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Cement plant audit is following three stage process in which we examines all aspects of cement plant operations and focus on the maximisation of plant profitability. We work closely along with our foreign Principal to provide superior services to our clients. 1 - DESK TOP STUDY Stage one involves the cement plant completing a questionnaire including information on; raw materials, kiln feed chemistry, product quality, fuels and the efficiency of plant machinery. From this, we complete a high level performance analysis comparing current cement performance against world best practice, focusing on improvement potential and identifying problem areas. An estimate for the profit improvement potential is then produced. If the potential savings appear less than 3 times the cost of the subsequent stages, no further action is taken, as it is unlikely that the results of the subsequent stages will be sufficient to ensure a maximum 1 year payback on the full cost of the process.  2 - ACTION PLAN DEVELOPMENT Stage two involves a site visit by a team consisting of 2 process engineers and a chemist, with the exact make-up of the team dependent on the findings from the first stage.. They will audit the current plant equipment, the available raw materials and the on-site manufacture process. A detailed report will then be produced outlining their findings together with recommendations and three sets of target savings. The first set of savings relate to short term sustained profit improvements which are estimated to be achievable over a period of 12-18 months, with no extra capital expenditure. The second set of target savings are those which can be achieved over a period of 5 years, which may involve some limited capital expenditure. The third set of figures relate to the plant's performance against world best practice, and while these targets may not be achieved in every area, these figures will give a reliable indication of a plant's current and predicted performance against other cement producers and importers.  3 - RESULTS DELIVERY Stage three involves the provision of all necessary technical and operational expertise to enable the agreed targets to be delivered. This is usually achieved through a mix of on-site and remote support and takes the form of a 12 month contract with us. |
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