BasicSkills

Plant Self-assessment grids

Plant name : Score

P1 Quarry operations
P2 Raw mix preparation
P3 Kiln & Mill operations User's guide (extract)
P4 Refractory selection and lining
P5 Major cleaning operations
P6 Management of contracted works
M1 Managing electrical distribution
M2 Mastering kiln mechanics
M3 Kiln stoppage maintenance management
M4 Management of contracted works
M5 Lubrication management
Q1 Lab reliability
Q2 Quality control Quality assurance
Pc1 Process measurement management
Pc2 Managing the critical process sensors
Pc3 Control system management
GuideGuideGuideGuide
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BasicSkills Plant Self-Assessment
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 Basic Skills Self-Assessment Grid
QUARRY OPERATIONS

Operational objective: safe operations, run according to Lafarge recommandations and best practices, in collaboration with other plant departments and
well documentated.

Level D Level C Level B Level A

Fully dependent Partly dependent Autonomous Optimize and share Level Comments
LONG TERM RESERVES

All permits are existing, the plant is

All permits are existing and land All permits are existing and automatically informed about the
Not all permit are existing and land
control to fullfill short term mining continuous contact with authorities is necessary update of permits. Long
Permit/ land control control to fullfill short term mining is
plan is given. Work on land control is maintained. Land control is followed term strategy for land control with
not given.
not systematic. consequently by the plant. continuous negociations with land
owners exist.
Mgrs

Some drillings with chemical data is Drilling and geological data are A block model not older than five
Geological data are missing. There
existing but not complete. available but not fully updated. years is based on reliable drill data
Data about long term is no reliable drilling campaign and
Geological studies are partly Topography is done. The block and geological information. It is used
reserves / Block model topography. Chemical data are too
existing. Block model is not reliable model can be used but is not very regularly. Topography is not older
doubtfull to build a block model.
because of missing/doubtfull data. accurate. than 1 year.

The blasting pattern contains all

Blasting plans exist but some
specifications (diameter, inclination,
information required at level B are Face profiling is done to identify
Mgrs

There is no formalized blasting spacing, burden, depths, blasting

Basic blasting plan missing. Explosives' user guideline where the distance between the wall
pattern. materials, charge detonators).
provided by suppliers is taken into and the drill could be a problem.
Geological specifities and safety
account.
aspects are precised.

P1
A drilling protocole is systematically
There are well-defined practices

Quarry operations 1/3

BLASTING & DRILLING

written, with indications on material

Drilling protocole for There is no formalised drilling (such as verify with a lamp that the The Best Practices for drilling &
All

characteristics (soft or hard),

operators protocole. blast holes are straight) but they not blasting (from LNA) are applied.
warnings (caverns, cracks) and
formalized.
targets.

The basic blasting pattern is

customized for each blast. Each It is based on the profiling and the
The specific blasting plan is done
There is no specific or not regularly plan contributes to improve the blast borehole tracking. Video of each
Specific blasting plan but their is no formal process of
up-dated blasting plan. design thanks to analyses (vibration, blast are used to analyse it for
improvement between two blast.
fragmentation, muck pile profile, continuous improvement.
back break).
Mgrs

Several criterias are regularly

Fragmentation performance is not
monitored. Number of big blocks
Blasting optimisation
(which cannot be put in the crusher)
is > 20/ 1000t.
LOADING AND
Some adjustements are done
according to experience and some
measurements. There is no precise
monoritoring neither formalized
action plan.
This optimisation is the result of a
assessed to control fragmentation
constant improvement loop through
efficiency such as performance of
successive trials, including a
the primary crusher, number of big
systematic recording, analysis &
blocks/1000t (< 10 for level B) and
comparison with previous trials, up-
fragmentation curves. Drilling and
dating of basic and detailled plans,
blasting costs are calculated.
new targets. Recommandations are
Recommandations from Geomining
all applied.
Guide are applied.

Fuel and tyres consumption is

Some effort are done to improve Rolling resistance is minimized.
HAULING

recorded, long term calculations

road conditions. No evaluation of Water trucks wet roads lightly and
Keep roads in good Road conditions are not optimized at (unit cost per ton) are run to better
All

road conditions on productivity and frequently. Roads are maintained by

conditions all. evaluate the impact of roads
maintenance cost is done. graders not only to clear debris but
conditions on maintenance cost and
also to ensure drainage and level.
productivity.

There is no specific selection
CRUSHING & SIZING
procedure. There is no optimisation
Equipment selection
to minimize downtime and to
lengthen equipment life.
All
There is no regular 1st level
inspection, vibration are never
Maintenance of
measured. Check-lists exist (from
equipment
supplier e.g.) but are not used
because they are not operational.
PILING, RECLAIMING,
Choose the appropriate No stock pile logic defined in
PROPORTIONING
method for pile common in anticipation, no control
All
composition and on the quality of subcontractors'
homogeneity (based on work, no formal and regular check
quarry specificities) on pile homogeneity.
The capacity of equipment is no
Mgrs
adjusted to the need and/or Best
Equipment capacity
Practices concerning equipment are
not known.
Safety practices (pre-
There is no check-list, no risk
operation inspections,
assessment and no formal
clean up, fire protection,
inspections. Recommandations for
personnel protection
mining operations (Geomining
equipment, access to
Guide) are not applied.
machine…)
There is no specific traffic
coordination and only a few traffic
Traffic coordination
signals. There are often incidents
SAFETY
and some of them are recurrent.
All
Benchs are not securised and
Road construction and maintenance is done from time to
conditions time. Recommandations are not
applied.
External people could enter in
External people (in particular
quarry without difficulties. Limits of
Fencing the quarry children) enter easily into the quarry.
the quarry are signalized . Some
Recommandations are not applied.
recommandations are applied.
The fleet is used close to its
You have a complete benchmark
capacity, integrated in quality
that integrates all choice criterias
control process to deliver the
The choice is done only according a (best operating cost, maintenance
requested quality on time with high
small number of criterias. There is requirements & costs, cost effective
reliability (RF>= 86, 87) Equipment
no formal studies to help select the repair strategy and after-sale
is choosen taking into account rock
equipment. service, life expectancy, re-sale
properties, capacity and size for
value) and that you could share with
output material according to the
other plants.
Quality Control plan.
1st level of inspections, vibration
1st level inspections are done, but measurement (4 times /year) and Regular wear measurements are run
observations are not formalized and hammers control (frequency to anticipate changes of spare parts,
measures ( for vibration for example) according to abrasivity) are regularly to optimize preventive maintenance
are not always interpreted. Check- done. Check-lists for inspections are scheduling, predicts maintenance
list exist but maintenance jointly created by Quarry and costs and to help select new
department is not involved. Maintenance Dpts, using check-lists equipment.
from suppliers.
The stockpile logic is defined in an Sampling frequency between
Regular checks are run to control
unformal way, subcontractors are crusher and prehomo piles is
the adequate proportioning and
not involved, few controls are run adjusted according to complexity (1
homogeneity of piles. Basic
afterwards and only some people or 2 /shift) ; the stockpile logic is
principles for pile constitution and
are applying the basic principles for reported in the QC Process plan and
reclaiming are known and applied.
pile homogeneization. is applied
P1
Guidelines and procedures for
Best practices for each equipment Best practices and guidelines per
efficient blending versus equipment
are known but not completely equipment are used. Most of the
Quarry operations 2/3
(Geomining Guide) are formalised
implemented and/or their capacity is time capacity of equipment is fully
and applied. Full capacity is always
not fully used. used.
used for every blending equipment.
Adapted check-lists for 1st level-
inspection of mobile equipment are
Some check-lists for 1st level- The Geo. Guide and assessment
rigourously used by workers before
inspection of mobile equipment are tool are used for regular internal
each operation. Cleaning is part of
used by workers before each audits. Recommandations for mining
the inspections. Sub-contractors are
operation. Housekeeping is not operations (Geomining Guide) are
involved in inspections. Every
perceived as a priority. all respected. There are safety
employee feels responsible for
Recommandations for mining inductions for subcontractors and
keeping equipment in good shape
operations (Geomining Guide) are employees in compliance with
(Clean = Safe). Recommandations
known but not always applied. Lafarge and legal rules.
for mining operations (Geomining
Guide) are respected,
These documents and maps are
Specific documents and maps
Rules exist but are unformal or not systematically shared with new
describing the safety rules for traffic
clearly communicated in particular to comers and subcontractors. As
and who is allowed to drive, how,
subcontractors. much as possible, one way traffic is
what, when exist are communicated.
implemented.
Benchs are not completely Full protection from the crest of the
securised and maintenance of roads bench. Roads and sign roads Local legislations or documentations
is not very regularly done. (speed limits) are constantly are systematically applied and all
Recommandations of the maintened. Recommandations of recommandations of the Geo. Guide
Geomining Guide are known but not the Geo. Guide are respected and too.
always applied. local legislation is applied.
Alarms for blasting operations are
External people cannot enter in the
indicated on boards and made
area. Limits of the quarry are fenced.
public.The quarry is surrounded with
Legal rules and Geo. Guide (Site
a buffer zone except for justifiable
security, Appendix V) are applied.
cases.
 Angles for reposition are respected Additional preventive action have
Angles for reposition are respected
Slope stability and No special actions concerning this and verified by geotechnical been run in the plant to avoid
but not verified. Mobile equipments
dumps management point. technics. Bottoms of dumps are all accident linked to slope stability or
are not always secured against falls.
secured against falls. dumps.

Water intrusions are controlled and There is a full compliance with

There is no problem but nothing is
minimized by adequate measures. in legislation. Water is evacuated out
Mgrs

There are problems of water done to avoid them. Legislation is

Ground & surface water the quarry (chanels, collectors). A of the quarry in a clean way, without
intrusion. Legisation is not applied. taken into account but not
water permit is regularly issued, any danger for personnel &
systematically applied.
according to local legislation. equipment.

Water sprays are functioning for

haulage roads and benches, open
Stake holders For continuous improvement, dust
No specific actions are done to Actions to reduce dust emission are surface is minimised everywhere,
relationship / Dust sources are regularly analysed and
reduce dust emission. not systematically done. wind protection is added when
emission corrective actions are taken.
necessary. You are in compliance
ENVIRONMENT

with the legislation.

Noise limitations are respected for

Noise analysis are run for crusher,
trucks, reloaders, belt conveyors.
mobile equipment, screens,
All

Stakeholders Noise is not monitored or there are Some actions are done to reduce Detonating cords are avoided or
conveyors for full compliance with
relationships/ Noise complaints from stakeholders. noice but not systematically. covered if you have to use them.
legislation and good stakeholders
Closest neighbours are informed
relationships.
about blast campaigns.

Vibration measurements are done Blasting vibrations are monitored in

Vibration are not monitored or there
Stakeholders from time to time and some actions sensitive areas for each blast (two The quarry is in full compliance with
are problems with stakeholders
relationships/ Vibration are consequently carried out but times a year for other sites). Action legislation and with local standards.
about that.
there is no formalized action plan. plan including targets exists.

P1
Rehabilitation plan is partly The Lafarge rehabilitation policy as
A rehabilitation plan which takes into
Mgrs

There is no formalised rehabilitation formalized but local legislations and explained in SQRP and Geomining

Quarry operations 3/3

Rehabilitation account Lafarge policy and local
plan. Lafarge policy are not systematically Guide (Appendix V) and the local
legislation exists.
considered. legislation are fully respected.

Areas which are not homogeneous

Short term reserves are not Mine Cad reports are used in order
Planning phase for There is no real plan for the short are identified and a plan is done to
QUALITY CONTROL

precisely known : their exploitation is to optimize the composition of the

short term reserves term exploitation. obtain a final mix with regular
approximatively planned; mix.
Engineers/ Managers

composition.
Chemical analysis of drilling cutting
Continuous corrections are done
Loading and feeding are not done Some chemical analysis are done are sufficient to be representative for
Quality Control of according precise chemical analysis
according to the composition of the and give indications for loading and the blast material. These analyses
blasted material to optimize the quality and regularity
blast material. feeding but they are approximative. define loading sequences and feed
of the crusher feed.
to crusher.
The QC plan is in line with the Compoptim or a similar mix
Quality Control plan exist but is not
QC in feed to the There is no formalized Quality blending rules and the composition calculation tool is used to set targets
fully applied. It is updated only from
crusher Control plan dedicated to this point. specifications, is rigurously applied for composition of material after the
time to time.
and regularly updated. crusher

All characteristics of reserves and

DOCUMENTATION AND LEGAL

Your block model and geological deposit, property limits, mining rights
Block model doesn't exist or is not A block model is generated and up-
data are not complete enough to and methods, transportation and
Long term mining plan usefull. Guidelines for future dated every 5 years, with support
have a good vision of your long term crushing system, reclamation plan
exploitation are not defined. from Technical Center specialists.
exploitation. and cost, clinker quality and cost
Engineers/ Managers

targets are detailed.

AFFAIRS

All permits to operate are there,

You don't have any 3D digital map.
Short Term mining plan
The short-term mining plan is not
(yearly up-dated)
updated or not complete.
You have a 3D digital map but it is
following legal requirements.A 3D
not updated and environmental, Lafarge guidelines are fully applied
digital map with ownership and legal
legal consideration ar enot always (cf Geomining guide "Mining plans").
situation is regularly up-dated.
taken into account.
Environmental risks are identified.

You have all permissions for

Safety rules (Geomining guide Safety rules are respected but there
explosives using. They are stored in Implementation of specific actions to
Explosives appendix IV) are not always is weakpoint(s) in the procedure
a safe place, explosives & go further than the general safety
management respected and not formally (transit, vehicules contaning
detonators separately. Only rules.
communicated. explosives, etc)
authorized people blast.

