Time
Sr. # Short Term Planning
0 Safety
Stock taking of Raw
materials, Clinker, Cement,
1 1st week
Additives, Fuels, Spares &
Packing materials
Reviewing “The Inward &
Outward System” of gates for
2 for any leakages
all types of human &
material’s traffic.
Packers’ efficiency &
3 1st week
accuracy test system
4 Cost Review
Review of Production Norms
5
& KPIs
Coal & other Fuel (s), Raw
6 Material’s Yards Management
review
Maximizing availability of
7 2nd Week
Plant
Review Plant Mechanical
8 3rd Week
Health
Course of action
line
1. Safety System review
1st week
2. Safety certification & on ground safety culture.
3. Safety Norms & safety Objectives.
Stock taking committee to be constituted comprising of
members from various departments.
1. The weighing Bridge Calibration
2. The documentation at Gate & weighing bridge to check
1st week
3. Reviewing the weighing & movements system of trucks,
vehicle for Cement dispatches.
Review or develop the accuracy & efficiency system for
packers with electrical, Instrument & production departments.
1. Cost Pie chart
2. Variable and fixed cost of Production 1st Week
3. Retention price of Product(s)
1. KPIs for plant
2. Capacity utilization
3. KPIs for HODs and Sectional In charges
4. Production Norms
5. Budgeted figures of Sales & production 1st & 2nd
6. Types of Production & Brand Names with Quality week
Specifications of Product(s)
7. Benchmarking of product(s) with market players in
Quality, Sale price, cost of production and other
Norms and KPIs
1. Quality wise & category-wise fuel storage through
Store & production Departments.
2. The mitigating the environmental impact of stocks
3. Review stock levels for optimize cost on fuel & raw
2nd week
material inventory.
4. Review the safety & security of fuel and materials.
5. Review Quality control procedures for sampling &
testing of coal through QC.
1. Maximize the MTBF
2. Breakdown to minimize through reliability and Planned
maintenance
3. The Predictive maintenance on the basis of the
periodical inspections as well as monitoring through
planning Department or third part inspections
1. Mechanical health of Critical Machines
2. List of critical maintenance undergone in last year
3. Health of Machine across the process flow
4. Review Maintenance modules & Machines history
 1. Major electrical maintenances undergone in last one
year
Review of electrical &
9 2. The health condition of the critical motors 3rd Week
instrumentation/PLC/DCS
3. Critical maintenance & health of Instruments.
4. PLC System & updates
Time
Sr. # Short Term Planning Course of action
line
1. Organization’s Objectives redefine
Review Management 3rd & 4th
10 2. Departmental objectives & Targets
Objectives Week
3. Tangible Objectives of Middle- and lower-line officers.
1. Drop test of Kiln and other units for production as well as
energy, fuel consumption
2. SHC and SPC norms, budgets and achievement review
3. Raw meal to clinker ratio
4. Consumption of raw material against budget
5. Input material sizes for Main Crusher and Raw mill
6. Output optimization with crushers, Raw mill, Kiln, Coal
mill and cement mills
7. Energy Audit through technical team
8. Energy & Mass Balance through Production
9. Minimizing Standard deviation through QC
10. Feed loss on weight and other
11. Chemistry set points review and optimization to reduce
Kcal/kg as well as power consumption.
12. Types & cost of fuels being used viz a viz changing fuel
1st 3
11 Process optimization types through target to production to archive Cheaper fuel
Months
cost.
13. Kiln, preheater and all pyro system to block leakages of
heat and entrances of excessive air.
14. Optimizing the Kiln cooler for WHR power & the kiln
optimization
15. Minimizing the Top cyclone temp & the Clinker
Temperature at exit
16. Maximizing the outputs of all operational units.
17. Clinker, Gypsum & PI ratio optimization
18. Use of Grinding aid for production & quality enhancement
19. Quality optimization and process stability for customer
delight as well as norms achievements
20. Reducing the Standard deviation in Chemistry as well as
process parameters.

1. Exercise of store inventory vs Lead team

2. Cost of inventory Vs Cost of shortage of spare
Optimization in Store 4 to 6
12 3. Inventory bench marking
Inventory Management months
4. Adaptation of Just in time concept
5. Review the SCM performance
 1. Reduce per ton cost of maintenance
2. Restructuring of maintenance teams
Optimization in Maintenance 3. Restructuring the maintenance phenomenon 4 to 6
13
cost 4. Strengthening the Planning section for Predictive and months
RCM and implementation of RCM along with Hybrid
maintenance where required.

