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5S Initiative at Jawaharpur
5S is a very simple model adopted for keeping the work place in order. Every 'S'signifies different aspects of keeping work place in order viz,
1.Sort (removal of unneeded items from workplace),
2.Systematic arrangement (place for everyth... view more...
Ariyalur Cement Mill Bag House
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Ariyalur enjoys significant cost savings, achieves ambitious goal to reduce power consumption in time
Unit Ariyalur faced tremendous teething problems in the raw mill grinding circuit since it commenced operations in 2009. As the raw material was high in moisture and clay content, it would not flow through. The circuitry would often get jam... view more...
Ariyalur improves Captive Power Plant availability, achieves zero refractory failure
The Captive Power Plant (CPP) at Ariyalur was commissioned in March 2010. Within six months, the CPP faced refractory failure in the Compact Separator Target area, a zone in the boiler through which flue gas flows at very high velocity. Sin... view more...
Case Study - Speed "Trebling of AP Sales in 120 days"
The trade sales in Andhra Pradesh, one of the four states in which Dalmia predominantly operates, had been tumbling over the last two months. On the other hand, the receivables were growing out of control, and there was no sign of recovery.... view more...
Case Study -30 Crores revenue for the Group - Breakthrough accomplished by Sugar Team
The sugar business had set up 3 greenfield, bagasse based cogeneration power plants during 2006-07. These were developed as CDM (Clean Development Mechanism) projects to contribute to climate change mitigation an sustainable development. Th... view more...
Cement Mill No.2&3 Productivity Improved by connecting to available ESP
Cm2 and 3 had been running with high osepa bag filter Dp (>400mmWc) during special cement grinding. Due to this high Dp problem, we are unable give continuous feed to ball mills and thereby production was not achieved beyond 40 TPH Ultim... view more...
Clinker Sales
As you know, the Kadapa Cement Plant, though having full capacity to produce cement of + 5000 tons per day, it is facing a peculiar problem of low dispatches to the tune of 2000 tons on an average per day and not more than that. view more...
Consistent Supply of Limestone To Crusher
Initiative: Increase the supply of limestone to crusher by increasing the transport vehicles to avoid the stoppage of both the kilns in the month of January'10. view more...
Cost Reduction in dewatering Operation @ KVK Mines Pit # 3
In order to meet the requirement of limestone for the DPM plant it has been planned to supply 6% from KVK mines Pit # 3 for the FY 2010-11. But due to the current economic trend prevailing in the cement market it has been decided to reduce ... view more...
Creating a green curtain between new Boiler and bagasse yard.
Cogen power plant at Ramgarh was installed in 2006-07 and was commissioned in Feb 07. Location of power plant was just adjacent to bagasse yard and it was a great nuisance for the working of manpower as well as equipment because of ingress ... view more...
Dalmia Cements HR meets ambitious recruitment goal, on-boards 98 sales personnel in 96 days
In June 2011, the Human Resources team for Sales and Marketing at Dalmia Cements was confronted with a Herculean task! A high employee turnover rate resulting from both involuntary and voluntary attritions meant that 41 replacement position... view more...
Dalmia Chini Mills Unit - Ramgarh
Cogen power plant at Ramgarh was installed in 2006-07 and was commissioned in Feb 07. Location of power plant was just adjacent to bagasse yard view more...
Dalmia Chini Mills Unit - Ramgarh Values at Ramgarh
Cogen power plant at Ramgarh was installed in 2006-07 and was commissioned in Feb 07. Location of power plant was just adjacent view more...
Dalmiapuram eyes higher profit margins with successful trial production of new Cement variety
Masonry cement is a new variety of special cement that generates much higher profits than other ordinary varieties. The Dalmiapuram unit decided to explore the possibility of producing it and adding it to its existing product range. view more...
DCBL Among the Top 50 in the Hewit Best Employer Survey
In the year 2006 the Corporate HR departmental team took a challenge /and pledged to build DCBL as an Employer of Choice. It was decided that the measurability of this initiative would be done through the Best Employer study that takes plac... view more...
DCBL reduces working capital requirements through quick adoption of LTU
The Government of India announced a Scheme to facilitate Large Tax Payers (defined on the basis of Tax deposited) for assessment under Central Taxes (Income Tax, Excise Duty and Service Tax) at single Administrative Office, called Large Tax... view more...
