Professional Documents
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7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator corresponds to the quantity of raw material mined / extracted
and transported from the quarry to raw material preparation or other process
steps. HTC Code 100-TEXTR-RAW.
Reference to Process
This indicator refers to:
Purpose
To measure actual quantity of raw material mined / extracted and
transported.
This indicator is the basis for measuring productivity, and is also needed to
elaborate specific production cost of the main cost center.
Calculation
This volume reflects the raw material mined / extracted and transported
directly to the crusher and / or to the stockpile at crusher area and also to
other process steps (cost centers) (see diagram below). The measurement
of the volume is made with feed belt scales or similar devices, e.g. in raw
material preparation process. If no such measuring system is available, the
extracted quantity of raw material can be calculated by counting the truck
loads and / or front end loader shovel loads multiplied by typical loading-
weight (determined weight of samples confirmed by bridge scales). The
water content of the raw material is included. Other purchased raw materials
must be weighed at the factory gate with bridge scales, however these
volumes are not considered in this process step, they will be reflected in the
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7.3.8.2 Raw Material Extraction Volume (t) 2o3
main cost center 'Raw Material Preparation'. Volumes sold out of this
process step will not be included in the calculation.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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7.3.8.3 Raw Material Preparation Volume (t)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator measures the quantity of raw material produced in the raw
material preparation process, for example crushing and homogenizing. HTC
Code 200-TPROD -RM.
Reference to Process
This indicator refers to:
Purpose
To measure the actual volume of raw material produced.
This indicator is the basis for measuring productivity, and is also needed to
elaborate specific production cost of the main cost center.
Calculation
The total volume corresponds to own mined / extracted raw material fed to
the crusher (or other size reduction equipment) and other raw materials
purchased and processed (e.g. correctives, alternatives and traditional raw
materials) in the process step, to be used internally for clinker and / or
cement production.
The measurement of the volume is made with belt scales or similar devices
in the crushing process and / or before the storage pile. The water content of
the raw material is included. The calibration of the belt scales have to be
confirmed by sampling the material flow on to trucks and by confirming the
weight by bridge scales and by audits of inventories at least once per year.
Volumes sold leaving this process step will not be included in the
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7.3.8.3 Raw Material Preparation Volume (t)
calculation.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
Example
A company purchases marl and clay and feeds them - together with the
limestone from the own quarry - into the first crusher, the volume of the
purchased material are reflected in the cost center 'Raw Material
Preparation'. The costs of the purchased material (marl and clay) have also
to be reflected in 'Raw Material Preparation'.
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7.3.8.4 Raw Meal Preparation Volume (t)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator corresponds to the quantity of raw meal produced in the raw
meal preparation process, for example grinding mills of all production units
in operation. The quantity calculated contains all raw meal types. HTC Code
300-TPROD -RAMEAL.
Reference to Process
This indicator refers to:
Purpose
To measure the actual volume of raw meal prepared. This indicator is the
basis for measuring productivity, and is also needed to elaborate specific
production cost of the main cost center.
Calculation
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7.3.8.4 Raw Meal Preparation Volume (t)
The produced quantity of meal can be calculated by the total of the materials
fed minus material humidity. In this case the quantities of the materials fed
have to be measured by feed belt scales or similar devices. In the
production process limestone, marl clay and similar are ground together with
correctives and alternative raw materials and / or mixed together.
Correctives are high-grade limestone, kaolin, iron ore, silica sand, alumina
ore and alternative raw materials can be slag, fly ash, waste glass, etc.
For all processes (e.g. dry, semi dry, semi wet, wet) the water content of the
raw-meal / slurry is not included. The raw meal produced is determined by
raw material fed to the system minus the loss of moisture.
Volumes of raw meal, filler, etc. sold leaving this process step will not be
included in the calculation of the indicator.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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7.3.8.4 Raw Meal Preparation Volume (t)
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7.3.8.5 Clinker Production Volume (t)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator corresponds to the actual quantity of clinker produced in
clinker production process, for instance kilns of all operating production
units. The quantity calculated comprises all clinker types as well as off
specification clinker. HTC Code 400-TPROD-CLINKE.
Reference to Process
This indicator refers to:
Purpose
To measure the actual volume of clinker produced.
This indicator is the basis for measuring productivity, and is also needed to
elaborate specific production cost of the main cost center.
Calculation
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7.3.8.5 Clinker Production Volume (t)
The raw meal / clinker factor corresponds to the mass reduction during the
burning process (raw meal fed to the kiln minus humidity, removal of
structural water, de-carbonization, dust loss in long kilns and by-pass). It lies
typically between 55% and 65%, for instance in order to fabricate 1 ton of
clinker, 1.55 to 1.65 tons of raw meal are needed (up to 1.8 tons for wet or
by-pass operation).
The calibration of the raw meal feeding weighing device and the
confirmation of the raw meal / clinker factor has to be done by internal
inventory audits. If differences of volumes determined physically and
inventories calculated are above 5%, then the measuring or weighing
devices must be re-calibrated. Inventory audits should be done once a
month. The kiln feed can be calibrated by re-circulating the flow through the
weigh bin (loss-in-weight method).