1. Incorporating the codes of ethics elements for HR

2. The restricting of HR duties, responsibility, competence
evaluation, training need assessments, Appraisal
methodology. Assessment of the HRM requirement and
right man for the right job.
3. HRM development
Human Resource 4. Training & development program for trainees, internees 4 to 6
14
Management and future requirements. months
5. Acquiring the Soft and hard skills for employees.
6. Redefining the Appraisal methodology as per international
requirements.
7. Developing the HSE culture in employees at all levels.
8. Employee Feedback & horizontal to vertical involvement
in improvements.

1. Type, made and origin of the existing refractories

2. Search of Alternative refractories
In 1st two
15 Refractory Cost optimization 3. References of alternative refractories from the industry for
quarters
benchmarking the Norms and cost of refractories.
4. Work for alternative refractory resource management

1. Setting & achieving the Industrial best practices & Norms

of spares per ton of production.
2. Indigenization and localization of spare and parts where
Spares & Parts
it’s technically feasible, Risks free and economically In 1st two
16 Indigenization, Reverse
viable. quarters
Engineering
3. Increase life with RCM and monitoring
4. Ensure the life expectancy through maintenance,
5. Critical machines to be covered under the Insurance.

Breaking the culture of “Doing
Business as usual” and
melting the Glacier for
17
Performance based Culture
with Punishments and
rewards.
1. Only few & extra ordinary employees adopt the out of box
solutions or make an extra mile, while mostly like comfort
zone and do business as usual.
2. Efforts to make the people’s attitude for excellence. In 1st two
3. To Introduce the reward & punishment policy for HSE as quarters
well as performance-based appraisal.
4. Make the employees take the ownership and feel pride
working with passion.
 Mid & Long Term Planning:
Sr. # Short Term Planning
1 Review the 1st two Quarters
2 Use of Alternative Fuels
3
Contracts renewals
4 Operational Manual
Course of action Time line
1. Review the plant performance on weekly & monthly basis
& target, objectives and progress review on directions set.
2. Review the HR performance
3. Review the HSE performance
4. The production achievements viz a viz sales & retention
5. Set new targets bi-annual and YTD for enhanced
achievements.
1. Review and set targets for using the alternative fuels,
2. Use of the local & international available combustibles,
3. Possibilities for use of Coke, Afghan & local coals, TDF etc.
4. Refused derived fuels possibilities.
5. Introduction and evaluating the Fuel that has the potential
to lower the carbon foot print, stable operation and lower
cost of production.
Review & renew the contracts if seems beneficial for long
terms policies.
1. Quarry Operation
2. Quarry machines & Quarry safety
3. Clay/Shale/Marl etc. transportation
4. Heavy Earth Moving Equipment beings used at plant(s) at
any area
5. Admin & security Contracts
6. Packing & Cleaning of plant
7. Technical workforce contract
8. Critical machines maintenance contracts
9. Insurance contracts
10. Transportation & travel
1. Operational manual for all Technical, Admin, Store,
Quality, Process, Security, HSE and Services operations to
merge or unify for avoiding conflicts in SOPs, WIs and
other related activities.
2. Incorporate the changes & unification along with inclusion
of HSE guidelines in every Operation, process or service.
3. Supply Chain Management, Inventory, Sales & Marketing,
Human Resource Management SOPs to be inculcating in
line with the Operational Manual so that clarity at all tiers
horizontally and vertically is achieved for sustainable
policies and growth.
4. HRM polices as per legal frame work.

5 Product Diversification
6 Resource sharing & utilization
SWOT Analysis of Business
7
Operations.
Core team Development for
8 objectives, mission and vision of Management. The
Operational Sustainability.
9 Alternatives to Raw Materials
10 NOCs & Licenses
1. Evaluation and review of Products being produced and the
adopted National & international standards.
2. Study to adopt the superior quality standards and value
addition to the product specification, grades and types as
per marketing demand as well as national trends.
3. Adaptation of the standards to minimize/optimize the
clinker ratio for cost as well as green productivity.
4. Specialized cements,
5. Pozzolanic, fly ash, bottom Ash, other additives to be
maximize in cement for special use.
6. Specialized cement like Low Alkali, Low heat, High early
strength, Slag cement and Oil Well cement
1. Through Skill diversification, the HR resource shall pe
make capable to work as Cement Engineer
2. The HR resource optimization & utilization between low
and high load areas and periods.
3. Resource sharing of similar equipment, machines, tools
across the organization and unit(s).
4. Check the Possibility for resource sharing/resource
acquiring with other organizations of similar businesses
for mutual benefits and lowering the cost of inventory.
Strengths, Weaknesses, Opportunities and Threats analysis of
the business and Brands for profitability, competence, cost,
quality, HR, capacity utilization, market expansion and
diversification.
Evaluate the strengths and competencies of the Heads, Line
Managers, Supervisors and technicians & then transform
them to the core team members to achieve the goals,
specialized skills and competencies to be transfer to build up
the 2nd & 3rd tier of the core teams as activators as well as
catalyst to the system.
Evaluate the existing raw materials and then search for the
alternative raw materials that may lower the cost, mitigate
the risks of HSE, improve quality, shift the responsibility of
organization to third parties, lower the use of own materials,
lower the taxes & govt dues.
Develop and sustain the relationships through relevant offices
for intime & smooth processing of NOCs for Lands, Operation
units, power plants, Boilers, XRF and other analyzers, the
NOCs for use of Chemicals, explosives, EPA, Software and
other licenses as well as NOCs etc. Insurance of IMS & other
Certifications.
 As a religious, national & international responsibility to
develop the culture of Tree plantation on sustainable bases
across the units through Tree plantation Drives at least twice
11 Tree plantations Drives a year. The Goals shall be achieved in collaboration with the
district administration and the NGOs. The plans shall be
distributed as CSR among the communities, EPAs, the School
in vicinities and Boy scouts or girl guides.