Energy efficiency drive and process improvements save Unit Ramgarh Rs. 2.63 crores per annum
Unit Ramgarh is one of the older plants within the Dalmia Group. With advancements in technology, the existing systems and processes at the plant had become energy inefficient. In 2009-10, electrical energy consumed was 43 Kilowatt hours wh... view more...
Expediting the deliveries of DG set & synchronization panel for CPP, Ariyalur
Initiative: Supply of one DG set & synchronization panel are required at Ariyalur urgently. view more...
Implementation of Document Management System in Projects
The Project Planning and Execution Function had to go through a cumbersome process of distribution, revision, redistribution and finalization of drawings. This led to spending a lot of time on back and forth clarifications. At the same, the... view more...
Improvements to cement packaging process saves time, increases packer output
Unit Kadapa produces several cement grades that are targeted for both trade and non-trade market segments; the packaging for each grade and segment varies. Three electronic packers automatically dispense all cement grades manufactured via 1... view more...
Improving Consistency of Kiln Operation and Production
Initiative
There was a phenomenon of excessive coating in the burning zone, inconsistency in kiln Operation and Production. This was due to incomplete combustion in PC due to coal firing location near kiln inlet view more...
Increments
For the last few years annual increments in DCBL were getting delayed by about three to four months resulting in dissatisfaction among the employees and the executive community. Mr. B B Mehta CEO Sugar raised this issue in a meeting of the ... view more...
Ingenious way to locally source components for plant equipment yields major savings at Dalmiapuram
Background:
Dalmiapuram has five cranes, each equipped with three master controllers for operation and control. The service life of these master controllers depends on the condition of nylon cams present in them. Nylon cams typically last ... view more...
Innovation, Courage and Speed Displayed by Legal Team
For executing the Mining Lease of PTK area in Tamil Nadu State, the government was demanding Stamp Duty on the annual estimated extraction of Limestone for thirty years which was more than the royalty on the entire reserves available. Our ... view more...
Inter-office collaboration ensures timely detection of adulteration, restores supply of quality coal at Kadapa
Coal for all three Dalmia Cement units is purchased by the Chennai office and transported to the respective units. In April 2011, the Quality Control (QC) department at Kadapa observed the quality of coal received was inferior, with low cal... view more...
Investor Relations
Investor relations represent a window of communication for financial markets, an external interface between the company and financial world. IR also includes elements of internal communication, whereby it is able to highlight to its managem... view more...
KHD Case Study Profile
DCVL had released orders for major Plant & Equipment for 5 upcoming projects in Feb 2008 and also released advances, as required. After the economic crisis blew over in Sept 2008, it was decided that no expansion could be taken up in th... view more...
KHD Kiln Upgradation from 1800 TPD to 3000 TPD in Dalmiapuram
Dalmia Cement 's Dalmiapuram unit started its operation in 1939 with a semi dry plant of Polysius - 250 TPD capacity. Subsequently it expanded with FLS 's 500 TPD -Folax and 500 TPD- Unax plants in 1940s and 50s, both wet Process plants. view more...
Kiln inlet trough plate replacement
In the recent Kiln stoppage due to excessive coating i.e. on dated 12/12/2009, We noticed trough plate segments in cooler while emptying the kiln after the coating removal. view more...
Land Acquisition, Kadapa
1970 acres of land was required to be acquired for the new Greenfield Cement plant at Kadappa in Andhra Pradesh. The mandate given to the corporate affairs team in Sep 2007 was that the land should be acquired as soon as possible so that pr... view more...
METICULOUS DETAILING FOR SUGARCANE PURCHASE CENTRE
Our neighbouring sugar factory Rosa Sugar Works, Rosa, has been operating one of our reserved sugarcane purchase centre Ladhauli C from season 2007-08. We have continuously been trying to get our centre back in our favour from The Cane Comm... view more...
Migration of asset accounting into SAP - saves Finance team' significant time & ensures data accuracy
At Dalmia, the process of managing and valuing assets of the company or "asset accounting" in financial parlance, was done manually using Tally or Microsoft Excel, despite the SAP system being in place. This process took about two... view more...
Plant and energy efficiency optimization at Jawaharpur yields overall returns of Rs. 4.57 crores
After the 2009-2010 season ended, Unit Jawaharpur set to analyze the Key Performance Indicators (KPIs) for the past season, and brainstorm to set new KPIs for 2010-11. As the unit assessed industry outlook for the coming season, it was obse... view more...