Collect all chemical
analysis necessary for
Raw Material : fuels,
All
physical and handling
properties (fineness, dust,
sticky).
At plant level, everybody
uses the same formulas
RAW MIX COMPOSITIO
Mgr
for the calculation and
common tools for
optimisation
Regular testing
Mgr
Identify the main drivers
(plant specific) for
optimisation
Check list for each new
Purchasing
product (chemichal,
physical analiysis,
hazards, suppliers
information)
Anticipate impacts on
All
fineness
IMPACTS ON PRODUCTION
Analyse emission impacts
All
(checked with legal There is no precise analysis.
constrains)
Anticipate the burnability
All
impacts
Operational objective: raw mix preparation ensures best clinker consistency and kiln line productivity optimization
Level D
Fully dependent
Most of the analysis are coming
from suppliers or run from time to
time. It is impossible to assess the
risk and the variability of these
materials from the collected data.
There is no common rules
concerning the use of calculation
tools. Several of them are used
giving slightly different results.
Tests are done but not
Testing is erratic and not coherent
systematically. Only a few people
(several factors changed in one test
are able to run them and to analyse
e.g.)
the results
They are not identified.
Information is partial and
desiminated between several
people
There is no anticipation.
The impact on burnability is not
correctly assessed or it does not
lead to new instructions for
operations
Basic Skills Self-Assessment Grid
RAW MIX PREPARATION
Level C Level B Level A
Partly dependent Autonomous Optimize and share Level Comments
All analysis are very regularly
collected (from the purchasing
department, lab, databases,
Some analysis are collected but not
suppliers, etc) in a formal document Quality audits regularly done to
systematically. Variability from batch
that is updated according to all control Quality management system.
to batch can not be assessed.
changes (new alternative fuels, new
materials, etc) and shared by
everybody.
Purchasing is involved in the
There is just one tool valited by TC.
In general you use the same tools process and systematically informed
Standardized calculation reports are
but it is not a rule. Simulation tools about the calculation results, key-
used. Simulations are regularly
are used from time to time. functions are fully aware of the
done.
standard tools and documentation.
Ressources and procedures exist on
site for regular raw mix and
alternative fuels sampling and You analyse results to optimize the
testing. Quality control is permanent. products' influence.
You have all permits to use the
P2 Raw mix preparation
products.
They are identified thanks to Level C + potential risks have been
Documents with best and worse
rigourous studies run jointly by all identified: what can happen in
scenarios have been written.
departments process with new tests, products?
Check-lists for all products that can
influence the raw mix preparation
Check-lists exist and are complete
are available at the Purchasing
but are not gathered in the There is a benchmark between the
Department. They indicate needed
Purchasing department and not different type of products.
information to use a material. They
regularly updated
are systematically consulted before
calculation.
1/2
You have an approximative idea on You have procedures for Risk management is included in the
fineness impacts but you haven't acceptance of raw material to avoid procedure and control chart has
formalized them. problem linked to fineness. been implemented.
Some analysis are run but only in You try constinuously to reduce
There are regular emission control
case of major incident (in particular if emission impacts (even though you
charts and environmental reports.
there no strong legal constrains) respect legal constrains).
Level C + for major change a
Burnability tests (K 1450) for a new burnability test (K 1450) is run.
raw mix composition are not run People are aware on test done by Study on burnability involving the TC
before burning but after, in case of external laboratory and control chart experts are done when necessary.
incident for parameter which influence the
burnability is implemented.
IMPACT
There is some procedures but there
Procedures for checking You have implemented a control
is no systematic control of You have procedure to check your
All and maintain reliability of loop to improve continuously
There is no procedure. equipment. Ponctual actions are raw mix about sampling system
dosing, testing and reliability of dosing, testing and
done to correct errors. There is no (accurate dosing).
mixing equipment mixing.
real improvement approach.

Storage capacity and You have an approximative idea on There is a calibration sheet, a Storage is optimized. Specific
IMPACTS ON PRODUCTION
Tech

logistic management They is no precise anticipation storage situation but you don't delivery and storage plan so that the solutions heve been implemented to
related to (silos, about the storage of raw materials. formalized logistical aspects linked material is in right amount, in right improve the storage conditions
deposit…) to it. time and in right place. according local conditions.

There is a daily morning meeting

There in particular collaboration focus on raw mix between quality
Homogeneisation and There is from time to time a meeting Actions based on the daily report are
between Process, Production and and production teams. A daily report
All

handling of raw materials/ between Quality and Production systematically taken to optimise
Quality on that point. Nothing is is written about the fluctuation of kiln
raw meal. teams. A short report is written. homogeneisation and handling.
formalized. feed & raw mix composition
checking the compliance to targets.

Raw Mix samples are done on a

Sampling (frequency, The sampling plan is updated and
There is no sampling plan Sampling is done from time to time regular basis according to
Mgr

procedures, optimized continuously according to

specificaly dedicated to raw mix. or/and is not reported. procedures (representativity) and
representativity) tests results.
the sampling plan.
IMPACTS ON CLINKER

Calculate variation (C3S,

The calculations are not frequent The calculations is regular and Adjustement are systematically done
C2S, C3A,sulfates, Calculations are not done or nor
Mgr

enough to efficiently adjust control chart is implemented to according to the temperature profile
alkalies ratio, liquid complete. They are erratic.
production factors . adjust production factors. (t°, lenght of burning zone).
phase)

"Classical" calculations are run

You have sufficient knowledge about
without specifying the specific You have defined your own

P2 Raw mix preparation

Get a plant specific set of Specific drivers are not identified process and production to do
ranges of the main drivers for the modulis/drivers taking into account
Mgr

modulis/drivers to control and only few indications are given to pertinent calculation and be able to
raw mix. Information given to what has the biggest influrnce on
the clinker quality the production team. give the best indications to the
production team could be more your process.
production team.
useful.

CCR operators have procedures Specific procedures documentation

CORRECTION

Establish corrective You use statistical tools but and documentation of actions for of actions are formalized to improve
Statistics skills are missing. Trend
Mgr

actions thanks to corrective actions are not systematic quick corrective actions with a reactivity of production team and
analysis are not run.
statistical control tools or badly communicated. shorter range than daily. They use consequently the efficiency of
control charts. corrective actions.

Some corrective actions are run but Procedures are formalized including
Set points, targets and There is no specific procedure if
you don't formalize a complete time schedule and techical center You have implemented a continuous
Mgr

plan actions if they are targets for raw mix quality are not
action plan. Targets are not up- reports are used (feasability, simix improvement process.
not reached reached, or they are not applied.

2/2
dated document…).

You are able to identify when you

Simulations are done but TC need to run a simulation and plant The knowledge about simulation
Raw Mix simulation recommandations are not applied. people are involved in the process. (how use simulations, what have
Mgr

You don't run simulations.

(simix, simpile…) Operators & supervisors are not You use TC reports and you can simulations shown/teach to us) is
really aware. It's only the job for TC. interprete results and do some fully capitalized
TRIAL/ PROCESS STUDI

corrections.

Risks have been all identified and

you use systematically a specific Risk management is an everyone's
Risk management is formalised but
Risk management for Raw document inluding all points you concern in your plant and you would
Mgr

There is no risk management. not complete. External experience is

Mix equipment have to survey (what to do in case of be able to share your experience on
needed to progress
anormal result). All trials are that with other plants.
scheduled.
INDUSTRIAL/ PR Level C + you are able to react and
There is a regular reporting including to adapt quickly to the evolution Like some effects appear only after
Continuous control of the You only run ponctual checks.
All industrial tests results, compliance (new alternative raw materials for several months, you analyse and
process concerning wear There is no analysis with time and
to targets, time scheduling, example). Validations on a time report also the process on longer
& corrosion reference data.
incidents, etc. schedule including the expectable basis.
effects of evolutions are planned.

You run a specific survey about laws

manager
Plant

Raw mix line compliance Local laws and legal affairs are not Local laws are known and legal Local laws are mastered and evolution concerning raw mix and
with local laws a major issue at the plant level. affairs are followed. communicated to concerned teams. preventive actions to avoid legal
problems.

Pre-start checks (kiln feed
system, cooler and clinker
Operators
handling, ID Fan, coal
conveying system, baghouse, Not all the checks are done.
preheat system, material flow,
common equipment, burner
pipe)
Operators
Preheating phase
Operators
Operate with stable
conditions and optimize
KILN OPERATIONS
performance.
Process inspections (false
Patrollers
air, hot spots, build-ups,
spillages, leakages, flap
condition, vibrations, noices,
dedusting system, etc.)
Engineer
Process audits (combustion,
Audits are not done.
heat balance)
Operators
Process incident
management (hot spots,
cyclone blockages, rings,
build ups)
Operational objective: produce more, with uniformity and minimum cost.
Level D
Fully dependent
The preheating program is not
precisely defined. Process
parameters (shell scanner, tire
creep, turning schedule, kiln hood
pressure, etc, cf list in the BP
"Preheating phase") are not
followed.
Operators are not able to maintain
stable conditions (kiln cycling).
There are no routine inspections.
Nobody is able to solve incidents
without the help of TC.
Basic Skills Self-Assessment Grid
KILN & MILL OPERATIONS
Level C Level B Level A
Partly dependent Autonomous Optimize and share Level Comments
Procedures are accurately followed
All equipment is checked according
whatever the situation. Checklists
Checks are all done but not to pre-start checklists; for each piece
are regularly reviewed and updated.
systematically according to a formal of equipment a check sheet is filled
A formal debriefing (Post audit) is
procedure. in and validated through a formal
organised one week after the start-
process.
up.
The start-up program (kiln
temperature increase per unit time,
All the parameters to be followed are
turning schedule, timing of
The preheating program exists but is recorded and deviations are
introduction of raw feed, etc) has
not complete and/or not consistent analyzed during the post audit (cf
been clearly defined considering the
with the BPs "Preheat the kiln BP "Post audit"). The schedules
type of start-up (cold or hot), the
refractory brick lining", "Preheating have been adjusted to plant
type of refractories, the design of the
phase" and "Kiln turning schedule". specifities taking into account these
kiln system and the mechanical
records.
system. All parameters are
accurately followed.
Operators are able to achieve and
maintain production targets and to
P3 Kiln & Mill operations
Operators are able to maintain keep parameters constant (volume Process deviations are
stable conditions but do not follow load, clinker cooler bed depth, hood systematically detected and
operating guidelines aimed at pressure, oxygen, calcination, ID fan analysed. Control charts and
maximizing production and meeting outlet pressure, free lime). Incidents procedures are regularly reviewed
quality targets. are analysed during reliability and improved accordingly.
meetings. Procedures and charts
are available.
Routine inspections are made, but Regular inspections are made, and Detailed checklists are used and
observations are not recorded and inspection routes are defined. work orders are automatically
checklists are not formalized. Checklists are available and used. generated.
Audits are done completely The TC is only consulted for
1/3
internally: all measurements, technical references on the full kiln
inspections, calibrations, analysis of audit; otherwise, all analyses and all
Audits are done but the plant needs
data and trends, reporting, etc are evaluations are mastered at plant
external help to perform them.
performed and mastered by the level. Audit follow-up has already led
plant team. A full kiln audit is to significant improvements at the
regularly done with the help of TC. plant.
Operators are able to bring
Each incident is analyzed and leads
Operators can only solve incidents equipment back to target range in
to an update of procedures /
with the help of management. There optimal time by using available tools
recommandation trees. Operators
are no procedures or tools to help like BP, Les Cas. Procedures /
are trained to solve incidents on a
them. recommandation trees are available
kiln simultor.
in the plant.

Operators
Controlled and emergency
shutdown
Supervisors
Ball charge sorting
Process engineer
Ball charge management
MILL OPERATIONS
Operators
Operations (feed, ventilation
and separator)
Patrollers
Routine inspections
(spillages, leakages, weigh
feeder cleanliness, belt
tracking, etc)
Shutdown inspections
(liners, diaphragms,
Operators
ventilation screens, ball
charge, nib traps, trunnions;
for separator: reject cones,
liners, selector blades,
distribution tables, etc).
Engineer
Audits (annual and
triennial)
Emergency procedures and cooling emergency shutdown, but there is
procedures are not followed and not no written procedure. Cooling
formalized.
The charge is sorted only when mill
performance is seriously affected.
Ball charge level is not monitored.
Ball additions are not done.
Operators modify levers only when
instructed to do so by the
quality/process team.
There are no routine inspections.
There are no shutdown inspections.
Audits are not regularly done and/or
are not performed by the plant team.
Operators are able to manage an
program is followed but not
formalized by a written document.
The charge is sorted from time to
time without any schedule.
Ball charge is not monitored with
enough accuracy to be really
managed. Ball additions are only
done to keep the charge constant.
Operators do not fully master all the
levers. Only some procedures are
available.
There are routine inspections but
observations are not recorded and
checklists are not formalized.
There are shutdown inspections but inspection sheets are formalized,
observations are not recorded and
inspection sheets are not formalized. trommel screens are systematically
Audits are done but the plant needs
external help to perform them (even
for short, annual mill audit).
There is an SOP for emergency
shutdown (power failure, PLC
Operators are able to implement the
failure, electrical distribution failure)
SOP in case of emergency
in order to secure equipment. There
shutdown without external help (e.g.
are cooling procedures including
they have sufficient electrical
turning schedule and temperature
background/training, know how to
curve for kiln, cooler grate
reboot the PLC).
protection, burner pipe protection, ID
fans.
The charge is sorted every
5000/7000 running hours and at
least once a year for the first
Additional sorting is done in case of
compartment; every 10000/14000
contamination (scraps, deformed
running hours and at least every two
balls, unsuitable size).
years for the second compartment.
Mill shutdowns are planned in the
production plan.
Charge is monitored with troughput,
Ball charge is also adjusted
power consumption and is estimated
according to the plant priorities
during the monthly inspection (by
(reduce mill power consumption or
measuring the heights in several
maximize production). Ball charge is
points). Ball charge size is adjusted
accurately monitored and the effects
according to material fineness
on performance are analysed and
curves in the different chambers
optimised (use of software) .The
(samples). All ball sizes are always
best practice "Ball charge
available in stocks in sufficient
management" is fully applied.
quantity for additions.
Operators fully understand the
Operators are able to anticipate
process and are able to adjust on
deviations and can make the
their own the different levers.
decision to stop the mill when out of
Procedures are implemented and
specifications.
used.
P3 Kiln & Mill operations
There are regular inspections, and Detailed checklists are used and
inspections routes are defined. work orders are automatically
Checklists are available and used. generated.
There are regular inspections and
Work orders are automatically
generated. Results of inspection are
used and analyzed. Diaphragms and
recorded and trends are analysed to
optimize mill performance.
cleaned.
2/3
The annual mill audit is done
completely internally: all tests, The TC is only consulted for
inspections, calibrations, analyses of technical references concerning the
trends and flow sheets, reporting, triennial mill audit; otherwise, all
etc (as per the BP "Ball mill analyses and evaluations are
optimisation and performance") are mastered at plant level. Audit follow-
performed and mastered by the up has already led to significant
plant team. The triennial mill audit is improvements at the plant.
done with help from TC.
 Test results are properly translated
All operators & technicians
Translation of test results into into operational parameters. Even if
understand perfectly the link
Take appropriate corrective operational parameters is under expert software is usually used for
Operators
between tests results and
actions for kiln or mill Corrective actions for kiln or mill control only if an expert software corrective actions (QMC, Lucie),
operations (eg: if blaine too high,
operations based on results operations are not appropriate and system (QMC, Lucie) is in use. operators are able to react
what action should be taken on
(feeders, separator speed, are not under control. Some tools exist for calculation and appropriately in case of sofware
separator and why?), and they are
QUALITY

etc.) decision making (charts, tables), but
they are not always used.
breakdown by using calculation and
involved in Quality Management
decision making tools (charts,
System.
tables, decision tree).

Quality is also an objective for the

The production shift is able to
Quality indicators and objectives are production shift. IQP are known and
Quality indicators and objectives are analyse quality indicators and
Quality indicators and taken into account by the production taken into account. Quality aspects
All

not a matter of concern to the objectives and to adjust production

objectives shift, but they are not fully are reviewed at daily production
production shift. parameters accordingly. Operators
understood by the operators. meeting and completely mastered
are involved in IQP review.
by the team.
Production mger
ENERGY

Use of alternative fuels is planned in The plant can use any kind of fuel,
Alternative fuels are regularly and
Fuels management (relevant Alternative fuels are used without advance in the production plan. Raw as per the ressource recovery lever.
properly dosed; some raw mix

P3 Kiln & Mill operations

only if plant uses alternative any planning, proper dosing system mix chemistry is designed taking into This fuel flexibility allows the plant to
adjustments are done on a day-to-
fuels) or raw mix adjustements. account the chemistry of alternative take get the best fuel prices
day basis.
fuel ashes. available.
EMISSION

MANAGE

Regulations are taken into account

MENT

Regulations on emissions are not and emissions are monitored, but Emissions are fully controlled. There Specific tools or management
Emissions management
All

really considered. Emissions are not the plant doesn't yet comply with is a real commitment within the plant systems have been implemented to
S

(dust, NOx, SO2, CO2)

monitored. local regulations (or the Group's and at BU level to reduce them. manage emissions.
expectations).