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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7.3.8.5 Clinker Production Volume (t)
Off specification clinker is the quantity of clinker produced, which does not
comply with the internal quality standard. The total quantity corresponds to
the total of all kiln lines in operation and different clinker types.
Clinker kiln dust volumes used in cement grinding or shipped should not be
included in the clinker production volume.
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7.3.8.6 Clinker Purchased / Transferred (t)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator calculates the actual volume of clinker purchased / transferred
from another Group company or third party or transferred from another plant
into the reporting plant. HTC Code 400-TPURTR-CLINKE.
Reference to Process
This indicator refers to:
Purpose
To measure the actual volume of purchased / transferred clinker as an
indicator of (e.g. shortage in clinker production)
Calculation
On plant level Clinker purchased / transferred must be determined
separately for:
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7.3.8.6 Clinker Purchased / Transferred (t)
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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7.3.8.6 Clinker Purchased / Transferred (t)
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7.3.8.7 Cement Production Volume (t)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator corresponds to the quantity of cement produced with grinding
mills and / or mixers (blenders) of all production units in operation. The
quantity accounted contains all cement types. HTC Code 500-TPROD-CEM.
Reference to Process
This indicator refers to:
Purpose
To measure the actual volume of cement produced. This indicator is the
basis for calculating efficiency indicators (e.g. productivity, electric energy
consumption) and is also needed to elaborate specific production cost of the
main cost center.
Calculation
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7.3.8.7 Cement Production Volume (t)
Inventory audits should be done once a month and compared with the actual
production volumes. If physical inventory varies more than 5% from the
calculated inventory based on the production volume, then the measuring or
weighing devices must be re-calibrated.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
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7.3.8.7 Cement Production Volume (t)
the HMR.
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7.3.8.7 Cement Production Volume (t)
Note that by-products are products and sevices incidental to the main
products sold. These are not included into the cement production volume.
(E.g. if 1,000t of high grade limestone ground in a cement mill is sold, than
the Cement Production Volume = 131,000 tons (110,000t - 1,000t + 15,000t
+ 7,000t).
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7.3.8.8 Cement Purchased / Transferred (t)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator calculates the actual volume of all types of cement
purchased / transferred from another Group companies or third parties or
transferred from another plant into the reporting plant.
Reference to Process
This indicator refers to:
Purpose
To measure the actual volume of purchased/transferred cement (e.g.
shortage in clinker production or cement grinding capacity).
Calculation
On plant level cement purchased / transferred must be determining
separately for:
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7.3.8.8 Cement Purchased / Transferred (t)
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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7.3.8.8 Cement Purchased / Transferred (t)
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7.3.8.9 Mineral Components Purchased/Transferred (t)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator calculates the actual volume of mineral components
purchased / transferred from another Group company or third party or
transferred from another plant into the reporting plant. HTC Code T00-
TPURTR-MIC.
Reference to Process
This indicator refers to:
Purpose
To measure the actual volume of purchased / transferred mineral
components.
Calculation
On plant level mineral components purchased / transferred must be
determined separately for:
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7.3.8.9 Mineral Components Purchased/Transferred (t)
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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7.3.8.9 Mineral Components Purchased/Transferred (t)
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7.3.8.11 Standard Clinker Capacity Volume (t/year) [by BDP]
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator corresponds to the quantity of clinker that can be produced
with a standard target OEE of 85% in function of BDP. The quantity
calculated contains all clinker types. HTC Code 400-TPYSTD-CLINKE.
Reference to Process
This indicator refers to:
Purpose
To describe the actual maximum quantity of clinker which can be produced
during a 12-month period in the main cost center 'Clinker Production'.
Calculation
The standard clinker capacity of a kiln is calculated as follows:
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7.3.8.11 Standard Clinker Capacity Volume (t/year) [by BDP]
Reporting
This indicator must be reported and reviewed on a yearly basis.
Equipment which were idle during the last 12 months and are not planned to
be used in the future 5 years according to the business plan do not have to
be considered.
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7.3.8.12 Standard Cement Capacity Volume (t/year) [by BDP]
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator corresponds to the quantity of cement that can be produced in
cement grinding with a standard target OEE of 85% in function of BDP. The
quantity calculated contains all cement types. 500-TPYSTD-CEM.
Reference to Process
This indicator refers to:
Purpose
To describe the actual maximum quantity of cement which can be produced
during a 12-month period in the process of the main cost center 'Cement
Grinding'.
Calculation
The standard cement capacity of a mill is calculated as follows:
Standard cement capacity (t/year) = BDP (t/h) x 24 hours x 365 days x 85%
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7.3.8.12 Standard Cement Capacity Volume (t/year) [by BDP]
Reporting
This indicator must be reported and reviewed on a yearly basis.
Equipment which were idle during the last 12 months and are not planned to
be used in the future 5 years according to the business plan do not have to
be considered.
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7.3.8.16 Specific Thermal Energy Consumption up to and including Clinker Productio...
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator measures the amount of thermal energy consumed in all
process steps up to clinker production in order to produce one ton of clinker.
