CEMENT

INDUSTRY
CASE STUDY
INTRUMENTATION AND CONTROL
MANAGER
 INTRODUCTION
• Hello, my name is KAILAS NATH KR, and I am an
instrumentation manager. I have 5 years of experience in
cement industry and currently working in Rafale cements. In
this role, I am responsible for overseeing the design,
installation, and maintenance of instrumentation systems
within my organization. These systems are used to measure,
control, and monitor various processes and equipment.
STORY
• Implementing modern technology in cement
industry
• Wide range of sensor
• Level detection sensor
• Used to measure quantity of gypsum in cement
• Sensor showed wrong composition in unit 2
• Reason : damaged 7/25 internal capacitor (ICs)
• Whether to replace 7 ICs or buy new sensor
• Cost of 1IC is 20k and cost of new sensor is 5 lakh
 PROBLEMS AND
SOLUTIONS
• Resolving internal conflicts: I decided to call a meeting. Meeting agenda was to discuss on
whether to buy ICs or go for new sensor. Some were against and some were in favour . As a
manager my role is to enlighten them with proper data and information to take a final decision .I
showed them break even analysis , profit margin of next 5-6 years and productivity and efficiency
of new product(senor).
• Limited budget: why 5lakh ? Things can be solved by replacing old ICs with new one in just 1.5
lakhs. So as a manager I need to convince them by pitching relevant points in favour of new
sensor. I explained them about long terms profits and new technology which can increase
productivity .and by having new technology it gives us edge over our competitors.
• Time management: Time is money. I backed my core knowledge on instrumentations, I knew the
shelf life of new sensor and how it can improve the productivity. And if, I replace those 7 ICs
there still remaining 18 ICs which can cause safety issues in near future. So, the best option was
to have new level detection sensor.
• Providing alternative: Because of faulty sensor, unit 2’s production was on hold.
Visual inspection : estimating the levels based on the appearance
Weight measurements: calculating the levels based on the weight.
SKILLS

• REACTION / RESPOND
• EFFECTIVENESS
• ASSERTIVE SKILL
THANK YOU