Digitalization & Automation

Digitalization & Automation

Digital transformation is rapidly changing the landscape of manufacturing activities and is a progressive step towards achieving business excellence. HCIL is currently in midst of automating and digitalizing its manufacturing processes under the guidance of HeidelbergCement AG. New initiative titled 'HProduce' will deliver significant improvement in operational efficiency and cost optimization. The key deliverables under this are

  • Increased throughput
  • Reduced energy consumption
  • Lower maintenance costs

These are achieved through real time analyzers that monitor consumption parameters and enable remote management of the systems.

Some of the initiatives that company has already implemented are-

1. Simple Help

 

Facilitate remote operation in case of exigencies, provide remote diagnostic data for breakdown of equipment including process control system, QC Lab equipment etc. and facilitate reduction in downtime.

2. Dalog Online Gearbox Monitoring

 

Better preventive maintenance available from time data and its analysis by experts sitting in shared control centres.

3. Upgrading process automation

 

Making automation systems more robust and glitch free from operations and IT security perspective.

4. GPS Implementation in Trucks

 

We have implemented GPS in all our outbound and inbound trucks which helps us keep track of material offloading to the dedicated location only. This helps in preventing our brand position in all our markets.

5. Contract Labor Management System (CLMS)

 

With more than 2000 contract workers maintaining attendance and generating billing becomes a cumbersome task. CLMS will help in automated attendance management with approval from respective HODs, ensuring compliance by contractor and at the same time generating automated invoices.

6. Robotic Process automation

 

With more than 2500 annual channel database to be created, the on-boarding process becomes a tough task. With the introduction of robotic process automation, the human intervention has been minimized and the robot works round the clock while scanning, archiving and validating all the supporting documents without any error.

Initiatives that are in pipeline –

i) Expert system

This digitalization tool will be used to run the three cement mills at Imlai in auto mode using advanced process controls. It will minimize human intervention, reduce power consumption, and deliver consistent quality.

ii) Remote Operation of Grinding Units

This initiative will synergise and unify technical support between Plants and facilitate flexible operation of the grinding units.

iii) PX Trend

Using the data gathered over long durations, it will deliver precise MIS which in turn will make available expert guidance for peculiar process problems. It will lead to improved preventive maintenance.

iv) App-based mobile maintenance

Improvement in reliability and Mean Time Between Failure (MTBF)