It includes drying raw material in the raw material preparation and/or raw
meal preparation as well as drying and preheating of fuels in the clinker
production. HTC Code L00-MJTUP -CLINKE.
Reference to Process
This indicator refers to:
Purpose
To measure the efficiency of thermal energy used in raw material extraction,
raw material preparation, raw meal preparation and clinker production.
Calculation
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7.3.8.16 Specific Thermal Energy Consumption up to and including Clinker Productio...
If measuring systems are not available at all or for individual cost centers,
the allocation of the energy consumption has to be estimated.
Reporting
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7.3.8.16 Specific Thermal Energy Consumption up to and including Clinker Productio...
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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7.3.8.17 Specific Thermal Energy Consumption Cement Grinding (MJ/t cem)
7 Management Accounting
7.3 Clinker and Cement Production
7.3.8 Volumes
Description
This indicator is a measure of the amount of thermal energy consumed in
cement grinding, to produce one ton of cement. This includes drying
gypsum, additives and mineral components in the cement grinding process.
HTC Code 500-MJT-CEM.
Reference to Process
This indicator refers to:
Purpose
To measure the efficiency of thermal energy used in cement grinding.
Calculation
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7.3.8.17 Specific Thermal Energy Consumption Cement Grinding (MJ/t cem)
If measuring systems are not available at all or for individual cost centers,
the allocation of the invoiced energy consumption has to be estimated.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
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7.3.8.17 Specific Thermal Energy Consumption Cement Grinding (MJ/t cem)
12-Month Rolling X X
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
The thermal energy consumption corresponds to the total energy of all types
of fuel fired in the auxiliary furnace for drying purpose and does not include
heat recovery from kiln exhaust gases and / or from cooler exhaust air.
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7.8.9.2 Clinker Shipped (t)
7 Management Accounting
7.8 Logistics and Distribution
7.8.9 Volumes
Description
This indicator corresponds to the volume of clinker shipped to own grinding
stations, plants and terminals (inter-unit) and to customers (outbound). HTC
Code 600-TSHIP-CLINKE.
Reference to Process
This indicator refers to:
Main cost center 'Shipping Station'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To measure the actual volume of clinker prepared and loaded in
transportation equipment, in order to leave a shipping station (plant, terminal
or warehouse).
Calculation
Shipped is the volume measured and registered on a bill of lading (own or
third party). It comprises both, volumes delivered and picked up.
Shipping does not include the activity of transshipment.
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7.8.9.2 Clinker Shipped (t)
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
Note that clinker purchased from third parties and shipped on our behalf
from their location is not included in the indicator, but must be tracked
independently for statistical purposes and the flow control.
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7.8.9.3 Cement Shipped (t)
7 Management Accounting
7.8 Logistics and Distribution
7.8.9 Volumes
Description
This indicator corresponds to the volume of cement shipped from the
shipping station to other plants, shipping stations such as terminals and
warehouses (inter-unit) and to customers (outbound). HTC Code 600-
TSHIP-CEM.
Reference to Process
This indicator refers to:
Main cost center 'Shipping Station'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To measure the volume of cement prepared and loaded in transportation
equipment, in order to leave a shipping station (plant, terminal or
warehouse).
Calculation
Shipped is defined as the volume measured and registered on a bill of
lading (own or third party). It comprises both, volumes delivered and picked
up.
Shipping does not include the activity of transshipment.
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7.8.9.3 Cement Shipped (t)
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
Note that cement purchased from third parties and shipped on our behalf
from their location is not included in the indicator, but must be tracked
independently for statistical purposes and the flow control.
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8.2.2.1 Clinker Factor Production (%)
Description
This indicator corresponds to the clinker contained in the cement production
volume. HTC Code 500-CF-CEM.
Reference to Process
This indicator refers to:
Main cost center 'Cement Grinding'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To measure the percentage of clinker in cement produced at plant level.
Calculation
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8.2.2.1 Clinker Factor Production (%)
finesse then the volume and the clinker content of this cement has to be
considered. (Cement Production Volume). The clinker content of the
transferred cement must be eliminated on sub-segment (all plants) level
consolidation.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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8.2.2.1 Clinker Factor Production (%)
This factor is different for each cement type and should therefore be
calculated for each cement type at plant and on company level. This factor is
used to calculate specific cost of clinker production in terms of cement
produced (LC/t). For reporting purposes the overall clinker factor production
per plant and all plants has to be considered. This indicator does not
consider volumes blended after cement grinding, (e.g. in Shipping Station.)
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8.2.2.4 Personnel Productivity (man h/t)
Description
This indicator is a measure of the total worked and paid hours including paid
overtime to produce one ton (at the related stage of production), by own and
subcontracted personnel. HTC Code C00-MANHT-CEM.
Reference to Process
This indicator refers to:
All main cost centers up to and including 'Cement Grinding'
Sub-segment clinker and cement
Segment cementitious materials
Purpose
To measure the efficiency of own and subcontracted personnel working in
the plant.
Calculation
The calculation for the man h/t cem should be done according to the cost
per ton calculation philosophy as shown in the example attached.
