Jinsoo park haneul lee byungdu so yunbae kim department of management information systems department of industrial engineering yongin university sungkyunkwan university samgadong, cheoingu yuljeon, jangangu yonginsi, 449714, korea suwon, 440746, korea. The sustainable concrete plant guidelines are organized according to the five life cycle phases of concrete construction as established in the nrmca sustainability initiatives. Specific heat consumption of clinker production mjtonne clinker 3540 alternative fuel rate incl. The diagrams illustrate the phases and apparatus to make cement and how cement is utilised in the production of concrete for construction. Essential construction kpis to improve profits and. Flsmidth is a world leader in building and maintaining cement plants, and that firsthand experience plays an important role when developing innovative automation solutions that enhance the production capabilities of customers plants. With enhanced processing and intuitive graphical presentations. The production of cement is a highly energy intensive process. Capable of measuring the cement bond in any wellbore fluid environment, the integrity explorer service eliminates the need to unnecessarily add wellbore fluids for evaluation. Performance management starts with figuring out what to measure.
Kpis for measuring performance of production systems for. We have kpis for both common departments as well as all 20 of the us governments major industry. Grinding operation consumes about 60% of total power in cement plants, raw material grinding more than 30%, while coal mill used in cement plant consumes 3%, cement grinding about 40%. Csi key performance indicators data and coverage for fy 201617 issue key performance data coverage indicator kpi % of clinker production climate protection total co emissions gross million tons 11. This paper examines the role of key performance indicators kpis that is believed to influence the environmental sustainability of cement production of pakistan. Aug 15, 2014 capacity utilization capacity utilization of cement companies can be tracked to gauge their operating health. Pdf key performance indicators for sustainable manufacturing. The bhge sbt seal advanced cement bond analysis service provides integrated assessment of cement seal quality for data acquired with the segmented bond tool sbt service. Kpi fy 201011 fy 201112 a climate protection excludes captive power without star cement co. As the worlds largest producer of variable frequency drives vital to modern cement production abb draws on its extensive cement industry knowledge to select the best drives to increase the through put, reliability and energy efficiency of your opera tions. Csi key performance indices cement operation only kpi fy 200809 fy 200910 a climate protection excludes captive power i co 2 emissions gross tonnes 23,546,758 25,950,920.
This paper proposes a set of key performance indicators kpis for evaluating the sustainable manufacturing believed to be appropriate to the cement industry based on the triple bottom line of sustainability. Environmental sustainability decision requires a scientific approach of identifying and prioritization of kpis. These kpis are grouped by both department and industry. History for 40 years, flsmidth has been a pioneer in highlevel expert control. The most common way to manufacture portland cement. Do you know all the kpis for a manufacturing operations manager.
Production and downtime management in cement manufacturing. Weve assembled a list of key performance indicators kpis for the manufacturing industry. Cement plant laboratories check each step in the manufacture of portland cement by frequent chemical and physical tests. Integrity explorer cement evaluation service baker. Cementitious sustainability responsible sourcing data 2015 kpi. For archived information about the csi, please visit here. Key performance indicators kpi are performance assessment tools that identify the extent of achieving the desired parameters in the industrial production lines, which is of major importance for the success of the manufacturing company. The rbt allows the detection of poor cement conditions before perforating enabling proactive, measures to be taken. Kpis and have semantic dependencies are excluded from the selection of kpi candidates.
Production volume 0 50 100 150 200 250 300 350 jan feb mar apr may jun jul aug sep oct nov dec21. A diagram of the process, which encompasses production of both portland and masonry cement, is shown in figure 11. Example kpis for the manufacturing industry, updated for 2020. Here is the complete list of the most important manufacturing kpis and metrics, that we will discuss in this article in every. Pdf impact of financial leverage on firms performance. Key performance indicators for sustainable manufacturing. Since cement is one of the largest consumed materials, it has to be produced in huge amount.
