Gujarat Ambuja - Redefining Operational Efficiency
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ENHANCING PRODUCTIVITY contd...
After spending two month studying the data available on
kilns from the other plants, the engineers eventually worked out a plan for
kiln modification. After the above plans were implemented, the same kiln
began producing 3500 tonnes per day. With a marginal investment of Rs 24
million, the plant was now producing 0.17 million tonnes more per year.
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To ensure consistency in the quality of material and
kiln temperature, GACL installed a centrally operated computerized process
control system. The system controlled around 3,000 operational parameters to
ensure quality at each step of the production process. The system utilized
raw material management software to evaluate the optimum mix and redesign
accordingly to get consistent quality and optimum utilization of raw
material.
In 1990-91, capacity utilization of the first plant at Ambuja Nagar was
140%. However, GACL's engineers continued their drive to improve capacity
utilization further and installed a 24-hour monitoring system and introduced
weekly checks to check faults before a breakdown occurred for certain key
components. As a result of these measures, capacity utilization went up to
143% that year.
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GACL decided to run its plants non-stop for 40 days
against the industry average of five. This was again inspired by the visit
to the Japanese cement plant, which ran for 100 days continuously. As a
result of all these initiatives, GACL achieved more than 100% capacity
utilization during 1999.
GACL's focus on quality control practices was manifested in its decision to
introduce the practice of reporting quality related data 48 times a day
instead of just once. And to ensure that bags contained the right quantity
of cement, GACL used Zero Error Electronic Rotary machines which checked the
quantity of cement in randomly picked bags. In the case of 50 kg bags, GACL
permitted a maximum variation of 200 gm.
The company also invested around Rs 60 million in pollution control
equipment to limit dust and debris in emissions and dust suppression and
extraction systems at brushing and grinding units. These pollution control
measures led to a significant decline in the plant's repair bills. Since
dust particles cause wear and tear of equipment, the decrease in such
particles led to a sharp fall in the number of breakdowns in moving parts
and gear boxes.
Around 81,000 trees were planted in Ambuja Nagar and an artificial lake was
also built. A portion of an old quarry was reclaimed and converted into a
vegetable garden. Because of the stringent environmental pollution control
norms at its plants, GACL was even able to maintain a rose garden near the
Ambuja Nagar plant.
The conveyor belt set up for the HP plant was totally covered and no
limestone dust escaped into the fragile ecosystem around the conveyor. And
because all three motors for the conveyor belt were located at the plant
site, there were no engine noises and noxious vapors along its entire
length.
CUTTING COSTS - POWER
CUTTING COSTS - FREIGHT
THE FUTURE
EXHIBIT I - GACL - STATE WISE PLANT CAPACITY
EXHIBIT III - VARIOUS AWARDS WON BY GACL
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