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8.2.2.4 Personnel Productivity (man h/t)
Note that in the case of central workshops for repairs and maintenance labor
hours and costs are directly allocated to the respective cost centers where
the work was performed. The supervisors hours are accounted with the
auxiliaries hours.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
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8.2.2.4 Personnel Productivity (man h/t)
Segment
Monthly
Year to Date (month) X X
12-Month Rolling X X
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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8.2.2.6 Specific Electric Energy Consumption up to and including Clinker Production ...
Description
This indicator measures the amount of electric energy consumed in all
process steps up to clinker production in order to produce one ton of clinker.
HTC Code 400-KWHTUP-CLINKE.
Reference to Process
This indicator refers to:
Purpose
To measure the efficiency of electric energy used in clinker production.
Calculation
The consumption of the electrical energy invoiced by the supplier and / or
measured at the generator in case of energy produced at the plant, has to
comply with the cost center boundaries defined. It is to be allocated
according to measuring systems by:
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8.2.2.6 Specific Electric Energy Consumption up to and including Clinker Production ...
If measuring systems are not available at all or for individual cost centers,
the allocation of the invoiced energy consumption has to be estimated
based on installed motor power (including all power consuming installations,
for instance lighting) per cost centers of those motors, which are normally in
use. In case of co-generation the generated energy is included.
For the calculation of this indicator see also 'Specific Electric Energy
Consumption Cement'.
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8.2.2.6 Specific Electric Energy Consumption up to and including Clinker Production ...
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
The binding quantity for reconciliation is the total one invoiced by the
supplier and/or measured by the generator in case of energy produced at
the plant. The shipping station at plant and third party consumption are
excluded.
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8.2.2.7 Specific Electric Energy Consumption Cement Grinding (kWh/tcem)
Description
This indicator is a measure of the amount of electrical energy consumed in
cement grinding, to produce one ton of cement. HTC Code 500-KWHT-
CEM.
Reference to Process
This indicator refers to:
Purpose
To measure the efficiency of electric energy used in cement grinding.
Calculation
The consumption of the electrical energy invoiced by the supplier and / or
measured at the generator in case of energy produced at the plant, has to
comply with the cost center boundaries defined. It is to be allocated
according to measuring systems by:
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8.2.2.7 Specific Electric Energy Consumption Cement Grinding (kWh/tcem)
If measuring systems are not available at all or for individual cost centers,
the allocation of the invoiced energy consumption has to be estimated
based on installed motor power (including all power consuming installations,
for instance lighting) per cost centers of those motors, which are normally in
use. In case of co-generation the generated energy is included.
For the calculation of this indicator see also 'Specific Electric Energy
Consumption Cement.'
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
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8.2.2.7 Specific Electric Energy Consumption Cement Grinding (kWh/tcem)
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
The binding quantity for reconciliation is the total one invoiced by the
supplier and / or measured by the generator in case of energy produced at
the plant. The shipping station at plant and third party consumption are
excluded.
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8.2.2.8 Specific Electric Energy Consumption Cement (kWh/t cem)
Description
This indicator measures the total amount of electric energy consumed in
order to produce one ton of cement. HTC Code 500-KWHTUP-CEM.
Reference to Process
This indicator refers to:
Purpose
To measure the efficiency of electric energy used in cement production.
Calculation
The consumption of the electrical energy invoiced by the supplier and / or
measured at the generator in case of energy produced at the plant, has to
comply with the cost center boundaries defined. It is to be allocated
according to measuring systems by:
https://web.holcim.com/harp/harp-man.nsf/cc370b1caeb602edc1256a72003376c4/3b4... 03.12.2002
8.2.2.8 Specific Electric Energy Consumption Cement (kWh/t cem)
If measuring systems are not available at all, or for the individual cost
centers, the allocation of the invoiced energy consumption has to be
estimated based on installed motor power (including all power consuming
installations, for instance lighting) per cost center of those motors which are
normally in use. In case of co-generation the generated energy is included.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
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8.2.2.8 Specific Electric Energy Consumption Cement (kWh/t cem)
Monthly X X
Year to Date (month) X X
12-Month Rolling X X
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
Power losses and measuring errors should be allocated to the auxiliary cost
centers.
The binding quantity for reconciliation is the total one invoiced by the
supplier and / or measured by the generator in case of energy produced at
the plant. The shipping station at plant and third party consumption are
excluded.
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8.2.9.1 Own Personnel (FTE)
Description
This indicator measures the number of full time equivalents on the payroll.
Part time employees, employees hired or leaving are converted to
equivalent of full time employees.
HTC Codes:
Reference to Process
The indicator refers to:
For example within clinker and cement production, number of own personnel
must be reported as follow:
All Corporate
Production Manufacturing
Cost
Centers
Plant X
All Plant Level X
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
The reference to process for own personnel (FTE) for the clinker and
cement production is all main cost centers up to and including 'Cement
Grinding' (and the related auxiliary and pre-process cost centers)
The reference to process for own personnel (FTE) for the aggregates
production is all main cost centers up to and including 'Processing' (and the
related auxiliary and pre-process cost centers)
Purpose
The indicator measures the full time equivalent (FTE) personnel assigned to
functions and tasks.
