Abstract: The introduction of siliceous mineral additions in cement production allows, in addition to the ecological and economic gain, improvement of concrete performance. This improvement is mainly due to the fixing of Portlandite, released during the hydration of cement, by fine siliceous, forming denser calcium silicate hydrates and therefore a more compact cementitious matrix. This research is part of the valuation of the Dune Sand (DS) in the cement industry in Algeria. The high silica content of DS motivated us to study its effect, at ground state, on the properties of mortars in fresh and hardened state. For this purpose, cement pastes and mortars based on ground dune sand (fine quartz) has been analyzed with a replacement to cement of 15%, 20% and 25%. This substitution has reduced the amount of heat of hydration and avoids any risk of initial cracking. In addition, the grinding of the dune sand provides amorphous thin populations adsorbed at the surface of the crystal particles of quartz. Which gives to ground quartz pozzolanic character. This character results an improvement of mechanical strength of mortar (66 MPa in the presence of 25% of ground quartz).
Abstract: This paper presents the findings of successful implementation of Business Process Reengineering (BPR) of cement dispatch activities in a cement manufacturing plant located in India. Simulation model was developed for the purpose of identifying and analyzing the areas for improvement. The company was facing a problem of low throughput rate and subsequent forced stoppages of the plant leading to a high production loss of 15000MT per month. It was found from the study that the present systems and procedures related to the in-plant logistics plant required significant changes. The major recommendations included process improvement at the entry gate, reducing the cycle time at the security gate and installation of an additional weigh bridge. This paper demonstrates how BPR can be implemented for improving the in-plant logistics process. Various recommendations helped the plant to increase its throughput by 14%.
Abstract: The substantial development of the construction
industry has forced the cement industry, its major support, to focus
on achieving maximum productivity to meet the growing demand for
this material. This means that the reliability of a cement production
system needs to be at the highest level that can be achieved by good
maintenance. This paper studies the extent to which the
implementation of RCM is needed as a strategy for increasing the
reliability of the production systems component can be increased,
thus ensuring continuous productivity. In a case study of four Libyan
cement factories, 80 employees were surveyed and 12 top and middle
managers interviewed. It is evident that these factories usually
breakdown more often than once per month which has led to a
decline in productivity. In many times they cannot achieve the
minimum level of production amount. This has resulted from the
poor reliability of their production systems as a result of poor or
insufficient maintenance. It has been found that most of the factories’
employees misunderstand maintenance and its importance. The main
cause of this problem is the lack of qualified and trained staff, but in
addition it has been found that most employees are not found to be
motivated as a result of a lack of management support and interest. In
response to these findings, it has been suggested that the RCM
strategy should be implemented in the four factories. The results
show the importance of the development of maintenance strategies
through the implementation of RCM in these factories. The purpose
of it would be to overcome the problems that could secure the
reliability of the production systems. This study could be a useful
source of information for academic researchers and the industrial
organizations which are still experiencing problems in maintenance
practices.
Abstract: The globalization of the Indian economy has thrown a great challenge to the Indian industries in respect of productivity, quality, cost, delivery etc. Achieving success• the global market has required fundamental shift in the way business is conducted and has dramatically affected virtually every aspect of process industry. The internal manufacturing process and supporting infrastructure should be such that it can compete successfully in global markets with better flexibility and delivery. The paper deals with a case study of a reputed process industry, some changes in the process has been suggested, which leads to reduction in labor cost and production cost.
Abstract: Despite of the preponderant role played by cement among the construction materials, it is today considered as a material destructing the environment due to the large quantities of carbon dioxide exhausted during its manufacture. Besides, global warming is now recognized worldwide as the new threat to the humankind against which advanced countries are investigating measures to reduce the current amount of exhausted gases to the half by 2050. Accordingly, efforts to reduce green gases are exerted in all industrial fields. Especially, the cement industry strives to reduce the consumption of cement through the development of alkali-activated geopolymer mortars using industrial byproducts like bottom ash. This study intends to gather basic data on the flowability and strength development characteristics of alkali-activated geopolymer mortar by examining its FT-IT features with respect to the effects and strength of the alkali-activator in order to develop bottom ash-based alkali-activated geopolymer mortar. The results show that the 35:65 mass ratio of sodium hydroxide to sodium silicate is appropriate and that a molarity of 9M for sodium hydroxide is advantageous. The ratio of the alkali-activators to bottom ash is seen to have poor effect on the strength. Moreover, the FT-IR analysis reveals that larger improvement of the strength shifts the peak from 1060 cm–1 (T-O, T=Si or Al) toward shorter wavenumber.
Abstract: In recent years, sustainable supply chain management
(SSCM) has been widely researched in academic domain. However,
due to the traditional operational role and the complexity of supply
chain management in the cement industry, a relatively small amount
of research has been conducted on cement supply chain simulation
integrated with sustainability criteria. This paper analyses the cement
supply chain operations using the Push-Pull supply chain
frameworks, the Life Cycle Assessment (LCA) methodology; and
proposal integration approach, proposes three supply chain scenarios
based on Make-To-Stock (MTS), Pack-To-Order (PTO) and Grind-
To-Order (GTO) strategies. A Discrete-Event Simulation (DES)
model of SSCM is constructed using Arena software to implement
the three-target scenarios. We conclude with the simulation results
that (GTO) is the optimal supply chain strategy that demonstrates the
best economic, ecological and social performance in the cement
industry.
Abstract: This study extends research on the relationship
between marketing strategy and market segmentation by
investigating on market segments in the cement industry.
Competitive strength and rivals distance from the factory were used
as business environment. A three segment (positive, neutral or
indifferent and zero zones) were identified as strategic segments. For
each segment a marketing strategy (aggressive, defensive and
decline) were developed. This study employed data from cement
industry to fulfill two objectives, the first is to give a framework to
the segmentation of cement industry and the second is developing
marketing strategy with varying competitive strength. Fifty six
questionnaires containing close-and open-ended questions were
collected and analyzed. Results supported the theory that segments
tend to be more aggressive than defensive when competitive strength
increases. It is concluded that high strength segments follow total
market coverage, concentric diversification and frontal attack to their
competitors. With decreased competitive strength, Business tends to
follow multi-market strategy, product modification/improvement and
flank attack to direct competitors for this kind of segments. Segments
with weak competitive strength followed focus strategy and decline
strategy.