Despite varying concepts, each practice uses key performance indicators kpis to assess, analyze and track manufacturing processes. Capex plans capex plans of large industrial groups leads to a surge in demand. The labs also analyze and test the finished product to ensure that it complies with all industry specifications. Key performance indicators for production monitoring. The kpi database helps you to find the right key performance indicators categorized by business framework, by industry and by process. Integrity explorer cement evaluation service baker hughes. This makes the service ideal for evaluating contaminated, lightweight, and foam cement slurries. Cement plant performance optimization benchmarking. The cement dedicated to making a difference sustainability. From the limestone quarry to the delivery of the end product, follow every step in the cement manufacturing process. Critical success factors for cement industry in india. You might think that participation incentives in any industry would primarily be based on financially rewarding employees. Overview of cement production cement is an important construction ingredient around the world, and as a result, cement production is a significant source of global carbon dioxide co2 emissions, making up approximately 2. The matrix classifies production systems for the production of multifamily residences along two dimensions.
The bhge integrity explorer cement evaluation service provides accurate information that helps operators gain an understanding of the cement bondregardless of weight or contaminationto make critical downhole decisions with confidence. Csi additional key performance indicators 2016 lafargeholcim. Kpi library key performance indicators kpi examples. This statistic shows the worldwide cement production, by major producing countries, from 2015 to 2019. For this study 23cement producing firms working out of these 18 are consolidated in the. In the cement production line, producing 1 ton of cement need grind at least 3 tons of materials including raw materials, fuel, clinker, mixed materials,gypsum. In addition to the traditional 3 ft amplitude and 5 ft vdl, the rbt has a radially. Cement production and downtime management pims, mes for cement processing plants analyze your production and performance kpis. Diversified and complicated manufacturing sites make optimal scheduling of production lines difficult. The production of cement involves a 5 stage, linear process that begins with the mixing of raw materials and culminates in the packaging of new cement. Its size, rigid isolator and powerful transmitter allow robust operations. Due to the gradual phasing out of the subsidies and the scarcity of these fuels domestically, using natural gas. The cost of cement plants is usually above 150m per million tonnes of annual capacity, with correspondingly high costs for modifications.
Manufacturing process lafarge in south africa cement. The cost of a new cement plant is equivalent to around 30 years of turnover, which ranks the cement industry among the most capital intensive industries. Driving supply chain improvement in the concrete industry. Each of the life cycle phases is further broken down into individ. There is a lack of quantitative kpis to measure performance at a strategic level. Models of future iea, csi, mckinsey, ccap, others all identify the same 4 levers for co2 control alternative fuels replacement of clinker. Conclusions the cement industry is an intensive consumer of natural raw materials, fuels, energy, and high pollutant emitting industry. However, a process of mentorship is one of the best motivators available. The following data has been collated against the sustainable construction forum scf key performance indicators kpis and targets, and is compliant with the requirements of the building research establishment bre environmental and sustainability standard bes 6001, issue 3. Each kpi within the template has been selected by manufacturing professionals, providing a best of breed set of kpis to optimise for your own use.
We discuss the construction kpis and critical metrics your company should be measuring to affect profits and productivity. Figure 1 control pyramid of business objectives figure 2 cascaded objectives to achieve the business purpose. Section 2 summarizes california cement industry statistics section 3 provides an overview of the cement production process. Key performance indicators identification and prioritization.
Cement evaluation radial bond tool baker hughes, a ge. You will be redirected to the full text document in the repository in a few seconds, if not click here. Net emissions from raw materials, kiln fuels and nonkiln fuels, excluding co2 from onsite power generation, divided by own clinker production. Gcca sustainability guidelines for the monitoring and reporting of. Sbt seal advanced cement bond analysis service baker hughes. Physical asset management the purpose of most equipment in manufacturing is to support the production of product destined to downstream customers. Global cement production top countries 2019 statista. Driving supply chain improvement in the concrete industry martin clarke chief executive, british precast. Lowcarbon roadmap for the egyptian cement industry 3 up until 2014, the egyptian cement industry principally used statesubsidised natural gas and heavy fuel oil to fire their kilns. This study is an attempt to set up a stochastic relationship between financial leverage and firms performance of cement industry operating in pakistan. A read is counted each time someone views a publication summary such as the title, abstract, and list of authors, clicks on a figure, or views or downloads the fulltext.