Calculation
For part time personnel the contractual time of working hours divided by the
Long term disability is considered for FTE calculations. Only when the
company has no more obligation to pay wages to the employee according to
local rules, such persons are no more included in the FTE calculation.
Reporting
The indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
But excludes:
Scholar program participants
Personnel with long-term disability according to local rules
Description
This indicator measures the number of full time equivalents personnel
working for the company but not on its payroll.
HTC Codes:
Reference to Process
The indicator refers to:
All Corporate
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8.2.9.2 Subcontracted Personnel (FTE)
Production Manufacturing
Cost
Centers
Plant X
All Plant Level X
Clinker and Cement X X
Cementitious X X
Materials
Company X X
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
The reference to process for subcontracted personnel (FTE) for the clinker
and cement production is all main cost centers up to and including 'Cement
Grinding' (and the related auxiliary and pre-process cost centers)
Purpose
This indicator describes the number of subcontracted personnel working in a
plant or other locations.
Calculation
This indicator must be determined for subcontracted personnel as done for
own personnel (FTE).
Reporting
The indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
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8.2.9.2 Subcontracted Personnel (FTE)
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
Note that:
Outsourced personnel in quarry activity or driving subcontracted trucks
are not included (as subcontracted personnel)
Due to the specific nature of the subject, third party services should be
analyzed as a cost indicator (not as an FTE Human Resources indicator)
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8.2.9.3 Accidents with Time Lost (#)
Description
This indicator measures the number of accidents occurred in a plant,
shipping station or other locations, it counts only those accidents where the
injured was absent from work for one day, one shift or more. The indicator
includes total of own and subcontracted personnel.
HTC Codes:
Reference to Process
The indicator refers to:
For example within clinker and cement production, number of accidents with
time lost must be reported as follow:
All Corporate
Production Manufacturing
Cost
Centers
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8.2.9.3 Accidents with Time Lost (#)
Plant X
All Plant Level X
Clinker and Cement X X
Cementitious X X
Materials
Company X X
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
Example: The reference to process for accidents with time lost (#) for clinker
and cement production is all main cost centers up to and including 'Cement
Grinding' (and the related auxiliary and pre-process cost centers).
Example: The reference to process for accidents with time lost (#) for
aggregates production is all main cost centers up to and including
'Processing' (and the related auxiliary and pre-process cost centers).
Purpose
To measure the industrial safety regarding own and subcontracted
personnel as part of the Group company social responsibility.
Calculation
Reporting
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8.2.9.3 Accidents with Time Lost (#)
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8.2.9.3 Accidents with Time Lost (#)
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8.2.9.3 Accidents with Time Lost (#)
Note that with death casualty severity will be: (1,000 + 25)*1,000 / 188,100 =
5,45
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8.2.2.9 Specific Thermal Energy Consumption Kiln (MJ/tclin)
Description
This indicator measures the amount of thermal energy consumed in order to
produce one ton of clinker, not including energy consumption in fuel
preparation, drying of raw materials, raw meal preparation and preheating of
fuel. HTC Code 400-MJT-CLINKE.
Reference to Process
This indicator refers to:
Purpose
To measure the efficiency of thermal energy used in the kiln system.
Calculation
Reporting
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8.2.2.9 Specific Thermal Energy Consumption Kiln (MJ/tclin)
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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8.2.2.9 Specific Thermal Energy Consumption Kiln (MJ/tclin)
(Mj/t)
))clin
Fuel MJ t MJ/t
clin clin
Kiln 1 Coal 96,750,000
Oil 29,250,000
Gas 16,650,000
Total Klin 142,650,000 45,000 3,170
1
Kiln 2 Coal 93,500,000
Oil 0
Gas 25,000,000
Total Klin 118,500,000 35,700 3,320
2
Total Plant 261,150,000 80,700 3,236
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8.2.2.11 Thermal Economic Equivalent, TEE (%)
Description
This indicator describes the economic benefit derived from using alternative
fuel by showing the relationship between the fuel costs and the theoretical
fuel costs if no alternative fuels were used.
Reference to Process
Clinker production main cost center
Pre-process cost centers 'Traditional Fuels Preparation and Handling'
and 'Alternative Fuels Preparation and Handling' (at plant only)
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
This indicator measures the economic benefit of substituting traditional with
alternative fuel.
Calculation
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8.2.2.11 Thermal Economic Equivalent, TEE (%)
Note that A, B, C, D, E, F and G refer to the lines of the table shown in the
'Comments and Examples'.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
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8.2.2.11 Thermal Economic Equivalent, TEE (%)
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8.2.2.12 Thermal Substitution Rate, TSR (%)
Description
This indicator describes the relation of thermal energy consumption of
alternative fuels to the total amount of thermal energy consumption in the
kiln system. HTC Code 400-TSR -FUEL.
Reference to Process
This indicator refers to:
Main cost center 'Clinker Production' excluding pre-process cost centers
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
This indicator measures the degree of substitution of traditional by
alternative fuels, based on thermal energy consumption in the kiln system.