All recommandations/ remarks are

Safety pep talks involving all
SAFETY

reviewed on a weekly basis by the

Safety pep talks are given from time operators are given at the start of
production manager; he/she
All

Safety pep talk There are no safety pep talks. to time (for example in case of each shift. All recommandations/

3/3
responds to requests and chooses
incident). remarks are written down in a
points to be mentionned at the
dedicated notebook.
monthly safety meeting.

Operational objective: choose and install refractories for maximum kiln reliability factor and minimum cost.
Level D
Fully dependent
Analyse the
performance of existing Kiln lining chart doesn't exist or is
bricks incomplete (type of bricks vs
position vs year, kiln shell T°,
coating formation, drilling, etc.)
Drilling and consumption (g/tonne)
estimations are not regularly done.
There is no RCFA (Route Cause
Failure Analysis) for refractory
issues.
Analyse wear
mechanism and
Production/Process No analysis of the type of wear, no
parameters (KFUI, comb. inspection reports after incident
Audit, fuel preparation, stoppages, and no analysis with
recent production data. Incidents are
PERFORMANCE ANALYSIS & FOLLOW-UP
etc.)
frequent and recurrent.
The kiln stoppage and start-up
procedures do not take into account
Engineers / Managers
the refractory properties.
Analyse cost situation
Equivalency chart not known.
Suppliers are not guided; they lead
the decision process.
Plant habits determine type of bricks
per zone. Basic rules of castable
application are not respected.
Purchasing documentation
incomplete.
Analyse refractory
incidents
Basic documentation (Supplier docs,
internal reports, etc.) is missing to
analyse incidents over a long period.
Incidents are recurrent, damages
are repaired but no collective
corrective actions are taken. No
specification given to suppliers, and
no supervision of refractory works.
Basic Skills Self-Assessment Grid
REFRACTORY SELECTION & LINING
Level C
Partly dependent
Kiln lining chart exists but is not
regularly reviewed. Data collection is Types and shapes of bricks are
insufficient for correct analysis.
No local working group to run RCFA
with recent production data or
previous audits. Improvements to
kiln operational procedures and
brick types are not made.
Local expertise is missing to run
correct diagnosis for wear
mechanism. No local working group
to run RCFA with recent production
data or previous audits and to
modify the kiln operational
procedures.
Kiln stoppage and start-up
procedures are not always used.
Equivalency chart not used. No clear Equivalency charts and trial
and collective analysis of refractory procedures are used. Specifications
consumption.
The type of bricks to use per zone is
not determined by technical or
operational considerations.
No local working group to run RCFA
with recent production data or
previous audits. Brick wear is not
analysed taking all factors (process,
raw mix, production, kiln mechanics,
etc.) into consideration.
External help is needed for
corrective actions. Methods and
expertise are lacking on site.
Level B
Autonomous
Kiln chart is regularly updated.
analysed.
Brick consumption is calculated and
optimised thanks to correct drilling
and laying operations.
Technical documentation and
expertise reports are available on
site to get wear diagnosis and
corrective actions, by taking into
account previous kiln inspections.
The kiln stoppage and start-up
procedures take into account
refractory properties.
to suppliers are clearly defined.
The choice of brick characteristics
per kiln zone is optimised. But no
review of similar bricks by
performing benchmarks and trials.
Incidents result in Root Cause
analysis by plant reliability
committee. Refractory wear is
analysed using operational
(overheating, coating failure, etc.)
and mechanical conditions of
equipment (ovality, etc.).
Corrective actions are clearly
defined and applied with help of
suppliers, contractors and TC.
Level A
Optimise and share Level Comments
Kiln lining chart is regularly updated
and analysed with an appropriate
computing tool (e.g. Winbrix ).
Operations documentation (IP21) is
used.
Drilling is carried out every meter
(avg. of 3 measurements). Regular
dialogue with Tech Centres leads to
technical improvements. BRIKK
database is also used to post lining
chart, incidents reports, repairs, etc.
Refractory are systematically
inspected and the wear profile of
refractories is analysed. Reliability
committees compare this
information with production/
mechanical/ process data, to enable
P4 Refractory selection and lining 1/2
cross-departmental documented
corrective actions.
The kiln stoppage and start-up
procedures take into account
refractory properties and are
regularly reviewed and
communicated.
Equivalency chart and trial
procedures used and updated.
Benchmarking and trials between
different suppliers are performed.
Participation in the Refractory
Network for choice of bricks.
Dialogue with Tech Centres, BRIKK
& Les Cas databases, lead to
technical improvements.
Refractory incidents are
systematically analysed according to
a well-known and accepted
procedure. Operations
documentation (IP21) is used. H18
Reliability committees bring together
all expertise areas and lead to
documented and controlled cross-
departmental corrective actions.
Supplier and contractor impact is
minimised.
 Update reporting
Installing bricks in kiln =
brick work preparation,
dismantling, cleaning,
base line tracing, brick
placing and laying, ring
closing, brick cutting,
joints (cardboard, metal
shims)
Installing castables and
concrete blocks in kiln =
planning / preparation,
anchoring, gas trapping,
homogenisation, dosing
(no excess water),
mixing, transport,
pouring, compaction,
REFRACTORIES INSTALLATION
curing, drying, heating-
up
Supervisors & operators
Installing bricks in the
preheater and cooler
(brick work preparation,
dismounting, cleaning,
base line tracing, brick
placing, ring closing,
brick cutting, joints,
anchoring, shelving)
Installing castables and
concrete blocks in the
preheater and cooler
(preparation, anchoring,
shuttering/gas trapping,
homogenisation, dosing
(no excess water),
mixing, transport,
pouring, compaction,
curing, drying, heating-
up)
Specific installations for
specific points (retaining Suppliers are not guided and
rings, nose ring, burner generally lead the operations.
pipe, etc.) Lafarge guidelines (retaining rings
shapes, insulating material,
compaction techniques, expansion
joints…) not known. No local
expertise on these delicate technical
issues. Tools and machines are in
bad condition or missing.
No operational procedures, no
collective formalisation effort.
Technical documentation (suppliers,
Tech Centres, etc.) is not used or
not known. No written trace of
previous incident analyses.
Basic guidelines are not known.
Quality of job depends on
contractors' knowledge; contractors
are not guided. Tools and machines
in poor condition or missing. No
warehouse for refractory storage.
Basic guidelines are not known.
Quality of job depends on
contractors' knowledge; contractors
are not guided. Tools and machines
in poor condition or missing,
Basic guidelines are not known.
Quality of job depends on
contractors' knowledge ; contractors
are not guided. Tools, cutting
machine in poor condition or
missing.
Gunning techniques systematically
used. Basic guidelines are not
known. Quality of job depends on
suppliers' knowledge; contractors
are not guided. Tools and mixer are
in poor condition or missing. No
mixing and casting procedure.
Operational procedures are missing
or are not applied because not
appropriate. No review of casting or
bricking plans. Audit, inspection and
incident reports are not
systematically written and used.
Lafarge guidelines as explained in
BRIKK are not systematically
applied. Operators and supervisors
do not have sufficient understanding
of brick installation. Operational
procedures are widely missing. Lack
of formalisation leading to vague
instructions to contractors.
Refractory not systematically stored
against humidity.
Lafarge guidelines as explained in
BRIKK are not systematically
applied. Operators and supervisors
do not have sufficient understanding
of brick installation. Operational
procedures are widely missing. Lack
of formalisation leading to vague
instructions to contractors.
Lafarge guidelines as explained in
BRIKK are not systematically
applied. Operators and supervisors
do not have sufficient understanding
of brick installation. Operational
procedures are widely missing. Lack
of formalisation leading to vague
instructions to contractors.
Lafarge guidelines as explained in
BRIKK are not systematically
applied. Operators and supervisors
do not have sufficient understanding
of brick installation. Operational
procedures are widely missing. Lack
of formalisation leading to vague
instructions to contractors.
Lafarge guidelines as explained in
BRIKK are not systematically
applied. Operators and supervisors
do not have sufficient understanding
of brick installation. Operational
procedures are widely missing. Lack
of formalisation leading to vague
instructions to contractors.
Most operational procedures exist.
Specifications to suppliers are
clearly explained and followed
(acceptance notes). Inspection and
incident analysis reports are
systematically issued and used.
BRIKK database is known.
Guidelines as explained in BRIKK
are known, applied and explained to
contractors. Most operational
procedures, drawings, and
installation guidelines exist and are
applied. No more steps, groove
formations or twisting effects.
Guidelines as explained in BRIKK
are known and applied. Some
mixing, vibrating, anchoring, etc.
procedures, plans and drawings
exist. Expansion, insulation, shell
protection, castables preparation
and compaction, etc. issues are
understood.
Guidelines as explained in BRIKK
are known, applied and explained to
contractors. Most operational
procedures and drawings for
installation of key bricks, joints, etc.
exist.
Guidelines as explained in BRIKK
are known, applied and explained to
contractors. Most procedures, plans
and drawings exist. Expansion,
insulation, gas trapping, etc. issues
are understood. No more burnt or
broken anchors and roof beams.
Castable curing is taken into
account in start-up procedure.
Guidelines as explained in BRIKK
are known, applied and mostly
formalised thanks to drawings and
plans. Castables curing is taken into
account in start-up procedure.
Guidelines for burner pipe refractory
installation are respected. No more
cracks or pinches around retaining
rings.
BRIKK and Les Cas databases
regularly consulted. Local experts
also contribute to BRIKK and BRS
databases and participate in the
Refractory Network. Local
procedures are regularly reviewed.
Regular dialogue with TCs leads to
technical improvements.
Knowledge and skills are formalised
into operational drawings and
procedures, and used for every new
comer. Procedures comply with TC
experts' and BRIKK
recommendations. Contractors
receive instructions and procedures
to follow. Supervision is systematic.
Know-how transfer is organised.
Knowledge and skills are formalised
into operational drawings and
procedures, and used for every new
comer. Procedures comply with TC
experts' and BRIKK
recommendations. No contractors
without supervision. Contractors
receive instructions to follow.
Supervision is systematic. Know-
how transfer is organised.
P4 Refractory selection and lining 2/2
Knowledge and skills are formalised
into operational drawings and
procedures, and used for every new
comer. Procedures comply with TC
experts' and BRIKK
recommendations. Contractors
receive instructions and procedures
to follow.
Knowledge and skills are formalised
into operational drawings and
procedures, and used for every new
comer. Procedures comply with TC
experts' and BRIKK
recommendations. Contractors
receive instructions and procedures
to follow. Supervision is systematic.
Know-how transfer is organised
Knowledge and skills are formalised
into operational drawings and
procedures, and used for every new
comer. Procedures comply with TC
experts' and BRIKK
recommendations. Contractors
receive instructions and procedures
to follow. Supervision is systematic.
Know-how transfer is organised.
 Safety for refractory
works
Basic safety rules not applied. No
specific precautions during
SAFETY
refractory operations, in particular for
dismantling and decoating, or when
All
using scaffolds. No written
instructions or supervision for
contractors; protective equipment
not systematically used.
Safety rules are regularly updated
All safety procedures are written and and communicated internally.
Basic safety rules are applied but
applied. Workers are aware of risks. Contractors receive safety
formalisation and communication
They are regularly informed of instructions and procedures to
are missing. Safety shields or cages
modifications in protective rules and follow. Safety audits are run during
are missing during decoating.
accept them. Safety shields or refractory operations. Safety aspects
Reporting of incidents is not
cages are systematically used when are systematically assessed when
systematic. No risk analysis. Lafarge
decoating. Lafarge guidelines for running trials. Lafarge guidelines for
guidelines for scaffolding and work
scaffolding and work at height are scaffolding and work at height are
at height not communicated.
known. known and available for suppliers
and new comers.
 Basic Skills Self-Assessment Grid
MAJOR CLEANING OPERATIONS

Operational objective: properly conduct all major operations to guarantee constant flow and prevent most blockages under the safest conditions

Level D Level C Level B Level A

Fully dependent Partly dependent Autonomous Optimise and share Level Comment

Daily checks are made for material

flowrate (by observing loading time)
Flowrate is only checked from time to and lumps. Silos are emptied out at
Technicians

Specific preventive actions are taken

Plant does not organize daily actions time; visual control is only done in least once a year to check the
to reduce build-ups and avoid
to detect blocages. Plant does not case of problem. Plant does not have available vs nomimal capacity and a
Silos and hoppers blockage (e.g. by painting the inner
check flowrate regularly. Visual SOP for silo blockage detection and visual control of build-ups is
surface of the cone silo or by
control inside silos is not done. does not monitor back pressure. performed; water infiltration and
installing vibrators).
PREVENTION AND DETECTION

Water infiltration is not checked. aeration blowers are regularly

checked. All these checks are done
according to procedures.

Spillage and pressure rises are

Technicians

Transport equipment (belts,
chain-supported, air, elevators,
drag chains)
Spillage is not usually detected.
Spillage is usually detected and
equipment pressure levels are
checked from time to time.
Procedures do not exist or are not
applied.
monitored continuously. Transport
equipment is inspected by production
and maintenance teams on a
scheduled basis to avoid spillages
(belt alignment, belt cleaning device,
bucket elevators recycling, etc).
Precise criteria have been
determined at plant level to identify
when cleaning is necessary.
Continuous improvement process is
implemented to minimize spillages.

P5 Major cleaning operations 1/3

Static pressure, gas temperature and
material build-up (with radioactive Kiln monitoring by kiln operators is
Technicians

detection system, if available) are sensitive enough to quickly detect

Pre-heaters (cyclones, pre-
calciner, risers)
Plant does not organize any routine
Plant does not monitor materials and continuously monitored to detect small process parameters (air
actions to detect build-ups and avoid
pressure regularly. Procedures exist blockage as soon as possible. The distribution, thermal profile, pressure
risks of blockage. There is no
but are not systematically applied. pre-heater is inspected very regularly change, etc.) induced by build-up
procedure concerning this issue.
(meal pipes, riser ducts, etc). All formation in cyclones, riser ducts,
procedures are accurate and fully and dip tube.
applied.

For each major cleaning operation a

Managers

There is no risk analysis done at
plant level. Risks associated with
Risk analysis
certain cleaning devices are not
precisely known.
WORK PREPARATION
risk analysis is done, taking into All the concerned persons are
Some risk analyses are performed
account specific risks such as involved in the risk analysis.
but not systematically and/or all risks
temperature, burying, suffocation, Significant actions have already been
are not taken into account.
falls, dust inhalation, electrical injury, taken to reduce the identified risks.
reduced visibility.

A prevention plan is decided at a

formal meeting with all works
supervisors. All potential risks are
A prevention plan exists but not all
reviewed and actions are taken to Every contractor is certified on safety
supervisors are involved. Thus, not
All

Prevention plan There is no prevention plan. reduce them. All concerned before admission to the plant and
all risks are analysed and/or are not
operators are systematically briefed they involved in the prevention plan.
fully communicated to operators.
on potential hazards, receive safety
training and have regular medical
checkups.