1. Energy audit of the plant(s) through experts

2. Energy Management system (ISO 50001)
3. Energy Blends for sustainability and self-reliance.
4. Eliminating energy leakages, replacing the intensive
energy eager machines with modern and low energy ones.
5. Energy efficiency relationship with production increase &
12 Energy Audits
Quality optimization
6. Use grinding aid, its alternatives to save energy on
grinding
7. Working towards total solar, wind and or environmentally
friendly energy sources.
8. Alternative energy for combustion at pyro system.

1. Technical audit of plant for the production capacity &

improvement in output.
2. Technical audit o plant for evaluation of input rates.
3. Mechanical health of plant
4. Civil structures and health of plants
5. Output values & the guarantees of each unit operation &
13 Technical Audit
unit processes, possibilities of using the design allowance
of units for output increase.
6. Product quality audits for Chemistry being used and
required for smooth operation of plant, for optimize cost
and the premium or targeted quality.
7. Alternative process techniques for increasing out puts.
1. ISO 26000 certification for CSR
2. Projects of Welfare to connect with nature and
CSR & Community welfare
14 community.
Projects
3. Saving in taxes through CSR projects as per EBR relevant
laws.
 Management commitment is vital for organizations. To
cement the relationships certain Employees welfare
programs shall introduce and sustained.
1. Health & fitness to make them available for work & save
on medical bills
2. Periodical Medical check ups for all and executive checks
ups for core teams.
3. Use of employee’s fund as investment for the benefits of
15 Employees Welfare employees
4. Education & Skill development of employees and family
5. EOBI and Social security at plant premises
6. Insurance & Takaful based pension schemes for
employees
7. Employees Children’s marriage fund
8. Employee’s interest free loans in limited scope
9. Awards and rewards, various scholarships
10. Subsidized food & wearing.
ERP and or SAP based MIS for,
1. Production
2. Quality and Products
3. HSE
4. Processes
5. Marketing
6. Supply Chain Management
7. Customer feedback & Ideas
16 ERP - SAP 8. Employees Management System
9. Norms, KPIs, Achievements etc. trends and Analysis
10. Machine learning & Data mining
11. Statistical Controls
12. Automations for weighing, Gates and exit, dispatch
controls
13. Ecommerce
14. Maintenance modules
15. Security & Admin systems
1. Minimizing the carbon & other emissions as per the
National standards as well as to work for the Euro Cement
level of carbon footprint.
2. Concrete design development with low clinker ratio to
mitigate emissions.
Green Concrete & Green
17 3. Maximizing the PI, Fly or bottom Ashes, Additives to
Productivity.
cement that support cost, quality and environmental
optimizations.
4. Green Cement with less impact on environment and
natural resources.
5. Cement with low combustion temperature requirement
 1. Work for possibility of expansions & investment that
decrease the cost and replace the deteriorating
technologies.
18 Expansions & BMRs
2. Investment for expansions & Quality diversifications
3. Investment for Environment improving technologies as
per legal frame work.
1. Expanding the land acquisition as & when available
2. Land for expansions projects
19 Land Acquisitions & Leases 3. Leases of Raw materials as well as Gypsum iron ore
4. Mining leases for local Coals
5.

Self-transport and support for cement dispatches in trucks

20 Self-Transportation & Fleets
and bulks

21 Self-reliance in Packing Working for indigenous system of Packing materials.

A comprehensive system of R & D in Organizations for

1. Process improvements and problem Solvig
2. For Electrical & Energy blends
3. For Mechanical, Instruments and DCS system problems
and improvements
22 Research & Development 4. Quality products, Product improvements and
diversifications
5. Funding the research programs at universities
6. Collaboration with other cement plants for R & D at home
7. Self-reliance in technology through concrete and solid
steps through APCMA.