Aspiration Aspiration

Communities 2012 2013

1 Improving Safety Score from 68% to 90 %
2 Improving Electrical Efficiency at Madukkarai Plant 109 99
3 Reduction in Clinker Factor in PPC 71.77 68.2
4 Improving Thermal Efficiency at MDK Plant 3420 3390
Improving Kiln MTBF from 178 hrs to 350 hrs 68 90
5
Improving Kiln OEE from 68% to 90%
6 CPP-PLF Improvement to 90% 60 90
7 Cost reduction through Coal Value chain from 79 Cr to 73 Cr
Improving Mills MTBF from 127.6hrs to 150 hrs
8
Improving Mills OEE from 85.5% hrs to 90%
Yr 2011 Last month No.of action plan total savings No.of action plan
YTD
Achievd (May '12) initiated achieved completed

126.96 123.7
76.9 76.8 10 - 4
3442 3453
320.38 251

56.31 57.79
No.of action plan
in progress

5
Plant name Madukkarai
Improving Electrical Efficiency at Madukkarai Current stage of the project Idea evaluation and implementation
Project Name Plant Project team meeting frequency Weekly
Project KPI Electrical Energy Last date of review by Plant Director 30-May-12
Project start date 1-Feb-12 Date when last version uploaded in central portal 17-May-12

Baseline and aspiration Top ideas implemented / key activities planned so far Date Impact potential Month
Baseline Aspiration 2012 Aspiration 2013 KWH /T Cement June
116 (Best ever achieved) 109.0 99.0 1.Thickener 2 repairs and improving output rate of mills 17-Apr-12 1.8 1.8
2.Temp.based interlocking for KE fan bearing cooling 30-Apr-12 0.0025 0.0025
Current performance 3.EEL & Enexco packer comp.air lines interconnection
30-Apr-12 0.02 0.02
Last month (May '12) YTD
127.0 123.7
4.Reduce the size of pulley for motor 30-Apr-12 0.04 0.04
Project team
Master coach Abhijit Dutta - Sr.GM 5. Optimizing 661 BC 10 /10A with correct rated motor 30-Jun-12 0.013

Project lead/coach R.Venkatesh Dy. Manager , E&I 6.FRP blade for shell cooling fan 15-Jun-12 0.11

Team members K.Pitchai - Manager,E&I 7.Auto drain value usage for compressed air systems. 15-Jun-12 0.23
Navneet Singhal - EA to Director Plant
Athul - Dy.Mgr,E&I 8.Replacement of V-Seperator at VRM 30-Jul-12 2.69
Girish Udupa - Dy. Mgr - Process
Shafi Ahmed - Sr.Engg - Electrical
9.HT motor cooling fan VFD in phased manner 15-Jul-12 0.11
Palanisamy - Electrician
Velumani - Cell Operator 10.Install SPRS/ VFD for KE fan to reduce GRR loss
2.32

11.Install ZSS for all belts 15-Jul-12 0.02

12.VFD for cooler fans in phased manner 15-Dec-12 0.7
13.Replacement of liner plates of CM8
15-Aug-12 2.4
14.Install SPRS/ VFD for KE fan to reduce GRR loss
Plant name Current stage of the project Idea evaluation and implementation

Project Name Project team meeting frequency

Project KPI Last date of review by Plant Director
Project start date Date when last version uploaded in central portal

Baseline and aspiration Top ideas implemented / key activities planned so far Date Impact potential Month
Baseline Aspiration

Current performance
Before After

Project team
Master coach

Project lead/coach

Team members
Plant name Madukkarai Current stage of the project Idea evaluation and implementation
Project Name Improving Thermal Efficiency at MDK Plant Project team meeting frequency Weekly
Project KPI Thermal Energy Last date of review by Plant Director 30-May-12
Project start date 1-Feb-12 Date when last version uploaded in central portal 17-May-12

Baseline and aspiration Top ideas implemented / key activities planned so far Date
Baseline 2011 Aspiration 2012 Aspiration 2013
3,517 3,420 3,390 1. Recuperation efficiency for secondary air 880°C to 950°C by changing the burner pipe 18-Jun-12
position
2. Fine coal Moisture reduction from 3.5% to 2.5% 20-Jun-12
Current performance 3. Bottleneck of all constraints to run kiln on 2250 - 2300TPD 30-Jun-12
Last month (May '12) YTD 4. Replacement of Filter drum water spray nozzles 7-Jun-12
3,442 3,453 5. Insulation lining in cooler take off duct & throat wall 10-Jun-12