Calculation
https://web.holcim.com/harp/harp-man.nsf/cc370b1caeb602edc1256a72003376c4/c14... 03.12.2002
8.2.2.12 Thermal Substitution Rate, TSR (%)
the volumes of fuels measured with the specific net calorific value of the
fuels. It can be determined in own laboratory, by third parties, by literature
reference or by the one specified on the invoice.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
Fuels to prepare the fuels and raw materials for the kiln are not included in
this indicator.
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8.2.2.12 Thermal Substitution Rate, TSR (%)
Classification of Fuels
Name Fuel Type State Type
Alternative fuel gas Alternative Gas Non Renewable 12
Alternative fuel liquid Alternative Liquid Non Renewable 12
Alternative fuel solid Alternative Solid Non Renewable 12
Alumina smelter waste Alternative Solid Non Renewable 12
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8.2.2.12 Thermal Substitution Rate, TSR (%)
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8.2.2.12 Thermal Substitution Rate, TSR (%)
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8.2.2.14 Availability Index (Net and Gross, %)
Definition
Gross Availability Index of main equipment corresponds to the ratio of actual
operating time to calendar time (total time in the period). Net Availability
Index of main equipment corresponds to the ratio of operating time and idle
time to calendar time. HTC Code HAC* -AVAG or HAC*-AVAN (* code as
detailed as required).
Reference to Process
This indicator refers to:
All main equipment in all main cost centers up to and including cement
grinding
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
The Gross Availability Index measures the utilization of the equipment, as it
refers to actual operating time, while the Net Availability Index measures the
total time for which the equipment could potentially be operated.
Calculation
Actual Operating Time (h) x 100
Gross Availability --------------------------------------------
Index (%) = ---------
Calendar time (h)
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8.2.2.14 Availability Index (Net and Gross, %)
where
Operating time requires that the main equipment is operating and that it is
fed.
Reporting
This indicator must be reported and reviewed on monthly, 13 weeks and 12-
month rolling average according to the table below*:
This indicator is only relevant on main equipment level. For this reason no
aggregation or consolidation is necessary.
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8.2.2.14 Availability Index (Net and Gross, %)
h h h %
1 05.01.98 168 168 100.00%
2 12.01.98 06.01.98 Bearing #2 12 168 156 92.86%
Failure
(kiln)
3 19.01.98 168 168 100.00%
4 26.01.98 26.01.98 168 168 100.00%
5 02.02.98 05.02.98 ID Fan 24.5 168 168 85.42 %
Failure
(kiln)
6 09.02.98 168 100.00%
7 16.02.98 19.02.98 Ext Power 48 168 120 71.43%
Failure *
8 23.02.98 168 168 100.00%
9 02.03.98 03.03.98 Bearing #1 18 168 142 84.52%
Failure
(kiln)
10 09.03.98 168 168 100.00%
11 16.03.98 168 168 100.00%
12 23.03.98 29.03.98 Refractory 72 168 96 57.14%
Patch (kiln)
13 30.03.98 168 168 100.00%
Total 182.5 2,184 2,001.5 91.64%
https://web.holcim.com/harp/harp-man.nsf/cc370b1caeb602edc1256a72003376c4/942... 03.12.2002
8.2.2.14 Availability Index (Net and Gross, %)
2001.5 h x 100
Gross Availability --------------------- =
Index (%) = ------- 91.64%
2184 h
(2001.5 h + 48 h) x
100
Net Availability Index ---------------------------- = 93.84%
(%) = ---------
2184 h
Examples of idle time are:
Lack of demand
Logistical constraints, i.e. full silos
Lack of power supply from external provider
Off-peak power utilization
Natural disasters without impact on the condition of equipment (e.g.
earthquakes, before 2nd wave)
Raw mill is down due to kiln shutdowns, and no activities / no
maintenance that affect the condition of the raw mill equipment are done.
This is idle time for the raw mill
Strikes
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8.2.2.14 Availability Index (Net and Gross, %)
Example
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8.2.2.15 Production Rate Index (%) [by BDP]
Description
This indicator corresponds to the actual production rate expressed as a
percentage of the Best Demonstrated Practice (BDP). HTC Code HAC*-PRI
(* per kilns, per mill).
Reference to process
This indicator refers to:
All main equipment in all main cost centers up to and including 'Cement
Grinding'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To measure the rate of a process in order to identify and further eliminate
rate losses.
Calculation
For Kilns:
Actual Production Rate (t/day) x
100
Actual Production Rate -------------------------------------------
Index (%) = ----------------
BDP (t/day)
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8.2.2.15 Production Rate Index (%) [by BDP]
BDP (t/h)
For operating units where more than one product type is produced,
the Production Rate Index (%) should be calculated by weighing
the Production Rate Indices with the actual operating times for
each product:
Reporting
This indicator must be reported and reviewed on monthly, 13 weeks and 12-
month rolling average according to the table below*:
This indicator is only relevant on main equipment level. For this reason no
aggregation or consolidation is necessary.
Example: The BDP of a mill had changed from 70 t/h to 80 t/h in December.
