3 results were declared on Friday.

Brand transition from Century to UltraTech, which is 55% complete, is likely to touch 80% by September 2020. A report by Jefferies India Pvt. Ltd highlights that the Ebitda per tonne for premium brands is about ?5-10 higher per bag than the average (A cement bag weighs 50kg). Of course, with competition increasing in the arena, it remains to be seen how brand premiumization in the cement industry will pan out. UltraTech Cement scores well among peers here.

However, there are road bumps ahead for the cement sector and for UltraTech. Falling gross domestic product growth, fiscal slippages and lower budgetary allocation to infrastructure sector are making industry houses jittery on growth. Although UltraTech’s management is confident that cement demand is looking up, sustainability and pricing power remains a worry for the near term.

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