Carbon costs will be a major production cost in the future. Cement is seldom used on its own, but rather to bind sand and gravel together. Key performance indicators kpis are accessed from a smart database datapro, including configurable events such as. Cement plant key performance indicators cement fuels scribd. They give manufacturers valuable business insights to meet their organizational goals. Our recommendation engine offers suggestions for performance indicators and measures based on your business process and interests.
The kpis are then used to develop an evaluation model of sustainable manufacturing. The remainder of this report is organized as follows. Key performance indicators means factors by reference to which the development, performance or position of the business of the. Informs webinar shows the relevance of key performance indicators in cement logistics and supply chain management register now. Even if an organization does not employ formal continuous improvement initiatives, efficiency gains can still be realized by borrowing lessons learned through the visual. The cement industry is considered of strategic industries. Llc i co 2 emissions gross tonnes 25,740,501 27,469,355 26,187,142 28,3,152 ii co 2. Key performance indicators need to be simple and focused 75% people trained to practitioner level. List of key performance indicators kpi cement co2 protocol. The production of cement in india started in 1889 by company based in kolkata. Ielts task 1 process cement and concrete production.
Thus, it is essential to evaluate the sustainable manufacturing in this industry. These kpis are further categorized into seven major groups. Monitoring frequency and service modules are customizable so plants can match them to their own site requirements. A cement is a binder, a substance used for construction that sets, hardens, and adheres to other materials to bind them together. This paper has developed a set of key performance indicators kpis for sustainable manufacturing evaluation in cement. The balance of domestic cement production is primarily masonry cement. Cement plant key performance indicators free download as pdf file. Cement provides the chemical bonds that hold the other materials together to form a dense rocklike substance. Specific heat consumption of clinker production mjtonne clinker. Both of these materials are produced in portland cement manufacturing plants. Evaluates the widest range of cement weights in the industry. Egypt has increased cement production from 4 million tons in 1975 to 46 million tons in 2009, and now accounts for around 1. The 75 kpis every manager needs to know published on.
Production planning kpis assist in effective evaluation of all aspects of the product life cycle right from product design and development, product management, employee training, product quality control, facility management, to product packaging and dispatch. The cement industry is likely to use the ccs infrastructure developed for the power sector. Key performance indicators for sustainable manufacturing evaluation in cement industry. Identify how downtime is affecting your production targets, and get decision support on what actions to take for improving the performance. A manufacturing kpi or metric is a welldefined measurement to monitor, analyze and optimize production processes regarding their quantity, quality as well as different cost aspects. The cement dedicated to making a differencesustainability initiative howard klee ficem coprocessing forum coral gables, florida. A hydraulic cement made by finely powderising the clinker produced by calcining to incipient fusion a mixture of argillaceous and calcareous materials. A unique set of kpis aimed at the manufacturing and engineering industries. Cement plants performance levels to maintain smooth system operation. History for 40 years, flsmidth has been a pioneer in highlevel expert control systems for cement applications. The world consumption of cement is rising at an increasing rate creating significant levels of pollution and.
This paper proposes a set of key performance indicators kpis for evaluating the sustainable manufacturing believed to be appropriate to the cement industry. Cement mixed with fine aggregate produces mortar for masonry, or with sand and gravel, produces concrete. Dust emissions contribute about 6% of the pm 10 in greater cairo reaching as much as 30% in. It is so simple with the industry compared to major industries, and depend on the availability of the necessary raw materials for it. Concrete is the most widely used material in existence and is only behind water as. The analytical hierarchy process ahp methodology is. Key performance indicators kpis are a vital tool for measuring businesswide performance and are longestablished within sales, financial and operational departments. Ecsprocessexpert is a development of ecsfuzzyexpert, which was the first expert system engineering platform in the cement industry. Our commitment to quality performance is demonstrated by our rigorous adherence to the lafarge quality technical standard and iso 9000 series certification. Buy production kpi benchmarking dataasaservice products from opsdog. These kpis track performance in areas such as production costs, labour costs, production losses and cycle times. Weve assembled a collection of key performance indicators kpis and metrics. Cement is on the radar of all policy makers around the world. Key performance indicators for co2 and energy in cement.
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