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8.2.2.15 Production Rate Index (%) [by BDP]
Then the 12-month rolling Production Rate Index must be based on 80 t/h
for all 12-month periods which include the month of the change (December),
i.e. the periods September to August, October to September etc.
Rate Rate
Index
t/h %
05-Jan- 60 90.91%
98
12-Jan- 61 92.42%
98
19-Jan- 61 92.42%
98
26-Jan- 62 93.94%
98
02-Feb- 57 86.36%
98
09-Feb- 60 90.91%
98
16-Feb- 59 89.39%
98
23-Feb- 61 92.42%
98
02-Mar- 60 90.91%
98
09-Mar- 61 92.42%
98
16-Mar- 61 92.42%
98
23-Mar- 60 90.91%
98
BDP = 66 t/h
57
t/h
The Production Rate Index of the week ------ = 86,36 %
of 02-Feb-98 is ---
66
https://web.holcim.com/harp/harp-man.nsf/cc370b1caeb602edc1256a72003376c4/e77... 03.12.2002
8.2.2.15 Production Rate Index (%) [by BDP]
t/h
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8.2.2.15 Production Rate Index (%) [by BDP]
91.72% * 1816.5 h +
95.82% * 235 h
Production Rate Index ------------------------------------ = 92.19%
(mill) = ------------
2,051.5 h
Purpose
The BDP is necessary for calculation of Standard Clinker Capacity,
Standard Cement Capacity, Production Rate Index and therefore Net OEE
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8.2.2.15 Production Rate Index (%) [by BDP]
Calculation
A. BDP for Kilns
The BDP for kilns is the highest historical production rate (tons/day)
achieved during the last 24 months before the budget phase. The BDP
fulfills the following additional conditions (see also graph):
Note that for new kilns or major investments the following applies:
In the first year of operation the design capacity is used as BDP. Afterwards
the BDP has to be determined according to the definition. If the production
time is below 24 months the rules to determine the BDP have to be applied
on the actual period the main equipment is in operation (at least twelve
months). The BDP may not be lower than the design capacity.
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8.2.2.15 Production Rate Index (%) [by BDP]
Changes of BDP
If it is required to change the kiln BDP, it must only be changed for the next
budget, even if major process changes influence the clinker capacity
considerably. It will become effective as of January 1st of the following year.
B. BDP for Other Equipment (Raw Mill, Cement Mill, Coal Mill, Crusher, etc.)
The BDP for Other Equipment per product (e.g. different cement types
ground on the same mill) is the arithmetic average of the five highest
historical production rates (tons/hour) achieved during the last 24 months
before the budget phase, which fulfills the following additional conditions:
If the operating time per day and per product is at least 8 hours: the BDP is
the arithmetic average of the five highest production rates of the days with at
least eight hours operating time per day during the considered period of 24
months.
If there are not sufficient 8-hour runs: the BDP is the arithmetic average of
the five highest production rates during the considered period of 24 months.
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8.2.2.15 Production Rate Index (%) [by BDP]
Changes of BDP
If it is required to change the BDP, this should only be done at the end of the
year (for new budget), even if major process changes influence the
production capacity considerably. It will become effective as of January 1st
of the following year.
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8.2.2.16 Net Overall Equipment Efficiency, Net OEE (%)
Description
This indicator is a measure of the potential performance of a kiln taking into
account Net Availability Index (%), Production Rate Index (%) and Quality
index (%), excluding periods when the kiln was unable to run. HTC Codes:
400-OEEN-CLINKE and 500 -OEEN-CEM.
Reference to Process
This indicator refers to:
All kilns within main cost center 'Clinker Production'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To indicate the potential performance of a kiln.
Calculation
Net OEE (%) = Net Availability Index (%) x Production Rate Index (%) x
Quality Index (%)
For industries with an insignificant level of final product rejects such as the
oil and cement industries, the quality index of the OEE calculation is set to
100%.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
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8.2.2.16 Net Overall Equipment Efficiency, Net OEE (%)
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
Note that the 13-week period is more useful for analyzing short-term trends,
but can be heavily influenced by planned shutdowns (e.g. kiln relining). The
12-month period is more useful to understand overall trends.
Example
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8.2.2.16 Net Overall Equipment Efficiency, Net OEE (%)
Example: a company with two plants and two kilns in each plant:
Plant 1 Plant 2
Kiln (BDP ) Kiln (BDP )
1 1 3 3
Kiln (BDP ) Kiln (BDP )
2 2 4 4
Net OEE kiln % x BDP + Net OEE kiln % x BDP + Net OEE kiln % x
1 1 2 2 3
BDP + Net OEE kiln % x BDP
3 4 4
Net OEE (%) = ------------------------------------------------------------------------------------------------------
--------------------
BDP + BDP + BDP + BDP
1 2 3 4
When a BDP is adjusted, the OEE rolling averages have to be
recalculated using the new BDP, in order to maintain consistency
of the figures.
Example
The BDP of a kiln had changed from 1,200 t/d to 1,250 t/d in December.
Then the 12-month rolling OEE must be based on 1,250 t/d for all 12-month
periods which include the month of the change (December), i.e. the periods
September to August, October to September etc.