A safe work permit including specific

There are specific safe work permit
Safe work permits are delivered but hazards is systematically delivered
(e.g. for confined space) including
All

Safe work permit Safe work permits are not delivered. not systematically and/or they are not before any intervention and signed
also specifc requirements, air
complete. by the responsible person and the
monitoring, emergency numbers, etc.
concerned operators.
WORK PREPARATION
Critical areas are not fully secured.
All
Securing the area There are no written procedures
concerning this point.
Cleaning plan for regular
Mgrs
There is no scheduled combining of
operations (conveyors,
major cleaning operations.
cyclones, etc)
Technicians
Not all precautions (cf level B) are
taken before entering the silos.
Silos and hoppers
Procedures do not exist or are not
CLEANING EXECUTION (if contracted use grid P6)
applied.
Technicians
Not all hazardous parts of equipment
Transport equipment (belts,
are provided with guards. There are
chain-supported, air, elevators,
no written procedures concerning
drag chains)
interventions on transport equipment.
Routine coating cleaning operations
Technicians
in pre-heaters are executed without
Pre-heaters (cyclone written procedures, and only from
blockages) time to time. Cyclone blockages are
not cleared according the BP
"Clearing cyclone Blockages".
Technicians
Checks (cf level B) are not done by
the manager in charge before
Kiln
sending personnel into the kiln.There
are no written procedures.
Procedures exist and are applied, but are installed according to
some hazardous points remain within procedures. Access to equipment is
work areas (inadequate work
platforms, difficult access, etc).
A schedule exists but does not take
into account all the works and/or is
not updated.
Precautions are taken, but some
procedures are lacking.
Most hazardous parts of equipment
are provided with guards. Written
procedures concerning maintenance
work on transport equipment are
applied, but some may be lacking.
Routine coating cleaning operations
in pre-heaters are executed on a
regular basis, but procedures are
only partly written. Cyclone
blockages are cleared according the
BP "Clearing cyclone Blockages" but
there are no adapted procedures
available in the plant.
Checks (cf level B) are done by the
manager in charge before sending
personnel into the kiln. Written
procedures are partly available.
All unnecessary equipment is
removed and protection installed to
prevent fires due to spillage of hot
materials. Suitable work platforms
After each operation a debriefing is
organised in view of improved
secured and easy to use (especially securing of the area for future
for poke holes). Equipment is locked operations.
out. Adequate lighting is provided. All
safety equipment is prepared and
emergency escape areas are
designated.
A cleaning plan exists and is The frequency of cleaning operations
updated; it describes each operation, is adjusted according to previous
its frequency and responsabilities. experiences.
All devices affecting the silo are
locked out. The cleaning operation
starts only after an inspection inside
P5 Major cleaning operations 2/3
from the top of the silo, and after
Root cause analysis involving
determining the safest way to work.
operators is carried out for all near
The cleaning operation is performed
misses. Safety procedures and
according to the BP "Silo entry and
training are adjusted accordingly.
cleaning". Written procedures
covering all aspects from preparation
to hand-back to production are in
place and fully applied.
Robust guards prevent access to all
hazardous parts of conveyors and
transport equipment. They are
Root cause analysis involving
removed only after isolation and
operators is carried out for all near
lockout, with non-reverse ratchet
misses. Safety procedures and
engaged where necessary.
training are adjusted accordingly.
Procedures are available and strictly
applied (e.g. no cleaning operation
performed on equipment in motion).
Routine coating cleaning operations
in pre-heaters are executed
according to a written procedures
describing the operations and safety Root cause analysis involving
risks. All actions mentionned in the operators is carried out for all near
BP "Clearing Cyclone Blockages" misses. Safety procedures and
(part 9, page 7) are taken for every training are adjusted accordingly.
operation of blockage clearance, and
are included in procedures available
in the plant.
Before sending anyone into the kiln,
the manager in charge checks that all
A safety tunnel is used for any
safety conditions are met: heat,
intervention in the kiln. Root cause
secured access to the kiln upstream
analysis involving operators is carried
and downstream, coating, dust. A
out for all near misses. Safety
safety tunnel is used for every major
procedures and training are adjusted
intervention in the kiln. Written
accordingly.
procedures are in place and are fully
applied.
CLEANING EXECUTION (if contracted use grid P6)
Working conditions (team
No precautions of this kind (cf level
All
staffing, breaks and first aider
B) are taken.
skills)
Technicians
There is no continuous
communication with CCR and/or
Provide close supervision operational conditions are not
continuously monitored during the
operations.
Not all required equipment is
Availability of safety available or is not adequate
All
equipment (especially PPE) or not in good
working condition.
Technicians
Hand-back process is done without
Checking before release
any written and precise procedure.
RE-START
There is no formal release to
All
Release to production production once the cleaning is
finished.
In case of emergency, precautions
are not systematically taken;
operations may take place without
enough people or without a first aider
on hand.
Continuous communication with CCR
is usually maintained but not
systematically and/or operational
conditions are not always
continuously monitored during the
operations.
All required equipment is not always
in good working condition, but is
usually available.
There is a written procedure for
hand-back, but it doesn't precisely
state all the steps to be followed
and/or if it is complete, it is not
correctly applied.
A specific protocol to ensure release
to production is followed but not
always formalised by a written
document. All aspects are not always
communicated.
Enough persons are systematically
and constantly posted and are
provided with relief breaks to All operators participating in cleaning
minimise heat stress effects. At least operations are trained as first aiders.
one member of the cleaning team is
fully trained as a first aider.
There is close radio communication
with CCR and continuous monitoring
of operating conditions to prevent
hazards from hot spillages, After each operation a debriefing is
blowbacks, flushes, and to ensure organised in view of improving the
safe working conditions process and working conditions.
(temperature, air composition, etc)
P5 Major cleaning operations 3/3
and full application of cleaning
procedures.
Relevant PPE are available in
sufficient quantities and suited to
each individual. All safety equipment
Some aditionnal equipment is also
is available and in good working
used to avoid specific hazards.
condition (first aid boxes, proper
Equipment is not only maintained, it
drench showers, fire extinguishers,
is also improved.
etc). Equipment is regularly checked
and maintained, and an inventory is
done regularly.
Equipment is carefully checked
before hand-back and material and
tools are cleared from cleaning sites.
Additional safety actions have been
There is a systematic check that
taken (e.g. locks keyed differently
nobody remains in the area, that the
with different colors)
area is cleared. Remove padlocks
and tags according to detailed
procedures.
There is a formal release involving
cleaning and production teams after
all necessary equipment inspections
Process for release to production is
(door closed, dampers, guards are in
formally defined in a procedure.
place) and before tests of the
installation. All useful information is
systematically communicated.

Identification of a
All
contract need.
Specification of the
All
service/supply
CONTRACT
Plant + contractors
Qualification of
contractors (to be
assessed by plants where
local conditions allow it;
otherwise write "Not
applicable")
All + Purchasing
Contract
Formal communication
about plant
All
characteristics and
technical risks for all the
FOLLOW-UP
contractors' workers.
Supervisors
Explaining the work to the The contractor receives insufficient
contractor focusing on information about the content and
the safety risks. the risk of the work.
MANAGEMENT OF CONTRACTED WORKS
Operational objective: no accidents, no delays, no claims and with minimum cost.
Level D
Fully dependent
The need is not well identified.
The subcontracted work is not
formally defined.
There is no qualification of
contractors.
There is no contract formalization.
Contractors' workers do not receive
formal communication on safety.
Basic Skills Self-Assessment Grid
Level C
Partly dependent
The need is partly identified.
Definition of subcontracted works is
incomplete. There is no information
to the subcontractor about risks
analysis and safety.
Contractors follow a qualification
process but without previously
defined criteria.
Contracts with contractors are
signed without systematic
comparison with other offers.
Contracts do not include all the
required documents or their content
is poor (no clear description of the
work to do, no clear definition of
responsibilities, etc).
Contractors' workers sometimes
receive individualized
communication on safety and on
plant in general.
The contractor receives information about the content and the safety
about the content and the safety
risks of the work, but this process is explanations in the related work
not formalized.
Level B Level A
Autonomous Optimise and share Level Comments
The need is formally identified but it The need is formally identified and
is not formally requested. formally requested.
The largest contracted works are All the subcontracted works are
defined through a specification that systematically defined through a
includes technical conditions, specification that includes technical
deadlines, works quality, risk conditions, deadlines, works quality,
analysis and contractor's obligations risk analysis and contractor's
in terms of safety. obligations in terms of safety.
Contractors requested by the plant
P6 Management of contracted works
are qualified: they should have
experience in the cement industry
showing their technical capabilities The certification of new contractors
to do the work and meet the is done according to a defined
requirements previously defined in process including tests.
terms of respect of legal rules as
well as safety and environmental
prerequisites .
Contracts with contractors are
signed after a comparison with other
offers. Contracts include all the
required documents: specifications, There is template for common works
contract conditions, standards, rules. proposed by the BU's lawyers, and
In some cases a work order is for major operations or investment,
included to better describe the contract documents are reviewed by
work. Each contract includes the the BU lawyers.
names of Lafarge and contractor
managers responsible for the
contract.
1/2
Before starting the work all the
contractors' workers receive
All the contractors' workers receive
individualized communication on
individualized communication on
safety and on plant in general. The
safety and on plant in general.
worker signs an acknolweldgement
of this training.
Before starting the work the
contractor receives information
Contractors' workers sign an
acknowledgement of receiving all
risks of the work through
this information. There is a system
in place to control all entries of
orders, especially in terms of safety.
contractors' workers into the plant.
Lock out/tag out procedure is
included.
 Lafarge contract manager checks in
Supervisors + Mgrs the field that the work done by the
contractor meets expectations. A
FOLLOW-UP

report is written in case of

Lafarge contract manager deficiencies, especially in regards to The plant maintains a partner
Follow-up of works in the
There is no follow-up of the work sometimes checks in the field that safety. The plant assesses the relationship with the contractor with

P6 Management of contracted works

field and assessment of
done by the contractor in the field. the work done by the contractor quality of works done by the the aim of improving and avoiding
contractor
meets expectations. contractor. This assessment is used failures.
to decide to continue or not working
with the contractor in the future.
There is a special procedure for
monitoring high risk works.

Lafarge contract manager is present

Lafarge contract manager is physically to check that all the
Lafarge contract manager is not sometimes physically present to contract conditions are met and the
physically present to check that all check that all the contract conditions quality of the works is as expected. The acceptance includes required
Mgrs

Acceptance of the works

the contract conditions are met and
done by the contractor
the quality of the works is as
expected.
RECEPTION
are met and the quality of the works He signs the acceptance document. tests and a check-list is used to
is as expected. He signs the In the case of Projects a provisional accept works.
acceptance document. acceptance is carried out that must

be confirmed when the guarantees

are fulfilled.

The concerned Operations

department closes the Work Orders

2/2
Purchasing closes the requests with finished by the subcontractor and
Purchasing closes the requests
Mgrs

a formal acceptance from includes the relevant information in

Closing No closing process formalized. without a formal acceptance from
Operations or Projects in order to the equipment history. Certificate of
Operations or Projects.
proceed with payment. completion is issued and
performance of the contractor is
appraised.

Incoming substation :
equipment condition
(lighting, ventilation,
ELECTRICAL SUBSTATIONS
Technicians
pressurisation, filtration, air
conditionning, cleanliness,
It is not regularly inspected.
locked access, telephone in
service, unusual sounds,
fire detection, etc) and
checks for proper
functionning
Substations : equipment
condition (lighting,
Technicians
ventilation, pressurisation,
filtration, air conditionning,
cleanliness, locked access,
telephone in service,
unusual sounds, fire
detection, etc) and checks
for proper functionning
Technicians
Circuit Breakers/
Switches
DISTRIBUTION EQUIPMENT
Technicians
Transformers
Basic Skills Self-Assessment Grid
MANAGING ELECTRICAL DISTRIBUTION
Operational objective: ensure an uninterrupted power system to ensure reliability and safety
Level D Level C Level B Level A
Fully dependent Partly dependent Autonomous Optimise and share Level Comment
The electrical network supplier is
challenged to ensure distribution
There is a formalised monthly
quality and effective maintenance.
inspection to check high, medium
Every three years a thermographical
and low voltage equipment. Work
There is a regular inspection, but it is analysis is done and equipment is
orders are used and include a formal
only partly formalised (no checklist controlled by constructor. Every
checklist. Documentation including
and/or no work order). intervention is recorded. Fire
single line diagram is available near
detection is done by a certified
each piece of equipment.
contractor and is formally reported.
Work orders are automatically
generated.
There is a formalised monthly Every three years a thermographical
inspection to check medium and low analysis is done and equipment is
voltage equipment. Work orders are controlled by constructor. Every
There is regular inspection, but it is
used and include a formal checklist. intervention is recorded. Fire
They are not regularly inspected. only partly formalised (no checklist
Documentation including single line detection is done by a certified
and/or no work order).
diagram is available near each piece contractor and formally reported.
of equipment. Work orders are automatically
generated.
While running according to checklists
and formalised procedures and
There are first-level inspections while
circuit breakers/switches are annualy
running (visual control, meter
inspected during shutdown (checks Every 4 or 5 years circuit
reading, checking hydraulic controls,
There is no regular preventive for cleanliness, tightness of breakers/switches are also inspected
etc) but no formalized yearly
inspection. connections, poles, contacts, fuses, by the constructor. Work orders are
inspection during shutdown.
hydraulic controls, dielectrical check, automatically generated.
Checklists and procedures are partly
etc.). Work order are systematically
available.
used. In case of incident a dielectrical
analyse is done.
All transformers are checked
annually: oil analysis, number of
regulator adjustments, first-level
Inspections are done from time to checks (temperature, noise,
Every 3 years a thermographical
There is no regular preventive time but they are not planned. leakage), dessicator, voltage
analysis is done. Work orders are
inspection. Checklists and procedures are partly balance, electrical and non electrical
automatically generated.
available. protections are tested, cleaning,
tightness of connections. A work
order is used including a written
checklist.
DIST
Cos phi is monitored and recorded.
During each major turnaround Alert is automatically generated if the
condensers are cleaned and visually Cos phi is not correct. Supplier and
Technicians

Inspections are done from time to inspected (overheating). Every 2 or 3 plant cos phi data are compared and
There is no regular preventive time but they are not planned. major turnarounds protections are corrective actions are taken if
Condensers
inspection. Checklists and procedures are partly checked (max intensity, thermal, necessary. Every 3 years a
available. homopolar, fuses). Consumed thermographical analysis is done.
current is measured annually under Work orders are automatically
running conditions. Work orders are generated.
systematically used.

Map of the network is regularly

updated. Distribution network is Work orders are automatically
Technicians

Map of the network is not updated or completely inspected (cable generated according to a defined
Map of the network is not available.
Distribution network not complete. Inspections are done connexions, cleaning of isolators, route. Thermography is done for all
There is no regular preventive
inspection from time to time but they are not checking of cable head condition) the network over a period of three
inspection.
planned. over a period of three years. All years. All cables routes have ground
inspections are scheduled and work identification markings.
orders are systematically generated.
NETWORK

Readings are automatic; an expert

Tech.

Energy metering and The main substations are equiped All shops are equiped with electrical
Only incoming meters are installed. system enables load shedding in
management with electrical meters. meters which are read monthly .
case of excessive loads.

All the electrical distribution network

has multi-level protection. All network
Distribution network is not optimised A selectivity study has been done
characterictics are known.
Managers

(no selectivity study). Only some and rolled out by a qualified

Performance of the distribution
Distribution network Performance of distribution system is indicators are taken into account to contractor, who is responsible for
system (selectivity, bus bars
performance not monitored. estimate performance. Some actions inspecting entire network once
dimensioning, voltage drops, short
have been implemented to correct yearly. Study is updated with each
circuit power, etc.) is monitored and
recurrent problems. modification.
maintained taking into account
network extension/modification.

