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CONFIDENTIAL

Driving Dream Run across ACC

April, 2013

Our journey towards moon continues significant improvement in Q1 2013


Baseline 2011 ACC Moon

2012 Actuals 2013 Q1 Actuals Best achieved number for Q1-2013

PPC clinker factor (Percent)

67.0

65.1

63.6

61.8 CD

60.0

PSC clinker factor (Percent)

46.3

44.7

43.8

40.0

39.5 EN

Thermal energy (Mj/t Clinker)

3100

3076 3070

2900

2881 CD

Electrical energy (kwh/t cement)

89.6

88.1

84.8

79.9

77.4 CD

CPP PLF (Percent)

56.9

60.0

62.6

85.0

88.7

CH-N
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However, significant savings potential exists across plants


2013-Q1 2013-Asp

67.3 Cr

My Moon 2013 Value at stake

PPC Clinker factor Percent PSC Clinker Factor Percent

63.6 44.7 84.8 3070 62.6

62.4 40.2 81.2 3025 79.4

60 40 80 2900 85

14.6Cr
4.2 Cr 15.5 Cr 8.5 Cr

Electrical Energy Kwh/T of Cement


Thermal Energy Kcal/Kg Clinker CPP PLF* Percent
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24.6 Cr
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* Doesnt include the saving from coal cost reduction

We plan to conduct Dream Run across plants in May to give a major thrust to our journey towards moon
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Dream Run is a proven methodology to accelerate performance improvement and then sustain it
We are here
Actual dream run Continuous improvement journey undertaken by plants Core project teams formed across projects Key areas of improvement identified Specific initiatives identified and driven Continuous review to identify more initiatives and drive program 2 weeks of intense pre-work to set-up dream run Fast-tracking execution of key initiative's Adhering to predream run check list Ensuring that all matter 1 calendar month proof of concept to high performance and sustain at next level Intensified review to drive performance Sustain performance beyond dream

Activate teams through meetings


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Dream run has already yielded very successful results in logistics


GIGO July GIGO Aug-H1 GIGO FTL

Improved and closed to target Improved but yet to reach target Not improved

July loading time

Aug-H1 loading time

Lakheri Gagal Tikaria Kymore Bargarh Sindri Chaibasa Jamul Damodar Wadi Chanda Kudithini Thondebhavi Madukkarai Simple Avg

3.2 2.6 2.2 7.9 4.2 2.0 2.2 2.4 4.2 4.5 4.1 4.7 2.9 4.4 3.7

0.9 1.9 0.7 2.6 1.5 0.5 0.8 1.2 0.9 2.2 1.3 1.5 1.5 3.0 1.5

Lakheri Kymore Bargarh Sindri Chaibasa Jamul Wadi Chanda

13.4 11.5 19.5 13.1 14.2 9.8 11.3 21.0

10.9 10.0 13.2 10.3 12.4 8.7 8.2 16.4

Simple Avg

14.2 14.2

11.2 9.0

3.7

3.0

"We never believed that we will be able to reduce GIGO less than 1 hour Team Damodhar ACC Limited

"ACC is now loading rakes within free Time Railway DOM


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Dream Run to be launched across all plants in four key manufacturing KPIs from 1st of May for a month

1
2

Specific Electrical Energy (KWh/T of cement)

Clinker Factor (PPC & PSC %)

3
4

Thermal Energy (MJ/T of clinker)

CPP PLF (%) (where applicable)

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Areas that plant leadership needs to drive before dream run to ensure success (along with central and regional PMO teams)
Activities Timeline

1 Clearly define aspirations for the dream run (all 4 focus KPIs)
2 Align project teams on dream run (members, roles, etc. all 4 KPIs) 3 Project teams to review roadmaps, resources and initiatives to prepare 100% preparedness

By 16th April
By 17th April By 19th April
See detail checklist attached

4 Revisit review architecture for dream run and start driving reviews
5 Create communication plan and launch communication within plants 6 Conduct team building activities in the plant

By 19th April
By 23rd April 25th to 30th April

ACC Limited

Pre-Dream Run readiness checklist for Director Plant


KPI teams are fully aligned on the aspirations for the dream run KPI aspirations for dream run are significant stretch to current performance Plant teams have looked at the resource requirement for Dream Run (eg. Fly ash, coal stock
piles etc.) and ensured their availability

Planning and aspiration setting

Necessary spares required to ensure quick start-up during breakdowns have been ordered Performance dialogues across sections have been fully planned with zero non-conformance Plant Director and senior management team have done a walkthrough and inspected every sections readiness for the dream run Review of Dream Run KPIs and activities have been slotted in to daily and shift meetings Special Dream Run reviews every week with the respective teams have been slotted Each project team has reviewed the roadmaps and all possible initiatives that can be implemented in the plant have been fully implemented The capabilities of each team has been reviewed and necessary action taken to reinforce it Each individual in my department knows his targets/ activities to achieve the Dream Run KPIs Overall plan has been developed to communicate at organization, plant, section and area levels Dashboards have been developed for plant stations monitoring progress on Dream Run target Daily email templates are ready to communicate progress to my team on previous days performance Weekly email templates are ready to communicate progress to the plant

Execution and review

Communication

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Key activities that plant leadership will need to drive during dream run to complete it successfully
Activities 1 Project team reviews of KPI performance and debottlenecking of key issues 2 Detailed KPI review with Plant Leadership 3 Continuing the momentum in the plant through communication and buzz Celebrate success stories at all levels through emails, news flashes, posters Townhall meetings, Gate meetings, etc Leadership visit to plants 4 Daily performance dialogue meetings and ensuring that action logs from PDs are closed 5 Fully updated war room, plant MIS with coordination along with central/ regional PMO Responsibility PXM Head, MC, Coach, team PD, PXM Head, Project teams Plant Director Frequency Daily

Weekly
As per plants plans

Section heads

Daily

Plant Director, PXM Head

Daily/ Weekly

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The central and regional PMO team will give you whole hearted support for planning the Dream Run
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