1. Can anybody tell me Cement Production flow?
2. How can we configure the cost centers for cement plant to arrive fixed and variable cost for preparation of cost sheets for analysis purposes??
3. Can anybody provide me a document on configuration of cement costing so that it will be helpful for me because i am developing the software for cement costing.
Regards
Sriram M
Ramco Cements Ltd
Hyderabad
Hi:
Are you from accounting/finance department?
On what I understand the cement plant can be divided into the following cost center:
1. Crusher - This will depend on the number of your crusher facilities. In our case we have 4 crusher facilities located in different areas around the plant, so we have 4 cost centers. The crusher cost center will include the primary crusher, secondary (if any until third stage crushing), until bridge reclaimer
2. RawMill - This will include the areas from the rawmaterial bins, rawmill proper, rawmill recirculation, until the Blending Silo (where you store the rawmeal).
3. Kiln - This is from the conveying mechanism after the blending Silo, Preheater, Kiln Proper, Clinker coolers and clinker conveying system.
NOTE: you can create sub-cost center if you like.
4. Cement mill - From the conveying system of Clinker silo, to cement mill proper until Cement Silos.
5. Packing - This include all the flow clain and bucket elevator from Cement Silo until the rotopacker.
Fixed cost are normally includes the Maintenance stock, external labor, rentals, fees, wages, other fixed cost
Variable cost includes refractory bricks, castables, electricity, fuels, rawmaterials, liners, grinding ball/rollers..
Best regards,
Dear,
First of all you must have to develop the norms shee, norm sheet means consumption of all the comodities per ton of cement.
For emaple
| ITEM | Unit | ||
| Limestone | ton / ton Clinker | 1.078 | |
| Shale | ton / ton Clinker | 0.385 | |
| Iron Ore | ton / ton Clinker | 0.077 | |
| Total Raw Material | ton / ton Clinker | 1.540 | |
| Furnace Oil | ton / ton Clinker | 0.00125 | |
| Coal | ton / ton Clinker | 0.14195 | |
| TDF | ton / ton Clinker | 0.00400 | |
| Furnace Oil Equivalent | ton / ton Clinker | 0.0805 | |
| Diesel at Kiln | Ltr. / ton Clinker | 0.150 | |
| Diesel at Quarry | Ltr. / ton Raw Material | 0.850 | |
| Gypsum | ton / ton Cement | 0.050 | |
| Performance improver (L.S) | ton / ton Cement | 0.000 | |
| Power (Gross) | Kwh / ton Cement | 105.00 | |
| Paper Bags | No. / ton Cement | 20.200 | |
| Refrectory Consumption |
| Magnesite Bricks (M.Ton) |
| Alumina Bricks (M.Ton) |
| Alumina Castable (M.Ton) |
| Fire Bricks (Gm/ton of Clinker) |
| Grinding Media (M.Ton) |
| Grinding Media (Gm/ton of Cement) |
You have to work on these lines. I can only give you a tip, salary and wadges and other expances can be calculated from your Finance. Once agian i have to clear you that it is just an example, you have to develop your own data.
Regards
Hi friend,
I just joined a cement plant as an accountant, i want to know how the reporting format look like .
Thanks.