Plant efficiency increases Production and lowers cost
During a study of mill performance at Dalmia Chini Mills, Nigohi, teams led by Naresh Paliwal, Unit Head and Neeraj Bansal, General Manager - Engineering at the plant observed that bagasse pol (sugar that remains after sugarcane is crushed)... view more...
Pre-Heater Construction
Pre-heater (PH) is the tallest structure in a cement plant. Completion of the civil work for the pre-heater is an important milestone in the construction of a cement plant. Pre-heater is on the critical path of the project and affects the t... view more...
Prevent excessive spillage of cement from the filling nozzles
To increase the effectiveness of plants, it was being contemplated to stop running the old H & B Packer Machine (with only 60 TPD capacity and used for special cement) and avoid heavy spillage of cement in the spillage hopper during pac... view more...
Project Completion Report Kadapa
We initiated for project completion Report for Kadapa project in May 09 and started implementation in July 2009. The importance of this document is really high, because the kind of information in the document will work as guide to improve ... view more...
Quick Restoration of Plant Operations after an unexpected Failure
Initiative: Kadapa Cement Unit faced an unusual failure of the MV Drive Transformer of Raw Mill Reverse Air Bag House Fan on 24th Aug 2009. This transformer is an open type dry core and mounted in control panel. This is an advanced technolo... view more...
RAW MILL AVAILABILITY IMPROVEMENT
VRM-3 is one of the critical equipment in FLS plant. It has to support KHD plant also during monsoon due to insufficient capacity of VRM-2. Breakdowns found high in this section. Some breakdowns found repeating. view more...
Reduced plant downtime brings Rs. 50 Lacs savings at Dalmia Chini Mills, Nigohi
In July 2010, a study of plant downtime at Unit Nigohi revealed higher-than-average mechanical failures at the sugar mill. In 2008-09, over 60% of these were primarily caused by stalling of the Grooved Roller Pressure Feeder (GRPF), jamming... view more...
Reduction in mixing of material at Packing Plant : Kadapa
Kadapa unit dispatches various types of cement such as PPC, OPC43 OPC53 and SRPC. The frequent and quick changeovers are essential as per the market demand of cement. During these changeovers, the mixing of cements like OPC in PPC, PPC in O... view more...
Reduction of specific power consumption in FLS Coal Mill at Dalmiapuram
It was very evident from the false air study and discussion that paddle conveyor is the main source of false air entry, leading to increase in Specific Power consumption. After a detailed brain storming session amongst the members, it was ... view more...
Revamping damaged cables in KHD Coal Mill fire accident at Dalmiapuram
An unexpected fire occurred in the coal mill cable trench on 12th July at about 7.30 P.M. Even though best of the efforts were taken to quench the fire, phenomenal damage of cables had occurred. The area where extensive damage had happened ... view more...
SAP system re-design enables consolidated view of coal procurement and costs, improves decision - making
When SAP went live at Dalmia Group in December 2009, the accounting for coal in the system did not reflect the complete coal procurement process. The attributes of coal received at the port and the applicable duties and charges paid were no... view more...
Second annual Corporate Social Responsibility Report superbly showcases Dalmia Bharat's passion for "giving back"
Giving back to the communities we live in is not only a business imperative, at Dalmia Bharat Group but also our commitment rooted in Indian ethos and values. The company has a legacy of over seven decades of being of service to the communi... view more...
Speed in Identifying a New Supplier
Change of OEM M/s Pfeiffer,Germany to local Indian supplier from Ajmer for supply of RTD's view more...
Speed of delivery - Moving from one month to one day
DCBL, Kadapa is entitled to avail tax benefits for products it has manufactured and sold in Andhra Pradesh as part of a state government scheme under the Industrial Investment Promotion Policy (IIPP) 2005-2010. Submitting an Application cum... view more...
Speedy Procurement of 100 laptops
Indent received on 25.09.2009 to procure 100 Laptops within 5 days .The time frame for delivery was very less & required min. 7 working days. Enquiries & demo arranged within no time from the market. view more...
Speedy rescue and recovery operation at Dalmiapuram coal yard
Coal is a vital input in clinker production and is transported to the Dalmiapuram plant every week. On June 5 2010, while coal was being unloaded near the unit's coal yard, one wagon accidentally derailed at around 5.30 pm. As a result, oth... view more...