No load test (<20mn) is done

Technicians

monthly to check start up and

Emergency/Stand by Tests are done from time to time but abnormal behaviour. Every 2 or 3
There is no regular preventive Work orders are automatically
generators (uncoupled to they are not planned. Checklists and years load test is done to check
inspection. generated.
MV) procedures are partly available. running conditions and to clean the
AUXILIARY EQUIPMENT

motor. All checklists and procedures

are available.

Each month an on load test is

performed and temperatures,
Managers

Tests are done from time to time but pressure and load levels are Work orders are automatically
Power generators There is no regular preventive
they are not planned. Checklists and recorded. All checklists and generated. If possible, borescope
(coupled to MV) inspection.
procedures are partly available. procedures are available. Every 5 to inspections are done.
7 years global maintenance is done
(wiring, yoke, etc).
Technicians

All electrical auxiliary equipment is

Auxiliary equipment (UPS, inspected on a regular basis (e.g. Every 3 years equipment is inspected
Auxiliary equipment are not Inspections are done from time to
starters, VSD, marshalling annually) for preventive by the constructor (e.g. UPS batteries
inspected. time but they are not planned.
boards, etc) maintenance. Work orders including are changed).
checklists are systematically used.

Electrical lockout is systematically Training procedures are used for

Safety procedures are not formalised Safety procedures are applied but done prior to any work. Detailed newcomers. Procedures are updated
All

Safety procedures
or not accurate. not all formalised. electrical safety procedures are taking into account new equipment,
available and systematically applied. near misses, etc.
TY
 Involved personnel (including
contractors) are well trained in safety
Only some of the electrical team are
aspects. All personnel who work in All newcomers to the electrical team
authorised/ certified; other
SAFETY

Personnel authorisation/ Technicians do not receive formal electrical areas are certified and are properly trained. Visitors entering
All

populations involved are not

certification autorisation/certification. authorized in accordance with tasks the electrical substation are aware of
necessarily trained/aware of safety
they have to perform. They have electrical risks.
aspects.
good knowledge of the upstream
network and can anticipate the risks.

All required electrical safety All required electrical safety All safety electrical equipment is
Not all required electrical safety
equipment (PPE and tools) is equipment (PPE and tools) i+F8s regularly tested by a specialised
equipment (Personnal Protective
All

Specific safety equipment
Equipment and tools) is available
within the plant.
available but there is no regular stored in a dedicated place and an office. Additional equipement is
inventory to check if it is in good inventory is regularly done. always availabe for contractor
working condition. Equipment use is controlled. personnel, etc.
M2 Managing electrical distribution 1/2
M2 Managing electrical distribution 2/2
 Basic Skills Self-Assessment Grid

MASTERING KILN MECHANICS

Operational objective: perform all control measurements to prevent catastrophic failures

Level D Level C Level B Level A

Fully dependent Partly dependent Autonomous Optimize and share Level Comments

Check fastenings, running

conditions (noise, vibrations, Some daily inspection job plans
There is no daily inspection job plan Inspection job plans exist and are Daily inspection job plans exist and
temp, up and down movement), exist but they are not used. Daily
and/or some daily checks are not partially used. Daily inspections are are used. Inspections are done on
leaks and spills, measure tyre inspections are done from time to
done. done only on weekdays. a daily basis. Results are tracked.
migration (chalk) and check time.
safety aspects

Check uphill & downhill There is no checking of kiln Kiln movement is checked from Kiln movement is checked on a Kiln movement is checked on a
movement movement. time to time. daily basis. daily basis and recorded.

DC motor brushes are checked on

Check whether DC motor DC motor brushes are never DC motor brushes are checked DC motor brushes are checked on
a weekly basis & results are
brushes are sparking checked. from time to time. a weekly basis.
tracked.

There is no checking of teeth Job plan exists but is not used. Job plan exists and is used. Teeth Job plan exists and is used. Teeth
Check appearance of pinion &
appearance and/or nobody knows Teeth appearance is checked from appearance is checked on a appearance is checked weekly and
INSPECTION

girth gear teeth

M2 Mastering kiln mechanics 1/2

how to do it. No job plan. time to time. weekly basis. results are tracked.
Technicians

Roller position is checked regularly.

Check roller position with
regards to kiln movement
There is no checking of roller Roller position is checked on a
Roller position is checked from time At least one person knows how to
position. Nobody understands roller weekly basis. At least one person
to time. Nobody understands its link correct the problem if there is a
position and its link to kiln in the plant understands its link to
to kiln movement. discrepancy with regards to kiln
movement. kiln movement.
movement.

Vibrations are measured from time

Vibration measurement is not done
Measure vibrations of the drive
and no tools are available. Nobody
(overall level)
knows how to measure vibrations.
to time, but results are not always
reliable (the method is not always
the right one).
Vibrations are measured on a
Vibrations are measured on a
monthly basis and results are
monthly basis & results are reliable.
reliable & tracked.

Check for surface damage on
roller shafts
Job plan exists but is not used. Job plan exists and are used. Roller shaft appearance is checked
There is no checking of roller
Roller shaft appearance is checked Roller shaft appearance is checked on a monthly basis and results are
shafts. There is no job plan.
from time to time. on a monthly basis. tracked.

During major turnaround, verify

conditions (wear, profile,
Some measurements are done. Most measurements are done. A All measurements are done as All the measurements are done.
surface shape, etc.) and
There is no job plan. job plan exists but is not used. described in the job plan. Results are tracked.
position/ adjustment of kiln
components

Check oil/grease appearance,

LUBRICATION

There are no lubrication inspection Some lubrication job plans exist but Lubrication job plans exist and are Lubrication job plans exist and are
level, pressure and
job plans and/or some checks are they are not used. Checks are done applied. Checks are done only on used. Checks are done on a daily
temperature, Check for oil or
not done. from time to time. weekdays. basis. Results are tracked.
grease leaks/spills
icians
LUBRIC
There are no lubrication inspection Some lubrication job plans exist but Lubrication job plans exist and are Lubrication job plans exist and are
Check lubrication of roller
job plans and/or some checks are are not used. Checks are done applied. Checks are done only on used. Checks are done on a daily
bearings and pinion/girth gear
not done. from time to time. weekdays. basis. Results are tracked.
Technicians

M2 Mastering kiln mechanics 2/2

Sample oil from main reducer No oil sampling is done and/or Oil sampling is done from time to Oil sampling is done on a monthly
Oil sampling is done reliably on a
LUBRICATION

and from girth gear/pinion tank nobody knows how to take an oil time and/or sampling is not done basis and sampling operations are
monthly basis & results are tracked
for debris detection sample. There is no job plan. correctly. Job plan is not used. done properly. Job plan is used

During major turnaround,

There is no oil sampling and/or Oil sampling is done and/or Oil sampling is done and sampling Oil sampling is done reliably on a
sample oil from main reducer
nobody knows how to perform oil sampling is not done as it should operations are done properly. Job monthly basis & results are tracked.
and from girth gear/pinion tank
sampling. Filter cleanliness is not be. Job plan is not used. Filter plan is used. Filter cleanliness is Filter cleanliness is checked &
for analysis, check filter
checked. No job plan exists. cleanliness is checked. checked. maintained.
cleanliness
SKEWING

Engineers & supervisors know how Engineers & supervisors

Nobody knows how to skew kiln Certain people know how to check
to skew rollers. Certain people understand & know how to skew
All

Roller skewing rollers and/or roller technology is roller position but they are not able
know how to check kiln movement rollers, check position of rollers,
not understood/known. to skew rollers.
and induce it if needed. and check kiln movement.

PREPARATION
Define the kiln shutdown
duration and the number and
Mgrs
There is no preparation program.
dates of programmed kiln
shutdowns
Preparation of all works to
be done during the kiln
PORTFOLIO
shutdown:
Required
Mgrs
manpower and spare parts. There is no portfolio program.
Identification of urgent
works by knowing which
critical equipment might stop
the kiln
Schedule all activities to take
Mgrs
place during kiln shutdown
SCHEDULING
Coordination of all kiln
All
shutdown activities
Meeting with contractors to
All
define safety rules.
Technicians
Preventive maintenance
FOLLOW-UP
during kiln shutdown
KILN STOPPAGE MAINTENANCE MANAGEMENT
Operational Objective: Kiln shutdown meets cost and deadline expectations, with all works identified and completed.
Level D
Fully dependent
There is no schedule.
There is no coordination.
Compliance with safety rules by
contractors is not verified.
Preventive maintenance is not done
during kiln shutdown.
Basic Skills Self-Assessment Grid
Level C Level B Level A
Partly dependent Autonomous Optimise and share Level Comments
The duration is based on longer
The kiln shutdown duration is works deadlines. Dates are decided
determined based on objectives in coordination with Sales
Kiln shutdown duration is determined
described in the budget (utilization departement and other plants of the
based only on market needs.The
factor, clinker production and BU/Zone (use of same contractors,
number of kiln shutdowns is based
reliability). The number of kiln sharing markets, etc.) and
on the condition of refractory and
shutdowns is based on the condition Purchasing is involved to buy clinker
critical equipment. Dates are not set
of refractory and critical equipment. if neccessary. A system is in place to
or are not respected.
Dates are decided in coordination optimize shutdown duration.
with Sales department.
Rrefractory lining thickness
development and mechanical and
All work orders are prepared and
electrical equipment condition is
All the work orders are prepared and included in the kiln shutdown
monitored year round: the former
included in the shutdown portfolio. portfolio. Investments works are
with a scanner or other means, the
Investments works are included too. included. There is systematic
latter through preventive and
No systematic verification of spare verification of spare parts in stock or
predective (vibration, temperature,
parts in stock or to be purchased. to be purchased. This is organized
etc.) maintenance. This information
on schedule jointly with Purchasing.
allows identifying critical equipment
that could stop the kiln.
All the shutdown works are
scheduled, all possible conflicts are
All the shutdown works are
analysed, all works are coordinated. Shutdown duration, costs and
scheduled, but possible conflicts are
not analysed.
Critical path is identified and manpower are optimized.
shutdown duration is defined
according to shutdown program.
Coordination of all kiln shutdown Coordination of all kiln shutdown
activities is organized in a pre- activities is organized in a pre-
The coordination of all kiln shutdown
shutdown meeting. All concerned shutdown meeting. Meeting is
activities is not formalized.
plant departments attend this attended by all concerned plant
meeting. departments and contractors.
Prior to the start of kiln shutdown, a
High-risk works are identified. The
meeting is held between plant
applicable scaffolding policy is
Verification of contractor safety managers and contractors to check
implemented and all operations
actions is not formalized. that each contractor is taking
involving major safety issues are
necessary actions to ensure good
analyzed in detail.
shutdown safety results.
All specified kiln shutdown
First-level inspections are done
inspections are done as early as
during kiln shutdown, resulting in the
Kiln shutdown inspections are not possible, with formalized feedback
issue of work orders to be completed
well formalized.
during current shutdown or following
resulting in the issue of work orders
to be completed during current
one.
shutdown or following one.
FOLLOW
All Daily coordination of
shutdown works
FOLLOW-UP
Technicians
Control of works execution
and safety
Equipment test following
Tech
repairs/servicing
User training in case of
All
important modifications
RECEPTION
Transfer of responsability for
equipment having been
worked on, from
Maintenance/Projects to
Production
All
Program and coordinate
instalation test before kiln
start-up.
Closing of Work Orders,
including technical
All
information and cost.
CLOSING
Mgrs + Purchasing
Closing of all works
contracted during the
shutdown
There is no daily coordination.
No follow-up of works.
Equipment is not tested.
No training.
No transfer.
Kiln is started up without prior testing
of the installation.
There are no Work Orders.
No formal closing.
There is no formalized coordination
of all kiln shutdown activities.
Not all works are followed-up during
the kiln shutdown; this includes
safety supervision.
Some equipment is tested.
Users, like control room operators,
receive insufficient training when
new equipment is received or when
important modifications have been
carried out in the field.
No formalized reception of
equipment by the production team.
Kiln is started up after testing part of
the installation, but without following
formal procedures.
Work Order are used but are not
systematically closed. The global
cost of the kiln shutdown is not
estimated.
Purchasing closes all works or
supplying done by
contractors/suppliers, but there is a
lack of formal procedures.
There is at least one meeting per
A formal meeting is held each day to
week attended by all concerned
coordinate the shutdwon works; all
people to analyze in detail any
concerned people attend and
interferences. A brief meeting is held
analyze in detail all current and
each day to coordinate on-going
potential interferences.
works.
Safety supervision is reinforced by
an external additional check done by
a qualified company. Some risky
Plant supervisors check the
tasks are done by specialized
fullfillment of safety rules, the quality
companies: work at height, work
of all works (contracted or not) and
the productivity of the people under
involving cranes, scaffolding, etc.
Cleaning of major equipment is done
their responsibility.
prior to maintenance work. Work
areas are cleared of tools, spares,
etc.
The supervisor of each job
The supervisor of each job tests
systematically tests each piece of
each piece of equipment repaired.
equipment repaired, calling on
Lock out procedure is strictly
production people if required. Lock
obeyed.
out procedure is strictly obeyed.
Users, like control room operators, All users systematically receive all
receive suitable training when new necessary training when new
equipment is received or when equipment is received or when
important modifications have been important modifications have been
carried out in the field. carried out in the field.
In most cases, when equipment is In all cases, when equipment is
ready to be run the Maintenance or ready to be run the Maintenance or
Project supervisors formally transfer Project supervisors formally transfer
it to the production team. it to the production team.
Kiln is started up after all installation
A protocole is in place and is strictly
elements worked on have been
tested according to formal
followed, ensuring that all equipment
is tested before each kiln start-up.
procedures.
All Work Orders are systematically
All Work Orders are systematically closed and recorded, including
closed and recorded. The global cost technical feedback and financial
of the kiln shutdown is accurately information (spare parts, manpower
estimated. and contractors). Global cost is
precisely estimated.
A system is in place to ensure that
Purchasing follows formal acceptance documents for all
procedures to close in coordination contracted works or supplies are
with the Operations department all systematically delivered to the
contracted works or supplies. Purchasing dept. for kiln shutdown
accounting/payment purposes.
M3 Kiln stoppage management 1/2
M3 Kiln stoppage management 2/2