6. Installing new Solid flow meter in calciner route to minimize the variation of Kiln feed
Project team quantity 5-Jun-12
Master coach Mr.Abhijith Dutta - Sr.General Manager 7. False air arrested in Topcyclone, DDC and Cyclone 3 9-Jun-12
8. Reducing the moisture in Crusher Dryer by minimizing the water spray in cake Besta feeder 5-Jun-12
Project lead/coach Mr.Rameshbabu - Dy. Mgr, Process by providing
9. New the solenoid
Weighing system tovalve with timer
be installed in Calciner AFR feeding System 31-Oct-12
10. Providing Flow meter in Kiln and SLC oil firing system 31-Oct-12
Team members Ms.Nirmala - Dy.Manager - AFR
Mr.Sunil Pandey - Dy. Manager
Mr.Sivakumar - Dy.Manager
Ms.Sweta Singh - Analyst
Mr.Sivasamy - NMS
Mr.Ayyasamy - NMS
 Idea evaluation and implementation
Weekly
30-May-12
17-May-12

Impact potential
Kcal/Kg Clinker
4.5
2.5
4
1.1
2.3

2.1

3
3.2
2.8
1
Plant name Madukkarai Current stage of the project Idea evaluation and implementation
Project Name Improving Kiln MTBF from 178 hrs to 350 hrs Project team meeting frequency Daily
Project KPI Kiln MTBF Last date of review by Plant Director 30-May-12
Project start date 1-Feb-12 Date when last version uploaded in central portal 18-May-12

Baseline and aspiration Top ideas implemented / key activities planned so far Date Impact potential Month
Baseline Aspiration 2012 Aspiration 2013 Hrs MTBF June
178 300 350
Current performance Thickner 2 : Complete replacement with modified hydraulic Sep-12 24.0
Last month (May '12) YTD arrangement.
SOP of castable recommended by OEM to be followed for
320 251 bullnose Compl
Project team Further Improvement of Bullnose refractory life Oct-12 60.0 60.0
Master coach Abhas Mishra-CM(Maintenance) Induction Preheating arrangement for Burner pipe castable Oct-12 24.0
Improvement of kiln refractory life in 2nd pier area by replacing
2nd pier shell
Project lead/coach Gopichand Keswani Sep-12 120.0
Metallurgical improvement with other suppliers to achieve Dec-12 24.0
Team members Tirupati Rao,DM(Maintenance) enhanced life of the cake besta chain
Yamini Alamelu,DM(Civil) MOC of the clinker hammers to be changed Sep-12 24.0
Sagar Kumar Mangad,DM(mechanical) Heat recuperation zone grate plate support beams & flexible 24.0
joints cleaning must be done in planned stoppage Sep-12
SivaKumar,DM(Prod) Ensuring proper contact between shell and tip casting
Preparation to be carried out with dummy shell blue matching to
Natarajan.S,Asst.foreman ensure proper bolt tightness Sep-12 24.0
RajSekaran,Asst.foreman Alignment of cooler beams, grate frame & cross bar cooler drive
frame must be done once in a year (Key PMR)
Sep-12 12.0
"UT of all supporting rollers and shaft must be carried out
before replacement
Sep-12 24.0
Develop walk by Inspection routes and painted at site for better
understanding of the WBI Check sheet route
Jun-12 Intangible
Prepare Maintenance - Inspection checklist for all equipment
with daily, weekly and monthly maintenance schedules
Compl Intangible
TLM Best practices: Standardization of lubricant types, Reduction
in leakages, Lubrication schedules included in PMRs
Compl Intangible
Plant name Madukkarai
CPP-PLF Improvement to 90% Current stage of the project Idea evaluation and implementation
Project Name Chanda Plant Project team meeting frequency Weekly
Project KPI Plant load factor Last date of review by Plant Director 30-May-12
Project start date 1-Feb-12 Date when last version uploaded in central portal 18-May-12

Baseline and aspiration Top ideas implemented / key activities planned so far Date Impact potential
Baseline Aspiration 2012 Aspiration 2013 % PLF
76 60 90 Providing New Air cooled condenser assembly 30/06/2013 29.0
Consistent Load from Cement Plant Continuous 12.0
Current performance Relay Co-ordination 31/12/2012 0.2
Last month( May '12) YTD Reduction in Aux. Power Comsumption Continuous
56.31 57.79 Proper Mansoon precaution 15/06/2012
Project team Detailed failure analysis & RCFA Continuous
Master coach C Rajkumar - Chief Manager, CPP Field Instruments Protection Completed
Better co-ordination with CCR & reliable operation Continuous
Project lead/coach M Prakash kumar - HOD -CPP Equipment availability Continuous 0.8
Water problem Completed
Team members Vincent Thirumaran- Dy.Mgr.Maint Maintain the PC-7, crusher & screen reliability Completed
Yejas Mohaideen- Dy.Mgr.E&I Availability of adequate quality & quantity of coal Continuous
C Rajalingam- Asst.Mgr.E&I
Vinod Kumar- Dy.Mgr CPP
C Rajalingam- Asst.Mgr.E&I
Senthil kumar- Asst.Mgr- CPP
Rohan Chandak- Asst.Mgr- AFR
Kasi Raju - Asst.Mgr MIPS
Mohd. Ali - CPP
Joseph Jerrot - CPP