SPEEDY RESTORATION TO NORMALCY IN FACE OF NATURE'S FURY
One of the Linear Additive shed at Kadapa for the storage of additive materials, collapsed and was brought down to the ground on 1st June 2011 because of heavy wind and rain. The heavy wind sheared off the linear shed in three parts. The co... view more...
Sugar Greenfield Project
The DCBL Management took the decision to treble its Sugar Cane Crushing Capacity from 7500 TCD to 22500 TCD by setting up two Greenfield projects at Jawaharpur and Nigohi in May 2005. In addition to the Sugar plants it was decided to set up... view more...
Synergic Learning at Ramgarh
Industry uses a variety of technologies in operation and maintenance and accordingly technical personnel are highly trained in their respective areas. But they may not be that good in their cross functional areas. This reduces speed, teamwo... view more...
System integration ensures correct dispatch of cement quantity and regulatory compliance across plants
It is responsibility of Dalmia's management to ensure that every invoice records physical quantity of cement dispatched accurately. This is also an excise regulation requirement. Moreover, such a system can plug system loopholes if any, pr... view more...
The Dairy Co-operative Movement
The Dairy Co-operative Movement Before the cooperative movement began, the dairy industry view more...
To avoid the flushing of cement material in to the bucket elevator from Silo’s and from spillage air slide i.e
To increase the effectiveness of Plants dispatch activities, it was being contemplated to extract cement from Silo’s to FLS Packer Machine in FLS Packing Plant. There are two individual bag filters for Rotary Packer and auxiliar... view more...
TO INCREASE THE AVAILABILITY OF CANE FOR CRUSH
Before the start of previous season FY 2010-11, we had noticed that there were 5194 members who had not supplied cane to us in season 2009-10. These growers were having 5502 hectare of cane area with them. This was approximately 15% of tota... view more...
TO MEET OUT THE CHALLENGES OF GENERATING REQUIRED
This case study dealt with usage of wet coal in acute coal shortage condition, to meet out the continuous running of all cement plant equipments to avoid any production loss and also view more...
To meet the challenge of supplying Oil Well Cement beyond regular volumes from Dalmiapuram Works
To increase the effectiveness of plants, it was being contemplated to stop running the old Polysius Kiln (with only 200 TPD capacity and being used to manufacture Speciality cements) and produce Oil Well Clinker in one of the newer high cap... view more...
To operate Multi fuel Boiler on Coal fired
To increase the operation of Power Plant, it was decided to run it on Coal beside running on only Bio Mass fuel. Major changes and modification chalked out and completed as per schedule in small duration of End of November' 2009 to March' 2... view more...
Trebling of AP Sales in 120 days
The trade sales in Andhra Pradesh, one of the four states in which Dalmia predominantly operates, had been tumbling over the last two months. On the other hand, the receivables were growing out of control, and there was no sign of recovery.... view more...
Unit Kadapa cuts maintenance process time by 38%,
Cement rollers used for clinker grinding are subject to normal wear and tear. The maintenance team at a cement unit must therefore monitor it and "rebuild" the worn out metal when necessary. For a mill of Kadapa's size, this main... view more...
Unit Kadapa demonstrates 100% usage of Pet Coke
Pet coke is a popular alternative to coal in clinker production as a result of uncertainties about availability of coal as well as frequent fluctuation in its prices.
Since its commissioning in 2009, DCBL, Kadapa has used coal to produc... view more...
Unit Kadapa dewaters mine quickly,
Limestone, a key raw material in cement production is mined. Since the quality of limestone varies at different depths in the mine, it is necessary to dig deeper. This results in the formation of a pit, which is susceptible to flooding in ... view more...
Unit Kadapa improves maintenance process, cuts downtime and increases crushed limestone output
Limestone crushers, used in cement plants, are equipped with blow bars, which crush limestone boulders 1200mm in size to a desired size of less than 90mm. Like all other equipment, blow bars get worn out and must be replaced regularly, else... view more...
VALUE CASE STUDY FROM DPM
Procurement, Installation and Commissioning of Grid Resistance Regulator of FLS Plant Coal Mill Motor for Speed control view more...
VALUE CASE STUDY- CONSUMING THE AGED CLINKER
In cement manufacturing units normally the Clinker is being stored in the covered silos'and feed to Cement Mill to grind into the form of cement. view more...
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