Identification of a contract
All
The need is not well identified.
need.
Specification of the
All
service/supply
CONTRACT
Plant + contractors
Qualification of
contractors (to be
assessed by plants where
local conditions allow it;
otherwise write "Not
applicable")
All + Purchasing
Contract
Formal communication
about plant characteristics
All
and technical risks for all
the contractors' workers.
FOLLOW-UP
Supervisors
Explaining the work to the
contractor focusing on the
safety risks.
MANAGEMENT OF CONTRACTED WORKS
Operational objective: no accidents, no delays, no claims and with minimum cost.
Level D
Fully dependent
The subcontracted work is not
formally defined.
There is no qualification of
contractors.
There is no contract formalization.
Contractors' workers do not receive
formal communication on safety.
The contractor receives insufficient
information about the content and
the risk of the work.
Basic Skills Self-Assessment Grid
Level C
Partly dependent
The need is partly identified.
Definition of subcontracted works is
incomplete. There is no information
to the subcontractor about risks
analysis and safety.
Contractors follow a qualification
process but without previously
defined criteria.
Contracts with contractors are
signed without systematic
comparison with other offers.
Contracts do not include all the
required documents or their content
is poor (no clear description of the
work to do, no clear definition of
responsibilities, etc).
Contractors' workers sometimes
receive individualized
communication on safety and on
plant in general.
The contractor receives information about the content and the safety
about the content and the safety
risks of the work, but this process is explanations in the related work
not formalized.
Level B Level A
Autonomous Optimise and share Level Comments
The need is formally identified but it The need is formally identified and
is not formally requested. formally requested.
The largest contracted works are All the subcontracted works are
defined through a specification that systematically defined through a
includes technical conditions, specification that includes technical
deadlines, works quality, risk conditions, deadlines, works quality,
analysis and contractor's obligations risk analysis and contractor's
in terms of safety. obligations in terms of safety.
M4 Management of contracted works
Contractors requested by the plant
are qualified: they should have
experience in the cement industry
showing their technical capabilities The certification of new contractors
to do the work and meet the is done according to a defined
requirements previously defined in process including tests.
terms of respect of legal rules as
well as safety and environmental
prerequisites .
Contracts with contractors are
signed after a comparison with other
offers. Contracts include all the
required documents: specifications, There is template for common works
contract conditions, standards, rules. proposed by the BU's lawyers, and
In some cases a work order is for major operations or investment,
included to better describe the contract documents are reviewed by
work. Each contract includes the the BU lawyers.
names of Lafarge and contractor
managers responsible for the
contract.
1/2
Before starting the work all the
contractors' workers receive
All the contractors' workers receive
individualized communication on
individualized communication on
safety and on plant in general. The
safety and on plant in general.
worker signs an acknolweldgement
of this training.
Before starting the work the
contractor receives information
Contractors' workers sign an
acknowledgement of receiving all
risks of the work through
this information. There is a system
in place to control all entries of
orders, especially in terms of safety.
contractors' workers into the plant.
Lock out/tag out procedure is
included.
 Lafarge contract manager checks in
Supervisors + Mgrs the field that the work done by the
contractor meets expectations. A
FOLLOW-UP

report is written in case of

Lafarge contract manager deficiencies, especially in regards to The plant maintains a partner
Follow-up of works in the

M4 Management of contracted works

There is no follow-up of the work sometimes checks in the field that safety. The plant assesses the relationship with the contractor with
field and assessment of
done by the contractor in the field. the work done by the contractor quality of works done by the the aim of improving and avoiding
contractor
meets expectations. contractor. This assessment is used failures.
to decide to continue or not working
with the contractor in the future.
There is a special procedure for
monitoring high risk works.

Lafarge contract manager is present

Lafarge contract manager is physically to check that all the
Lafarge contract manager is not sometimes physically present to contract conditions are met and the
physically present to check that all check that all the contract conditions quality of the works is as expected. The acceptance includes required
Mgrs

Acceptance of the works

the contract conditions are met and
done by the contractor
the quality of the works is as
expected.
RECEPTION
are met and the quality of the works He signs the acceptance document. tests and a check-list is used to
is as expected. He signs the In the case of Projects a provisional accept works.
acceptance document. acceptance is carried out that must

be confirmed when the guarantees

are fulfilled.

The concerned Operations

department closes the Work Orders

2/2
Purchasing closes the requests with finished by the subcontractor and
Purchasing closes the requests
Mgrs

a formal acceptance from includes the relevant information in

Closing No closing process formalized. without a formal acceptance from
Operations or Projects in order to the equipment history. Certificate of
Operations or Projects.
proceed with payment. completion is issued and
performance of the contractor is
appraised.
 Basic Skills Self-Assessment Grid

LUBRICATION MANAGEMENT
Operational objective: lubrication costs are less than 4% of the maintenance costs and catastrophic incidents are avoided

Level D Level C Level B Level A

Fully dependent Partly dependent Autonomous Optimise and share Level Comments
The list is exhaustive and is
List of equipment with A list exists, but it is not exhaustive updated from time to time. Type of
List is exhaustive and regularly
description and location of and/or the type of monitoring is not procedures (e.g. systematic oil
No such list exists. updated. Maintenance procedures
all monitoring/ chosen according to well-defined changes vs. condition-based) is
are optimised.
maintenance points rules. chosen according to well-defined
rules.
LUBRICATION PLAN

All SOPs exist and include details

of oil and grease quality/quantity, SOPs are regularly updated, taking
Standard operating SOPs exist only for some
sampling points for specific testing, into account inspection/analysis
procedures for each There are no SOPs. procedures and/or some important
required levels and all necessary results, so as to optimise lubrication
Technicians

maintenance operation information is missing (cf. Level B).

instructions for each procedure mgmt. and machine lifetime.
(tools, known difficulties, etc).

All tasks are planned one week in

Planning is done but is not advance, taking into account any Planning is optimised in terms of
No formal planning for lubrication
Planning exhaustive (not all tasks are possible constraints (stoppage not stoppages. Each task/procedure
tasks.
planned). possible, ordering of material/ has been assigned a priority level.
equipment, delivery time, etc.)

Software is used systematically.

Use of software for Software is used only for certain
No software is used. Software is used systematically. Data and indicators (consumption,
lubrication management tasks/procedures.
cost, etc.) are analyzed.

Work Orders are used for All abnormalities are reported,

TASKS AND PROCEDURES

Work Order forms are inexistent or monitoring of levels, for oil make- possibly resulting in a new WO. All
Issuing of work orders Work Orders are sometimes used.
are not used. ups, 1st level inspections, taking of departments contribute to this
samples and oil changes. process.

Pumps are regularly checked

Technicians

Mgmt. is contracted out because no (manual mode and 1st level One spare pump is always
Mgmt. is contracted out for cost
Mgmt. of centralised lube one in the plant knows the systems, inspection) and maintained. When available. At least 2 plant persons
reasons, but no plant personnel are
system (if applicable) or no preventive maintenance work is contracted out, it is are competent in managing
qualified to monitor the work done.
procedures exist. coordinated and monitored by the centralised lubrication systems.
lube team.

Data is analyzed to detect possible

Communicating on tasks There is never any communication Make-up oil and operating hours Level C + any modifications of work
problems (e.g. oil leaks) and to
and procedures on tasks and procedures. are recorded. order instructions are noted.
optimise the lubrication cycle.

Viscosity, presence of water,

1st level analyses 1st level testing is performed The other plant teams are aware of
1st level testing not performed metals (magnet test) are checked
OIL ANALYSIS

(viscosity, presence of regularly, but observations are not the importance of being vigilant and
regularly. regularly. All abnormalities are
water, metals, etc. recorded. reporting all abnormalities.
recorded on the Work Order.

Samples are taken according to

Sampling frequency is optimized
WOs are issued for sample taking. well-defined instructions (same
Samples are taken only from time according to level of criticality
Sample taking Sample identification information is sampling point, equipment running,
to time. No formal procedures exist. (major equipment, incident cost,
recorded on the WO. etc.) Any problems with a given
significant oil quantity, etc).
sample are indicated on the WO.
ns
 Plant is autonomous in terms of Plant does not automatically accept
Technicians
Interpretation of lab results in not interpreting results of major standard lab interpretations. Lube
No plant persons are able to
Interpretation done internally, even if some plant analysis types (contamination, supervisor knows the plant's
interpret sample analysis results.
persons are qualified to do it. water, etc.) The Tech Centre is specificities and takes them into
contacted in case of difficulties. account when interpreting results.
OIL ANALYSIS

Close collaboration between plant

Plant personnel been trained by the Level C + a well-defined warning and labs. Labs know the plant's
Interaction with There is no real interaction with the
laboratories or know well the types procedure can be applied any time needs and there are technical
laboratories laboratories.
of analyses performed. the lab points out a major problem. exchanges between lab and plant,
if needed.

Tracking/trends are analyzed in a

Tracking/data retention is not
Tracking / data retention
systematic.
A file exists for storing all sample ID
Tracking/data retention is well-defined manner, with graphs to
info, along with all new, pertinent
systematic, but the information is identify drifts and to indicate when
info concerning each machine. This
not exploited. further testing is required. Risk
can help detect major problems.
mgmt is also optimised.

All lubricant users in the plant know

There is no dedicated storage area A dedicated area exists but is not Drums are easily accessible in a
Dedicated storage area the lubricant storage organisation
for lubricants. well organised. dedicated area.
and use if correctly.
LUBRICANT STORAGE

Capacity of retention basin(s)

Capacity of retention basin(s) is Waterproofness of retention
There are no retention basins. complies with legislation and/or
insufficient. basin(s) is checked regularly.
international standards.
Technicians

Safety
Safety instruction are not always
Safety instructions relating to fire Fire safety instructions are fully Persons not directly concerned with
followed. Extinguishers (indoors +
hazards are ignored. Extinguishers obeyed by all users. Extinguishers lubrication have been made aware
outdoors) work but are not
are inexistent or do not work. are inspected regularly. of safety issues.
inspected regularly.

Used oils/greases are destroyed or

Used oils/greases and their drums
Environment (disposal of Used oils/greases and their drums
are generally destroyed or
oil, grease and containers) are not disposed of.
recycled, but not systematically.
recycled (e.g. by the supplier). Absorbent materials are available
Systematic tracking ensures used in case of leaks. Elimination of
lube removal. Drums are also these materials is provided for.
removed.
M5 Lubrication management 1/2
M5 Lubrication management 2/2

Execute the sampling plan for
finished and in-process products
(ref. to Q2 grid for sampling plan
definition)
Inspect sampling and
preparation equipment (residual
material, mechanical aspects)
and do the cleaning maintenance
(to prevent contamination,
incidents, etc.)
Take representative samples
(size, tools, location, frequency,
method, etc.)
SAMPLING
Technicians
There is no sample identification
Handle the samples (identify and
between extraction and
maintain sample integrity)
preparation.
Prepare samples (split, crush,
prepare the composite,
pulverize, blend, screen and
store)
Identify samples for retention
Operational objective: lab reliability index is above 75%, and lab audits do not show serious deviation from good practices
Level D
Fully dependent
The sampling plan is not clearly
defined or presents weaknesses,
nor it is clearly communicated to
the operators & technicians.
No inspection of sampling and
preparation equipment nor cleaning
maintenance is done. This activity
is not described in the sampling
plan/procedure (if existing).
No sampling procedures exist or
are inadequate. Suitable sampling
tools are not available. No
sampling location marked in the
field.
No procedures exist for sample
preparation and integrity
maintenance. Proper tools are not
available.
Local standard for sample retention
is not applied; no identification, no
traceability.
Basic Skills Self-Assessment Grid
LAB RELIABILITY
Level C
Partly dependent
The sampling plan exists and is
satisfactory but it is not followed
accurately.
There is little inspection of
sampling and preparation
equipment, little cleaning
maintenance. These activities are
included in the sampling
plan/procedure but are not applied.
Some procedures defining
sampling tools, methods, size and
location are written but they are not
systematically applied. Suitable
sampling tools are available in the
field but are not always used
properly. Most of the sampling
locations are marked in the field.
Procedure / work instruction
defines how to maintain sample
integrity, but it is not systematically
followed.
Suitable tools and equipment are
available in the plant for sample
preparation and to maintain its
integrity, but are not always used
properly. Very few procedures are
defined for sample preparation.
Local standard for sample retention defined and documented
is understood & applied.
Level B Level A
Autonomous Optimise and share Level Comments
The sampling plan exists and is
The most critical steps are perfectly
complete. It is posted in the
understood by the operators, and
control room (and/or laboratory),
their experience is leveraged in
and all the samplings are done as
order to optimise the plan.
per the sampling plan.
Inspection of sampling and
preparation equipment and
cleaning maintenance is done by Inspection results are tracked and
operators & technicians. These the choice of equipment is
activities are part of the sampling optimised according to this data.
plan/procedure. Inspection
checklists exist and are used.
Procedures compliant to "cahiers
The critical steps are well identified
techniques" defining sampling
and their application is checked on
Q1 Lab reliability 1/3
tools, methods, size and location
a regular basis. Methodology is
exist, are well known and are
regularly reviewed & studies are
followed. Sampling tools are
done to identify the most
available in the field and are used
representative sampling points and
properly. All sampling locations are
methods.
clearly marked in the field.
Sample is well identified and
handled (integrity maintained, no
All the operators and technicians
possible contamination with other
are well trained in sample handling
products) between its extraction
and they understand its impact.
and preparation. Procedure / work
instruction exists.
Procedures exist, are well known
and followed. Suitable and well-
All the operators and technicians
maintained tools and equipment
are well trained for sampling
are available and are used
preparation and they understand
properly. Impact of sampling
the impact.
method on representativity and
results is well understood.
Samples retained for long periods
are identified in accordance with
Full traceability is ensured and is
identification rules. The part of a complete retention plan.
identification is unique, thus
ensuring good traceability.

Execute the testing plan for
finished and intermediate
product (ref. to Q2 grid for
testing plan definition)
Inspect lab equipment and check
environment (temperature,
humidity, alarm, cleanliness, oil
in the blaine, etc.)
Run check standard to ensure
low testing errors and
repeatability
Technicians
Laboratory tests are not under
Perform the analysis: manipulate control. Procedures are missing,
sample and equipment to do the and no technicians or operators
test have the required knowledge of the
tasks and equipment.
TESTING
Validate the results in acceptable
range tolerance and manage out
of specifications results (re-test,
management validation, inspect,
re-sample, etc.)
Report results
Execute the calibration plan (ref.
All
to Q2 grid)
Lab Accuracy Index
The testing plan is not clearly
The testing plan exists and is
defined or presents weaknesses,
satisfactory, but it is not followed
nor is it clearly communicated to
accurately.
operators & technicians.
No specific inspection of lab
Inspection of lab equipment as well
equipment and environment is
as environment is rarely done by
done by the technicians &
operators & technicians. This
operators. This activity is not
activity is included in the testing
described in the testing procedure
procedure but is not applied.
(if existing).
A check standard is run by
operators & technicians from time
Check standards are never run by
to time, based on specific
operators & technicians or/and
requirements by management. This
there is no knowledge about testing
activity is not really documented
errors and repeatability.
and is done only occasionally and/
or there is no action.
Procedures and/or work
instructions do not exist for all the
tests performed in lab and/or they
are not followed. Lab equipment
(weighing accuracy, blaine
apparatus, etc.) is used properly.
Appropriate control actions (re test,
Some non-compliant data have
etc.) are taken when result is out of
already been transmitted to
specifications, as per a well defined
production without any reaction.
decision tree. Production dept is
Control actions might not always be
informed about all non-compliant
taken.
data.
A reporting tool exists but is not
well understood by technicians &
No proper reporting tools exist.
operators. Errors are frequent in the
reporting (mis-typing, units, etc).
A maintenance & calibration plan
A maintenance & calibration plan is
exists but it is not complete and/or
not clearly defined and nobody is
nobody is really responsible for it
responsible for it.
and/or it is not followed.
<65 >65
The testing plan exists and is
The most critical steps are perfectly
complete. It is posted in the Control
understood by the operators, and
room (and/or laboratory), and all
their experience is leveraged in
testings are done as per the testing
order to optimise the plan.
plan.
Inspection of lab equipment as well
as environment is done by The test conditions are
operators & technicians. Inspection continuously improved.
check lists are used for follow-up.
A check standard is run on a There is regular dialogue with the
regular basis, as defined in the Tech Centres and with other plants
testing plan. Specific actions are via the Quality Network in order to
taken according to well defined have good knowledge of lab
procedures. Testing error and testing precision and inter-analyst
acceptability ranges are well-known variability to benchmark and to
and followed with control charts. progress.
Procedures and/or work
instructions exist for all the tests Methods are regularly improved
performed in lab and they are and certification process is in place
followed. Lab equipment (weighing for personnel performing lab
Q1 Lab reliability 2/3
accuracy, blaine apparatus, etc.) is testing.
used properly.
Some operators & technicians are
Level C + Plausibility of results is
able to analyse the results perfectly
taken into account . Trend of
and to estimate the influence of the
results is followed in order to
process on the results. In case of
anticipate out of specifications
deviation, a process is in place to
results.
identify the causes.
A reporting tool exists (can be xls
spreadsheet) and well used. A
A standard system of reporting is in
system is in place to minimise
use (as per Lafarge Standard) and
errors (mis-typing, numbers
is perfectly mastered.
roundings, units, etc.) and is
regularly updated.
Calibration plan exists and is
Calibration methods are optimised,
complete. All calibration tests are
Best Practices are challenged.
done as per the calibration plan.
>75 >85

