Project on cement industries

8/8/2019 Project on cement industries

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PROJECT

ON

CEMENT INDUSTRIES

PREPARED BY ±

MBA STUDENT (II SEMESTER



PRODUCTION PROCESS

Quarry: Typically limestone, marl and clays as

well as other materials containing the required

proportions of calcium, silicon, aluminium and iron

oxides are extracted using drilling and blasting

techniques.

Crusher: The quarried material is then reduced in size by

compression and/or impact in various mechanical

crushers. Crushed rock is reduced in size from 120 cm to

between 1.2 and 8 cm. Drying of raw material may also

be necessary for efficient crushing and pre-blending

Conveyor: Raw material is then transported from the

quarry using conveyors, rail wagons or other suitable

logistics solutions specific to the cement plant.



R aw mill: The raw materials are milled and dried in a

roller mill. Heavy rollers are held over a rotating table and

the course material is milled until it is fine enough to be

carried by air to a homogenizing silo.

Filter:

Bag filters comprise filters of either woven fabric or

needle felts to remove particles from kiln exhaust. The

exhaust gas from many kilns is used for drying raw

materials, thus improving the energy efficiency of the

plant



Preheater:

Cyclone preheaters enable the raw material of cement

production to be preheated before entry into the kiln. Thisincreases the energy efficiency of the kiln as the material

is 20-40% calcined at the point of entry into the kiln.

Kiln:

The kiln is designed to maximize the efficiency of heat

transfer from fuel burning to the raw material. In the preheater tower the raw materials are heated rapidly to a

temperature of about 1000°C, where the limestone forms

burnt lime. In the rotating kiln, the temperature reaches up

to 2000°C. At this high temperature, minerals fuse

together to form predominantly calcium silicate crystals -

cement clinker

Cooler:

The molten cement clinker is then cooled as rapidly as

possible. The ambient air used to cool the clinker is then

fed into the kiln as combustion air - ensuring high

utilization of the heat produced

Clink er silo:



Clinker may be either stored on site in preparation for

grinding to form cement, or transported to other sites

Cement mill:

Finish milling is the grinding together of cement clinker,

with around 5% of natural or synthetic gypsum. Other

cementitious materials such as slag, flyash or other

pozzolans may also be incorporated into the final cement

powder

Logistics:

Final cement may be transported pre-bagged or as a bulk

powder. The method of transport selected varies

according to location - and may include transport via

truck, rail or ship.



V

ARIOUSDEPARTMENT

IN

CEMENT

INDUSTRIES



1. FINANCE AND ACCOUNTS

2. MARKETING AND SALES

3. HUMAN RESOURCES AND

ADMINSTRATION



4. TECHNICAL AND OPERATION

DEPARTMENT

5. LOGISTIC DEPARTMENT



6. PROCUREMENT

DEPARTMENT

7. TREASURY

DEPARTMENT



Stores Management

Stock Policy

Stock R ecords

Control and Supervision R eceipt of Stores

Issue of Stores

Stock Check s

Disposal of Stores

Miscellaneous

Stock Policy

establish a stock policy

make the stock policy clearly known to all staff concerned

establish specific written instructions for compliance

specify in the policy :

the types of items that will be stockedthe factors that determine the stock levels

the inventory system to be adopted

Stock R ecords

maintain a complete and proper record of the items in stock with the following particulars

reference and description of each item

quantity and location in the store

expiration date (if any) of each itemdate and quantity of each transaction

current stock balance for all items

properly design and complete store vouchers to capture all necessary details of a

transaction

use sequential numbering control to facilitate checking of store vouchers



properly document and approve cancelled or amended transactions

securely hold all stock records

where a computer system is used, restrict the access to it and control it properly

implement effective information security protocols

Control and Supervision

maintain adequate division of labour between :

issue of goods

receipt of goods

updating of store inventory record

updating of accounting records

clearly define the duties of an officer in charge of a store and make them known

to the staff concerned

establish a procedure for handing over the management or supervision of a store

R eceipt of Stores

put in place adequate physical safeguards in the goods receipt procedure

properly document and account for each goods receipt voucher

establish policies and procedures for handling exceptional matters of goods

receipt

establish written procedures for lodging claims for supply and delivery problems

Issue of Stores

properly document and account for all delivery vouchers

issue store items on a "first in - first out" basis

properly control the issue of goods eg. check the voucher authorisations againsta record of specimen authorised signatures

Stock Check s

conduct regular and surprise stock checks

establish policies and control procedures to cater for stock discrepancies

set appropriate limits of authority for writing off any loss or deficiency of stores



Disposal of Stores

clearly define the items which are to be discarded

establish proper procedures for disposing of these items

Miscellaneous

regularly rotate staff members in more sensitive jobs (for example, stores-receiving staff)

regularly review the physical security of the store

undertake a corruption risk analysis of stores-related computer systems

conduct security checks of vehicles entering or leaving the store area

Total Quality Management and ISO

TQM Summary

Great Visions Consulting has helped very large to very small businesses and organizations in a variety of

industries create simple, cost-effective Total Quality Management programs.

The essential premise of TQM is that quality produces productivity and profitability . Therefore, to increase

your productivity and profitability, you focus on improvements in quality. Quality must exist not only in

your end product or service, it must also be a part of the process you use to create your goods and services.

An effective TQM program will allow you to produce greater quantity, faster and at lower costs, by reducing

your rework rates and cycle times.

Candidly, TQM has a spotty success record in Western business. The reasons for this are a combination of

the managers not understanding and not being committed to the TQM process, the company not having a

disciplined-enough culture to follow the TQM requirements, and an unrealistic expectation that TQM can

work magic or perform over-night turnarounds. In companies where these problems have not been present,

tremendous successes with TQM have been achieved.

TQM is a long term change strategy which requires great discipline and commitment in management. Before

we will contract for any TQM work, we spend significant time with senior management in a no-



fee exploration of TQM's benefits and requirements, so the management team can make an informed

decision as to whether or not to proceed.

If you decide to proceed, we will provide you the tools and training you need to establish and maintain your

own program, without outside consulting assistance after the first several months. Many companies get

hooked by consultants whose processes demand almost a permanent consulting relationship; we believe

that this is inappropriate, unwise, too costly, and even unethical.

Finally, we will help you create a program uniquely tailored to your company. In spite of what some books

allege, we have never seen a "one size fits all" program that works.

I SO 9000 Summary

ISO 9000 is mandated for many businesses intending to do business with members of the European

Economic Community, or with those businesses who do. If you fit into either of these categories, we can

assist you in getting the appropriate ISO 9000 program established in your company.

There is significant overlap between the requirements of TQM and those of ISO 9000. TQM is more

demanding in the area of continuous improvement, while ISO is more demanding concerning the creation of

documentation and the rigorous adherence to the requirements of that documentation.

As a consequence, our consultation assistance for a company pursuing ISO includes most of the work done

for a TQM client, plus assistance in creating documentation, training staff in creating and using checklists to

guide their work, training management to conduct internal ISO audits, as well as specific help in designing

measurement systems which are appropriate to the client's business.

Documents

Project on cement industries