Note that for other main equipment it can also be needed to calculate Net
OEE. In this case the same concept is applicable.
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8.2.2.17 Gross Overall Equipment Efficiency, Gross OEE (%)
Description
This indicator is a measure of the potential performance of a kiln taking into
account Gross Availability Index (%), Production Rate Index (%) and Quality
index (%), excluding periods when the kiln was unable to run. HTC Codes:
400-OEEG-CLINKE and 500-OEEG-CEM.
Reference to Process
This indicator refers to:
All kilns within main cost center 'Clinker Production'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To indicate the potential performance of a kiln.
Calculation
Gross OEE (%) = Gross Availability Index (%) x Production Rate Index (%) x
Quality Index (%)
For industries with an insignificant level of final product rejects such as the
oil and cement industries, the quality index of the OEE calculation is set to
100%.
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
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8.2.2.17 Gross Overall Equipment Efficiency, Gross OEE (%)
* Highlighted cells mean that the level and reporting period is requested in
the HMR.
Note that the 13-week period is more useful for analyzing short-term trends,
but can be heavily influenced by planned shutdowns (e.g. kiln relining). The
12-month period is more useful to understand overall trends.
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8.2.2.17 Gross Overall Equipment Efficiency, Gross OEE (%)
The BDP of a kiln had changed from 1,200 t/d to 1,250 t/d in December.
Then the 12-month rolling OEE must be based on 1,250 t/d for all 12 month
periods which include the month of the change (December), i.e. the periods
September to August, October to September etc.
Note that for other main equipment it can also be needed to calculate Gross
OEE. In this case the same concept is applicable.
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8.2.2.18 Mean Time Between Failures, MTBF (h)
Description
This indicator measures the average duration between any failures for a
main equipment. HTC Code HAC*-MTBF (*per kiln, per mill).
Reference to Process
This indicator refers to:
All main equipment in all main cost centers up to and including 'Cement
Grinding'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To quantify the frequency and average duration of failures, for a main
equipment in order to determine the overall effectiveness of a preventive
maintenance strategy. This indicator may be used to determine the need for
Preventive Maintenance Routines (PMR's) to be introduced or amended for
a main equipment. It can also be used to identify the need for changes in
operational procedures or engineering design. It should not necessarily be
used to determine the frequency of a PMR.
Calculation
Actual Operating
Time (h)
MTBF ---------------------------
= ----------
# Failures
Example:
Date Stoppage Duration
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8.2.2.18 Mean Time Between Failures, MTBF (h)
(h)
06.Jan Bearing Failure 12.0
98
05.Feb ID Fan Failure 24.5
98
19.Feb External Power 48.0
98 *
Failure
03.Mar Bearing Failure 18.0
98
07.Mar Bearing Failure 8.0
98
29.Mar Refractory Failure 72.0
98
Total 182.5
* Not an equipment failure
2,001.5
h
MTBF ------------ = 400.3 h
(h) = -----
5
Failures include all stoppages that result in other downtime (see Availability
Index) as well as uncontrolled shutdowns that lead to idle time.
This means that all stoppages are failures, not considering planned
shutdowns, which lead to idle time (peak hour, market demand, etc.)
Example of failures:
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8.2.2.18 Mean Time Between Failures, MTBF (h)
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
This indicator is only relevant on main equipment level. For this reason no
aggregation or consolidation is necessary.
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8.2.2.13 Coefficient of Variation of Cement Mortar Strength (%)
Description
This indicator is described by the coefficient of variation of the compressive
strength of cement mortar, according to local / regional requirements. HTC
Code 500-VARI-CEM.
Reference to Process
This indicator refers to:
Main cost center 'Cement Grinding' and 'Shipping Station'
Product sub-segment clinker and cement
Product segment cementitious materials
Purpose
To measure the variability of the cement mortar compressing strength as an
expression of the quality of the manufacturing process.
Calculation
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8.2.2.13 Coefficient of Variation of Cement Mortar Strength (%)
Reporting
This indicator must be reported and reviewed on a monthly basis and in
annual intervals, according to the table below*:
Monthly
The average value of the cement mortar strength
= 1
n
i
i=1
Equation 1
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8.2.2.13 Coefficient of Variation of Cement Mortar Strength (%)
__________________
(xi -
s _1_
m 2
= )
n-1
i=1
Equation.2
The above formulas calculate the monthly values of the average and the
standard deviation.
Equation 3
= YTD average
n=
n
m
m=1
Equation 4
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8.2.2.13 Coefficient of Variation of Cement Mortar Strength (%)
= average of month m
m
If the scattering around the average of the respective period also has
systematically changed, the standard deviations s , s , ..., s (see Equation
1 2 z
no.2) should also be separately calculated and noted. If, however, the
scatter remains the same and only the average is changing, the standard
deviation can be calculated including all periods together according to the
following equation:
__________________
(n
S= _1_
n-z - 1)
m
2
s
m
m=1
Equation 5
Annual
For full year figures of the average cement mortar strength and standard
deviation of the cement mortar strength apply the YTD formula for z=12.
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