Evaluate performance through
All
round robin /Interlab
(participation, follow up)
Technicians
Calibrate all equipment and take
appropriate action
MANAGEMENT OF LAB EQUIPMENT & REAGENTS
Mgrs
Manage non-compliant
equipment
All
Maintenance of Lab equipment
Use proper storage and disposal not disposed of properly or some
for chemicals & gas cylinders
Technicians
Use proper storage to maintain
integrity of certified reference
material & standards
Safe sampling and testing
Laboratory and sampling safety
SAFETY
items
All
The plant participates only in
mandatory Lafarge IU interlab
programs.
Some procedures exist for
calibration of lab equipment and
reagents, but this activity is not
under control.
No action is taken when equipment management is unsatisfactory.
is out of calibration.
Equipment is repaired or replaced
only once failure has occurred. No
preventive maintenance is done.
Chemicals and gas cylinders are
chemicals are not identified or no
MSDS sheets available.
No CRMs (Certified Reference
Materials) are used.
Risk assessment is done mainly in
a reactive mode.
Some sampling & laboratory
specific safety equipment is
missing.
The plant participates in additional
IU interlab programs from time to
time.
Some procedures exist for
calibration of lab equipment and
reagents, but they are not
systematically applied.
Non-compliant equipment
There are no defined actions to be
taken in case of deviation.
Most of the time, equipment is
repaired or replaced once failure
has occurred. However, some
preventive maintenance exists.
Chemicals and gas cylinders are
properly disposed of and chemicals
are identified, but some MSDS
sheets are missing / not completed
or updated.
CRMs (Certified Reference
Materials) are not necessarily
stored separately from samples.
They are not in a controlled
environment and/or certificates of
analysis are not available.
All major risks associated with
sampling and testing activities are
identified using an appropriate
methodology (ranking, etc).
Sampling & lab specific safety
equipment (PPE's, eye wash
station, showers) is well identified
(ref to risk assessment) and
accessible to all. Some equipment
is missing from time to time and/or
it is not used by all operators.
The plant regularly participates in
additional IU interlab programs. Innovative ideas or initiatives to
Results of interlab tests are share with other plants, tech
reviewed and appropriate actions centres, etc. have been
are taken and documented in case implemented.
of deficiency.
Procedures for calibration of lab
equipment and reagents exist, are
followed and comply with the lab
environment specification (T° /
moisture). All the calibration tests Calibration methods are optimised,
are done as per the procedures. Best Practices are challenged.
Best Practices (e.g. XRF software)
calibrations are implemented.
Records and corrections are kept
on file and are auditable at any
time.
Non-compliant equipment is well Non conformity report is
managed. Actions to be taken in documented and corrective /
case of deviation are well defined & preventive actions are taken
documented, and they are followed. accordingly.
Preventive maintenance is well
managed. Reliability indicator is
calculated & followed, and plan B is Initiatives have already been
identified. Key equipment is implemented to optimise the task.
identified and its replacement is
budgeted & planned.
Chemicals and gas cylinders are
properly disposed of. All lab
Q1 Lab reliability 3/3
containers are properly labelled Initiatives have already been
with the material they contain. implemented to optimise the task.
MSDS sheets are updated and
available for consultation.
CRMs (Certified Reference
Materials) are stored separately
Initiatives have already been
from samples in controlled
implemented to optimise the task.
environment and certificates of
analysis are available.
Level C + this assessment is taken
into account by operators at all Continuous improvement is
times and all necessary tools & encouraged through internal &
equipment are available in the plant external inspections and audits.
in order to prevent these risks.
Lab specific safety equipment
(PPE's, eye wash station, showers) All equipment maintenance is
is well identified and accessible to documented and auditable at any
all. It is available at all times and time. Continuous improvement is
used by all technicians & operators. encouraged through internal &
Equipment is inspected, cleaned external inspections and audits.
and maintained on a regular basis.
 Some technicians and operators do
The laboratory is kept clean at all
not systematically clean and tidy up
times. All operators & technicians Good laboratory practices have
their equipment after use. Some
Housekeeping & proper Laboratory housekeeping is not systematically clean and tidy up been defined and could be shared
cleaning instructions exist for
organisation acceptable. their equipment after use. Cleaning with other plants (give one example
critical equipment but are not
instructions for critical equipment in "comments").
followed or no such instructions
exist and are followed.
exist.

Some safety instructions exist but Continuous improvement is

No safety instructions defined for Safety instructions are well defined,
Safe handling & behaviour are not complete and/or not encouraged through internal &
the lab. documented and followed.
followed by everyone. external inspections and audits.

Establish plant's targets to meet
Quality Objectives (for finished
and in-process products)
Define the sampling plan for
finished & intermediate product
(method, location, frequency,
size, responsibility and safety)
QUALITY CONTROL
All
Define testing plan (method,
instrument, frequency,
parameters, responsibility and
safety)
Define Calibration Plan (nature of
No calibration plan is defined.
tests, frequency, responsibility)
Mgrs+Production
Define Quality control strategy
(measure variations, analyse
trends, statistics)
Ensure compliance to industry
standards (ASTM, EN or local
standards)
QUALITY ASSURANCE
Set IQP & Quality contract
Mgrs + Marketing
QUALITY CONTROL / QUALITY ASSURANCE
Operational objective: full compliance with relevant product standards, no customer complaints or concerns, no quality incidents and product-
related risks kept at a minimum.
Level D
Fully dependent
Plant's targets are not defined
through a controlled process and/or Plant's targets are established
they are not reviewed annually
and/or they are not defined for all process team.
products.
No sampling plan is defined.
No testing plan is defined.
There is no formalized Quality
Control strategy.
Local standards are ignored and
not reviewed on a regular basis
and/or the latest version of the
standard is not available.
No quality contract exists, or it is
established without communication
between plant and marketing.
Basic Skills Self-Assessment Grid
Level C
Partly dependent
annually for all products with the
A sampling plan is available but it is
not complete and/or it is not
reviewed on a regular basis.
A testing plan is available but it is
not complete and/or it is not
reviewed on a regular basis.
Calibration plan is available but it is
not complete and/or it is not
reviewed on a regular basis.
Key process parameters having
impact on quality are identified but
there is no precise strategy to
optimize them.
Compliance with local standards is
ensured. Latest applicable version
of standard is available in the plant. Level C + good management of
Audits and inspections are
performed as required by
standards.
Quality contract is established with
participation of plant and mktg, but
plant capabilities and customer
needs are not fully taken into
account. The IQP calculation is
based on quality contract.
Level B
Autonomous
Process levers are well known and
mastered.
Sampling plan is complete and is
regularly reviewed taking into
account the representativity of
samples.
Testing plan is complete and is
regularly reviewed & updated.
Calibration plan is complete and is
regularly reviewed.
Key process parameters, targets
and performances are reviewed
regularly (operation meeting). QC
records are maintained and
controlled. Trends are analysed
according to plant capabilities &
variability.
Active participation in certification
relations with the certification body. bodies.
Level C + contract is based on in-
depth knowledge of plant
capabilities and market data
(segmentation, value proposition,
etc.).
Level A
Optimise and share Level Comments
Trends are regularly analysed
thanks to statistical tools to
optimise plant levers.
Variographic analyses are run in
order to define sample frequency.
Methods are reviewed and
optimised.
Methods are reviewed and
optimised.
Q2 Quality control / Quality assurance 1/2
The calibration plan is regularly
challenged and improved &
systematic review of equipment by
metrological company is performed.
Actions are taken to optimize
performance. Benchmarking is
done with other plants having the
same equipment.
There is a formalized benchmark of
the plant's products versus the
market.
 Mgrs + M
QUA Quality objectives are set annually
Quality objectives are set annually
according to the quality contract
No quality improvement objectives according to the Quality contract
Set Quality improvement and result in an action plan which is Formalised benchmarking of the
are defined or they are not in line but there is no action plan resulting
objectives fully implemented. Personal plant's products versus the market.
with Quality contract. from it or the action plan is not fully
objectives are well defined through
implemented.
this action plan.

Characterisation of the product is

Characterise product to ensure
compliance with Quality contract
done using suitable techniques to
Techniques used for product
ensure compliance with quality
characterisation are inadequate to
contract. However, suitable
ensure compliance with quality
measurement tools are not fully
contract.
available to ensure total
compliance.
Characterisation of the product is
done using suitable techniques to
Innovative characterisation method
ensure compliance with quality
has been promoted at the plant.
contract. Suitable measurement
tools are available at the plant.

A system is in place to ensure

Q2 Quality control / Quality assurance 2/2

A system is in place to ensure quality of shipped material (release
quality of shipped material (release procedure) and proper equipment
There is no system in place to Methods (plant procedures, quality
procedure). However, proper are in place to avoid contamination
Ensure good delivery of product ensure compliance of shipped contract, transition production at
QM

equipment (storage facilities, and deterioration of product

and delivery of the right product product. Wrong deliveries are the bagging machine, etc.) are
proper loading and bagging, fringe (storage facilities, proper loading
experienced from time to time. reviewed and optimised.
QUALITY ASSURANCE

bin) is not fully available to ensure and bagging, fringe bin). Records
total compliance. of release exist & material shipped
is perfectly traceable.

Management of non conforming Re-introduction/re-process of non-

products exists but is not conforming product is tested for The plant is able to anticipate and
Manage non-conforming There is no specific management of
All

formalised and there is no specific compliance. A formal system is in prevent non- conformity from
products non-conforming products.
communication with Sales & place for communication & follow- occurring.
Marketing. up with Sales & Marketing.

All complaints are closed or in

The plant is involved in the process of active resolution and
customer complaints process, but corrective actions are documented. Preventive actions are taken
Complaints are not taken into
Mgrs

Manage customer complaints only a few get results and there is
account at the plant level.
no systematic approach to follow-
up on complaints.
Rules of communication have been following investigations of customer
established with Sales & Marketing. complaints.
The complaint handling BP is
known.

Control of records is done but is not Records are traceable (original The system guarantees that all
integrated into the quality plan. The version, changes, etc.). Quality data is retained for a significant
There is no control of records.
All

Ensure integrity of data retention policy is not clearly data can be retrieved easily period (Lafarge rule = 10 years)
Integrity of data is not ensured.
defined. Uncontrolled changes according to a record retention and can be extracted without
could happen. policy. possibility of data corruption.
 Basic Skills Self-Assessment Grid

PROCESS MEASUREMENT MANAGEMENT

Operational objective: well managed process measurements are fundamantal to optimising the reliability and efficiency of the process

Level D Level C Level B Level A

Fully dependent Partly dependent Autonomous Optimise and share Level Comments
Technicians/ Production

Perform basic Aims to continually improve the

operators

All basic measurements are conducted by

measurements Plant is not able to perform basic All basic measurements are accurracy of measurements and to
a Process Technician or Production
(temperature, moisture, measurements conducted by the Process Engineer increase the involvement of the
Operator.
pressure) production team

Pc1 Process Mesurement Management 1/2

Portable gas analysers (CO and CO2)
are used according to written procedures Operators in charge are able to
Plant does not perform sampling
Technicians

Measure gas composition Plant does not perform all the gas on a regular basis. The sampling system analyse the impact of gas moisture
and measurements properly.
& gas moisture with analyses. Moisture is not is chosen according to temperature, dust and composition on pyroprocessing
Procedures are missing. The
portable gas analysers, determined on a regular basis. concentration and moisture. The line characteristics (especially the
sampling frequency is not defined
psychrometer and silica Procedures are not fully applied if appropriate method for moisture flowrate) to optimize them.
and the accuracy of measurements
gel they exist. measurements is chosen according to the Adjustements are done by following
MEASUREMENTS

is insufficient.
temperature (if T° > 150°C, the silica gel procedures.
is used, otherwise psychrometer).

Plant is proficient in the use of isokinetic

dust method and the results
determination. The actual testing can be Technician performs all dust
Technicians

Dust measurement is not done on a

performed by competent persons from the measurements with an isokinetic
Measure dust level with regularly basis or the procedure is
plant or by contractors provided their dust sampling probe and masters
isokinetic dust sampling Plant does not measure dust level. not formalised. Technicians are not
work is overseen by a competent person all the sampling methods and
probe sufficiently trained to use the
from the plant. The plant follows the guidelines for location and data
isokinetic dust sampling probe.
country regulations for calibration, interpretations.
sampling and calculation (if available),
otherwise the international standards.
Technicians/ Production

Usually clinker production is estimated

from raw weighing feeders (calibrated by
regular material extraction) and from the Plant uses a system to record the
Plant does not weigh clinker and
Operators

raw mix coefficient. This coefficient is history of weigh checks.

Weigh feeder calibration Plant does not know check the raw mix on regular basis and
established and cross-checked through Organises meeting to discuss
check by belt weigh off accuracy of the material flowrate estimates material flowrate mainly
the effective clinker production. Clinker is measurements and implement
from stock data.
weighed during 24 hours at least once a actions plan to improve results.
year. Raw material flowrate is established
weekly.
 Does not have all the equipment (in
Availability of equipment, working condition) or measuring
measuring points and points necessary so cannot perform
calculation tools all the audits. Needs are not really
identified.
Does not own all the equipment but
The plant has all the necessary portable
borrows additional from other Performs tests of new equipment
equipment, measuring points and
plants or TC so that it is generally with the aim to continuously
standard calculation tools to conduct
available to perform the develop measuring techniques.
measurements.
measurements.

Calibration is done regularly (at least

Calibrations (infrared
EQUIPMENT MANAGEMENT

once a year) according to a calibration

pyrometer, thermocouple,
schedule and written procedures for all
stroboscope, non contact The plant organises the equipment
Calibrations are not done, only a Calibrations are done but not the required portable measurement
tachymeter, isokinetic calibration and ensures a complete
few procedures exist and/or they regularly, and most of the equipment. Last update of international
dust sampling probe, set of equipment is available at all
are not really applied. procedures are applied. and/or local calibration standards are
digital manometers, S and times.
known. The calibration is contracted to an
L pitot tubes,
Technicians

expert agency only if necessary (e.g. for

anemometers)
stroboscope).

Gas analysers calibrated, but not

every time for a series of tests A written procedure exists for the The plant organises the equipment
Gas analysers rarely or never
Calibration of Portable and/or written procedure exists but calibration of portable gas analysers and calibration and ensures a complete
calibrated and/or there is no written
Gas Analysers is not fully applied. Plant calibrates is fully applied for every series of tests set of equipment is available at all

Pc1 Process Mesurement Management 2/2

procedure.
the portable gas analysers from a done on site. times.
sample of standard gas bottles.

