Improving plant performance through

Operational Excellence

Cement industries

Cement industries

If you’re in the Cement industries you need the right strategy

Cement Industries The Cement industry is a capital-intensive, high fixed cost proposition. The capital cost of a new Greenfield project could be about 3-5 years of revenue. On the demand side, the cement industry in India faces an oversupply scenario and is prone to high demand variability across months and across regions. This is so, since, cement consumption is impacted by several macro-economic factors like monsoon, industrial growth, savings rate, interest rate, governmental policies etc. The cement industry is teeming with competitors, the pie is getting smaller, big fish are eating the smaller ones, and there is no place for players who aren’t ready to innovate, change and look at the current economic downturn as an opportunity. The future looks good – it is the present that needs attention. The only way an organization can survive this turmoil is by adopting the right approach. This is the challenge most CEOs of well-run cement companies in India are facing today When companies go through testing times due to a market slowdown, the morale and energy levels of employees go down more than proportionally. Whereas, this also happens to be the time when these are needed the most to exploit improvement and cost reduction opportunities. Fortunately, there are leaders who convert this threat into an opportunity and drive the organization to the next level of operational excellence. For such leaders, there is never a dearth of approaches.

Performance Improvement through OE Operational excellence model helps achieve business goals while lowering costs and improving cycle times. It standardizes processes and integrates operations across multiple channels of supply and distribution, supporting high-volume, low-margin business strategies

The Mattcons consulting team assists its clients to increase the value of their corporation, division, or individual facilities. Our consultants are focused Cement industries specialist and have developed cutting edge methodologies for the analysis and integration of business solutions that withstand market cycles, and aims to maximize the enterprise value to the shareholder.

Major Challenges & Opportunities

Volatile Commodity Market.

Utilizing Maximum plant efficiency.

Faster time to market and Delivery.

Higher Energy Consumption.

Competition for self space.

Unplanned down time of process and equipment was very high.

Higher Level of Solid Wastes in Operation process.

High demand variability across months.

Shortage of Skilled Manpower in Operation Process such as Engineering and Production.

Survival of the fittest

Mattcons approach towards Operational Excellence.

Our Expertise At Mattcons We look beyond cost management and focus on maximizing the income-generating potential of employed capital. Our Consultants have deep experience helping clients achieve and accelerate growth in their core business and beyond. Combining creativity and analytical insight with client engagement, our approach helps clients overcome both external and internal barriers to growth.

Value Proposition

Increasing Profitability and Cash Flow

Mattcons strategies, tools and techniques and our methodologies designed for improving business performance, improve equipment uptime (OEE), reduce scrap, improve yield, improve quality & productivity, accelerate set-up/change-over times,

reduce lead times, optimize inventory.

Driving Culture Change

Companies who successfully leverage operational excellence as part of a strategic platform for growth often achieve market performance well beyond their nearest competitors. We can help you how to expand continuous improvement into non-manufacturing areas, how to enhance sales force productivity, how to optimize the maintenance activities and enforcing the employees in all level.

Supporting Growth Initiatives and New product development

We will share best practices for applying process excellence to new product development and commercialization, Efficient product development processes closely integrated with the operational processes . You will gain important advantages, such as reduced lead time to market, improved quality and increased development capacity.

Beyond the Basics

Many manufacturing organizations need to expand continuous improvement throughout the enterprise and seek training to expand capabilities into marketing, customer service, engineering ,new product development and quality control.

Supply Chain Management : The Real Improvement

The complex and often costly internal supply chain processes is one area that many businesses seek to improve. By “killing complexity” in the overall supply chain system,

companies will experience better, faster delivery with lower costs.

Focus on Maintenance : Key for enhancing Profitability.

Proper maintenance of plant equipment can significantly reduce the overall operating cost, while boosting the productivity of the plant. Hence another perspective of looking at maintenance function is not only to maintain but also to enhance the process or the plant operation system as a result of turnaround planning.

Key Results Reduce Manufacturing Cost by 20 % Number of Breakdown reduced by 50% OEE improved by 30 % Reduction Defective Products by 50% Customer Complain down by 60% Inventory down by 30% Major Accidents reduced by 100% Improvement of Suggestion 10 times Improve 5S score by 80% Reduce Energy Consumption by 20%

Methodologies

TPM, 5S and SMED Lean Manufacturing Value Chain and Value added analysis Management System Strategic Alignment RCM and TQM

Return Over Investment (ROI) 10 to 33+ Folds of investment in Consulting fees.

It is a program that is more than just worthwhile.

Pick our brains before Making your next move.

If you are interested in scheduling a no obligation 30 minute consultation to discuss any performance improvement. please contact:

E-mail : dsahoo@mattcons.com

Phone : +91 - 902.900.5850

More About Mattcons "We partner with clients in all sectors and regions to identify their highest-value opportunities, address their most critical challenges, and transform their businesses. Our winning combination of local know-how, international orientation and customized approach ensures that our clients achieve sustainable competitive advantage, build more capable organizations, and secure lasting results. We seek to be agents of change—for our clients, our people, and society broadly”

Management Consulting

Technical Consulting

Green Consulting

Training and Certification Courses

Projects

Maintenance Products

CMMS - Computerized Maintenance management software .

Operation Outsourcing

Operation Outsourcing Manufacturing Outsourcing

Contact Us

+91-22-412-36302 askus@mattcons.com www.mattcons.com

Mattcons Services Private Limited. Waghbill Naka, GB Road, Thane (West), Mumbai - 400607

Regd. Office – Kalyan Nagar, Pallahat, Khurda, Orissa, India – 752055

MATTCONS Offering’s

Lean Manufacturing Reliabity centered Maintenance Total Quality Management ISO Series

Total Quality Management Supply Chain Management Operational Excellence Total Productive Maintenance.

Vibration Analysis IR - Thermography Wear debris analysis

Motor Current Analysis NDT techniques Rotor balancing

Public Seminar and Workshop On -site Training (OST) On Job Training (OJT) Process improvement

Organization Development Change Management Online Certification Courses Certification Courses

Project Management Pre project Engineering Services Engineering Services Construction and Field services

Technical Support Decommissioning Environmental services

Carbon Risk Management Carbon Fund Management Carbon Portfolio Valuation

Carbon Pricing Carbon Neutrality Carbon Rating (MATCARATS)