Equipment are maintained according to a

No maintenance is conducted on The plant organises the equipment
schedule. Usually it would an involve
Portable equipment the portable equipment. Equipment Maintenance is conducted, but not maintenance and ensures a
offsite contractor. Calibration and
Maintenance is kept in poor condition and is on a planned basis. complete set of equipment is
maintenance recording of main portable
consequently quite unreliable. available at all times.
equipment is implemented.
Technicians / Production operators

Reviews the effectiveness of the

A plan exists for verification of the process control instrumentation and
Verfication of Process process control sensors on a frequent aims to optimise the information
Control Instrumentation basis (e.g. gas analysis weekly, presented to the CCR operators.
Verification not done or only Verification done, but no planning
(for temperature, pressure, temperature and pressure 3 monthly) This would include additionnal
partially done. or corrective action procedure.
speed of rotation, gas Procedures are used to determine sensors where necessary,
analysis) corrective action when significant reviewing the location of sensors
differences are found. and new improved sensors for
PERFORMANCE MANAGEMENT

greater reliability.

False air is not measured
False air measurements frequently or only in case of
problem.
The plant follows a plan to track false air All the measurements data are
False air is tracked and repaired,
level in the preheater, raw mill, coal mill recorded and compared with other
but with a frequency of two months
and cement mills on a regular basis, at plants results to identify points to
or greater.
least monthly. be improved.

Fans are checked at least yearly and

after any major work in accordance with
Fan performance checked, but not the Best Practice 'Monitoring the
Discusses issues with suppliers
Fan Performance Fan performance checked only on on a planned basis, or no follow up Performance of Fan Systems'. Suppliers
and continually seeks to maximise
Management a few major fans, not systematically actions defined. Manufacturer are involved if necessary. This should
Technicians / Engineer

fan efficiency.
specifications are not known. have a follow up check list on
actions/checks to make in the case of
finding low efficiency.
 Technicians / E
PER
Sharing of audits with other plants
An audit plan exists concerning all the
and Technical Centre. Specific
Audits are mainly done internally, audits. Assistance of TC's is not required,
Audits (Mini and full mill audits / measurements are defined
occasionally with the assistance of but sometimes discussed with TC for
audits, Mini kiln audits, Audits are not done by the plant. to investigate opportunities to
TC's. There is no formalized audit second opinion. All audits have brief
combustion audits) optimise the process not covered in
plan and/or no written reports. written report with conclusions and
standard audits. For example -
practical actions to improve the process.
precalciner temperature profile.
 Basic Skills Self-Assessment Grid

MANAGING CRITICAL PROCESS SENSORS

Operational objective: the data provided by sensors are reliable enough to allow process control optimisation

Level D Level C Level B Level A

Fully dependent Partly dependent Autonomous Optimise and share Level Comments

Determine needs and

Formal needs analysis is done in
techniques to be used (for No needs analysis is done and/or Comparative study of the various
Informal needs analysis is done in collaboration with process dept.
gas analysis, determine no collaboration with process dept. techniques available, taking into
collaboration with process dept. Agreement is reached as to choice
gases concerned, ranges in the choice of method. account past experiences.
of method.
and testing principles)
All

Sampling point location Partial study, not sufficient to Formal study considering
Distance between sampling point
(for analyser probes: No formal technical study on ensure best location is chosen (e.g. accessibility, representivity of
and analyzer is minimized
place, direction, angle and sampling point location. no comparison of alternative measurements and manufacturer
(response time < 30 seconds).
cooling) locations). recommendations.

Pc2 Managing critical process sensors

Choice made in formal manner
Sensors are chosen with no
All criteria not always considered based on needs of process,
Mgrs

Choice of sensor device consideration of criteria given in B Study of sensors already installed
when choosing, and/or choice not reliability, precision of
(cf. table below) and/or without collaboration of helps optimize future choices.
made in a formal manner. measurements and supplier
process dept.
recommendations.

Partly formalized tech. study does Specs are formalized and include Comparative study of sensor
Tech. Study preparation
No formal tech. study prior to work. not address all issues related to plant specificities and supplier quality (reliability, response time,
INSTALL

for installation
sensor installation. recommendations. etc.)
Technicians

Work is improvised due to lack of

Installation/wiring Prior tech. study is only partial Prior tech. study is complete and is Electrical diagrams are
prior tech. study or because it is not
(contracted out or not) and/or its application is not verified. followed; results are validated. systematically updated.
followed.

Validity and integrity of signal are When in doubt, internal

Calibration is not rigorously and/or Calibration is done only as per
Calibration checked. A formal procedure exists comparisons are systematically
systematically done. manufacturer recommendations.
for calibration and implementation. done.

1/2
Analyzer environment is temp.
Supplier recommendations for There is a system for eliminating
No study is done of analyzer controlled and equipped w/
Gas Analyzers: Ensure installation are followed, but build ups (if study indicates need)
environment; no actions are taken dry/clean compressed air blowback
stable environment and cleaning of probe an other actions and temp. monitoring to ensure
to ensure stable measurement system (if study indicates need).
measurement conditions to ensure stable conditions are stability of measurement
conditions. Probe condition is regularly
done only occasionally. conditions.
checked.
All

Measurement chains are

Gas Analyzers: Identify Measurement chains not identified Measurement chains are written Integrity of measurement chain is
systematically identified, from
measurement chain and for all sensors and/or are not down but are not always analyzed systematically checked after
analyzer to control system. Data
check data integrity written down. in terms of data integrity. modification.
integrity is ensured.
 Scheduling of preventive checks is
Maintenance plan is regularly
Maintenance plan is formalized, but according to sensor type (supplier
Mgrs
There is no formalized updated and optimized (scheduling
Written maintenance plan does not contain all instructions (cf. recommendations); visual checks
maintenance plan. adjustments, specific checks noted,
Level B). every 6 mos., preventive
etc.) based on lessons learned.
maintenance, calibration.

They are not regularly inspected
Maintenance of other
and action is taken only in case of
sensor types
problem/incident.
Some critical sensors are regularly
checked, but no details study has
been done to determine criticality
levels.
Regular visual checks of all critical
Job plan is optimized according to
sensors (identified by study), with
maintenance experience with each
an updated record sheet for each
type of sensor.
one.

Cabinet inspection is done weekly

Cabinet is regularly inspected and and according to a detailed
Technicians

analyzer calibrated, but there are procedure. Preventive replacement Job plan is optimized and
Maintenance of gas Cabinet is inspected only form time
no written procedures. Preventive of filters, pump valves, humidity measurement chain (probe to

Pc2 Managing critical process sensors

MAINTENANCE

analyzers to time and/or same for calibration.

maintenance actions are not sensor, etc. Analyzers are analyzer) is regularly recalibrated.
systematically done. calibrated monthly with standard
gases.

Sensor condition is systematically

checked and main maintenance
Level C + measurement chain is Manufacturer servicing is
Annual shutdown No particular maintenance program work is done (dismantling and
checked with CCR at the end of the scheduled during kiln stops.
maintenance during annual kiln shutdown. cleaning). Replacement or
annual campaign. Transmitter scales are checked.
servicing of analyzers is
considered.

There is a list of sensitive parts (i.e. Maximum unavailability time is

No particular management system Management is done on an those that should be in stock); list is known and supplies are maintained
Spare parts management
for spare parts. informal basis. kept up to date to track parts based on knowledge of most critical
availability. parts or most probable incidents.
All

Operations personnel are trained in

1st level maintenance, and
Operations personnel point out all Failure rates and system
No permanent, organized procedures are available to them

2/2
Collaboration with observed irregularities but are not unavailability due to minor incidents
collaboration with operations and are used (incident simulation,
operations personnel able to take appropriate action. is analyzed. Preventive measures
personnel. checklists, coherence between
Observations are followed up on. are taken.
diagnosis and prescribed actions,
etc.)
HISTORIZATION

Daily analysis of historized data for

Data historization rigorously done Historized data for the various
all sensors in collaboration with
Analysis of historized Data historization not always done only for some sensors and/or sensors are systematically
All

process dept., taking into account

sensor data and/or not analyzed. analyses are done only by process compared to check signal quality.
stability or measurement conditions
teams. Drifts are tracked and analyzed.
and measurement reliability.

Gas/Fire detectors are

SAFETY

Gas analyzer safety: Past experiences (including form

systematically installed and
Secure the installation No particular safety measures are Not all safety measures are other plants) are known and taken
All

regularly tested. Standard gas

(possible presence of in place for gas analyzers. implemented (cf. level B). into consideration when deciding
cylinders are store outside the
toxic gases and acids) on analyzer safety measures.
analyzer cabinet.

Hardware management (I/O
cards changes, input equipment
replacement, input systems
network verification, etc)
Technicians
Backup parts management
Hardware
Adding components (minor
modifications, network
extension, addition of a rack,etc.)
Utilities (air-conditioning,
MAINTENANCE
All
dedusting, UPS…) and safety
issues (fire in particular)
Data backup management
Technicians
Software
Security management (access,
anti-virus…)
Applications development
(security, start up, equipment
control, problem solving
loops,etc)
Technicians
Equipment follow-up
General
PCS maintenance procedures
Operational objective: control system is reliable and ensures safe operations and protection of equipment. It provides accurate reporting and allows
process optimisation
Level D
Fully dependent
I/O cards are only changed after
failure.
There is no backup management.
The modifications are always
driven by suppliers.
There are no special PC room
and/or computers are not always
dedusted and/or they are not
protected from fire.
Disk backups are not done
systematically.
Nothing special is done for security. passwords are not often changed
The plant need external help to
develop these types of applications.
There is no follow-up.
There are no procedures.
Basic Skills Self-Assessment Grid
CONTROL SYSTEM MANAGEMENT
Level C
Partly dependent
I/O cards analysis are
systematically done when a
stoppage takes place because of
I/O card or hardware problems.
Some procedures are written and
control system inspections are
done but not planned around plant
stoppages.
The plant can manage small
modifications such as I/O
configuration but needs external
help for software programming.
Computers are installed in a
Air-conditioning and UPS are
special room, regularly cleaned and
provided.
protected from fire.
Disk backup are systematically
done but their follow-up is not
planned or the scheduling is not
always respected.
The system is secure but
and antivirus is not always updated. regularly and antivirus is updated.
The plant can perform some of
these developments but needs
external help to solve problems of
software programming (for
example).
Equipment is monitored with the
PCS system tools.
Some procedures are written and
used.
Level B Level A
Autonomous Optimise and share Level Comments
All the analogical loops are
The cards are protected with fuses protected against electrical
and all I/O cards/hardware malfunctions. All hardware
replacements are anticipated and problems are identified thanks to
planned with the maintenance preventive maintenance and
team. communicated to the supplier for
analysis.
Procedures exist and are used.
Backup parts are regularly checked. There is a "virtual store" between
All the spare parts are available in plants of the same region or with
the plant and equipment supplier where all spare parts are
inspections are planned during the registered.
plant shutdown.
Hardware configuration of new All the modifications are managed
shops and network connections can internally, including reporting,
Pc3 Control system management 1/2
be handled internally. timing and all commissioning.
Preventive maintenance is done for
protection systems and needs are
anticipated according to the system
changes.
All backups are done and easily
Software agent have been installed
retrievable.Bachups are stored in a
to verify that backups have been
fireproof cabinet located in a room
done.
other than the PC room.
Secure connections to Lafarge
Internal network access is well
networks can be managed at plant
managed, passwords are changed
level. A technological watch is in
place for antivirus systems.
Automation team is able to design
Loops are optimised and
sequences and shop startups
automation team is able to
including active security. Control
anticipate Process, Electrical and
loops are regularly reviewed and
Mechanical troubles.
incidents are analysed.
Historic data are used to follow all Automation team is able to create
equipment with a daily reporting. new reporting (SQL query).
Procedures are regularly updated.
All procedures are written and used
New ones are created when the
regularly.
need arises.
 DOCUMENTATION
Application documentation is
Technicians available and regularly updated
Documentation is up to date and
Original documentation is available. caters to the specific needs cement
There is no documentation for (functional analysis, operator
Documentation PCS & IT Additional plant-specific plants,
applications installed at the plant. manuals, latest electrical drawings,
documentation is partially written. Documentation can be used by
etc,). Classification system is clear
contractors.
and logical.

Best available tools are identified

Techonogical watch for Needs are systematically identified, thanks to a thorough technological
No technological watch and/or Some needs are identified, but are
All

computer products. Anticipation and are based on failure rate watch. Precise studies are done to
changes not anticipated. not based on failure rate analysis.
UPGRADE

of system developments. analysis. optimise upgrades according to

plant needs.

All technical specification are

Ability to design major upgrades
The plant can write some written by the plant team,
internally (e.g. integration of a Nobody can write specifications for Comparative grids are done for
All

specifications but they must be IT knowledge is sufficient for to

new shop into the existing this kind of project. benchmarking of integrators.
checked externally. manage integrators and evaluate
system)
their work.

Pc3 Control system management 2/2

PCS Administration (access
NETWORKING & INFRASTRUCTURE

All PCS administration is done by

configuration, I/O mgmt., There is no PCS administrator in Problems are not always detected Warning system is installed for
All

the plant, including programming

configuration & the plant. and/or solved internally. detecting problems.
and problem solving.
parameterisation)

IT network administration, mgmt

Network administration is done by
of data extraction systems and There is no network administrator Problems are not always detected Warning system is installed for
the plant, including programming
Management

tranmission of data to other in the plant. and/or solved internally. detecting problems.
and problem solving.
systems

Licences of all software versions

IT licences management (at BU The plant cannot quickly give the Licences availability ( for multi- Licences costs are optimised
are systmatically registered: a
or plant level) stauts of licences. licence) can be known at any time. thanks to multi-licences or other.
status can be given at any time.

All applications are connected

The PCS system is connected to
The architecture application can within the plant. Knowledge of the
No structure for architecture external applications and external
All

Inter-application architecture only connect a part of systems PCS team is sufficient to manage a
application has been developed. access to plant databases are well
within the plant. contractor for developing inter-
managed.
application architecture.
Technician

Most plant problems are solved All hot line calls are logged for
There is no hot line or support Support exists but only small
Internal support (hotline) internally, only the most analysis (statistics, weakness, etc)
s

available internally. problems are solved.

complicated require external help. and identifying FAQs.
SUPPORT

Modifications are systematically Booklets giving usefull information

Formal communication with other
There is no communication with communicated and the other teams about IT networks and tools are
Training/communication with teams within the plant is done only
other departments in the plant even are trained in first level given to all plant employees and/or
other departments for major modifications or if a new
Management

when the IT system is modified. diagnostics/interventions ( e.g.: there is specific training for
system is implemented.
restart the server) newcomers.

Know-how transmission All essential procedures are

People in charge of control system
concerning older equipment and Some essential procedures are written : the knowledge is shared
This Know-how is not transmitted. are members of a community of
old software versions used in the written. within the department and
practices.
plant. transmitted in case of departure.
 The grids are sorted by domains: each department of the plant should assess collectively its own level under the
responsibility of the manager.
(that explains why there are two grids about contractors, one for the maintenance team and one for the production team)

Two levels of responsibility are mainly
identified: Technicians (operators,
supervisors, etc.) & Managers.
Each level includes the level below
(i.e. you are at level A only if you do what is
described at level B & A, etc.)
The column «comments» should be used in
particular:
- each time you hesitate between two levels
- each time you choose level A
- each time the task does not concern your plant