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The big announcement from LafargeHolcim this week was the launch of its Industry 4.0 plan known as ‘Plants of Tomorrow.’ The scheme hopes to use automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies across the company’s entire production process. Operational efficiency gains of 15 - 20% are promised.

There wasn’t much detail beyond the use of the Siggenthal integrated cement plant in Switzerland as the ‘lighthouse’ of the scheme, where around 30 proof-of-concept technology ideas will be tested. One technology it did flesh out a little was its long-running Technical Information System (TIS). This follows the work between Holcim and the power and automation product supplier ABB. LafargeHolcim says that over 80% of its plants around the world use the TIS to provide data transparency at plant, country, regional and global level. It added that some country operations have more than a decade of historic technical data available. This last point is pertinent as the data could potentially be used to support the training of any machine learning algorithms the company might want to invest in. The building materials company also mentioned its LH Maqer subsidiary. This startup incubator was launched at the end of 2018.

LafargeHolcim appears to be playing catch up here with Cemex, which has steadily been promoting its own Industry 4.0 developments in recent years. Emphasis on ‘promotion’ here as only yesterday, the day LafargeHolcim made its big reveal, Cemex happened to release information about a recent roundtable in France that it participated in on digitisation and productivity in the construction sector.

Notably in March 2019, the Mexican multinational struck a deal with Petuum to implement its Industrial AI Autopilot software products for autonomous cement plant operations at its plants around the world in March 2019. Readers can find out more about Petuum’s work with Cemex in the June 2019 issue of Global Cement Magazine. In late 2017 Cemex too set up a division, Cemex Ventures, to engage with startups, universities and other organisations. Cemex has also been building its digital customer integration platform Cemex Go since around the same time.

One interpretation of Industry 4.0 is as a German-industrial approach to the so-called fourth or digital revolution pushed by Anglophone software companies. The idea of taking as much data from a production process, such as making cement, is enticing but the prospect of actually doing something useful with this tsunami of information is daunting. Typically algorithm techniques or predictive maintenance seem so far to focus on discrete parts of a process such as a finish grinding mill or final product logistics networks. Companies like Germany’s Inform focus on the latter for example and, incidentally, it celebrated its 50th anniversary this week.

If automated systems start making apparently nonsensical yet useful decisions across the whole raw materials, production and supply chains, then Industry 4.0 will reach its full potential. This moment, if it comes, will be analogous to the time IBM’s computer Deep Blue managed to beat chess grandmaster Garry Kasparov in the late 1990s. What’s more likely are automated systems that can perform consistently outside the human operator comfort zone edging up against hard physical process constraints.

Meanwhile, what will be interesting to watch here is whether LafargeHolcim will be able to leverage any advantage over Cemex by having more cement plants to pull data from. Before LafargeHolcim started selling off its south-east Asian subsidiaries it had more than three times as many cement plants as Cemex. If data really is more valuable than oil these days then starting late in the industrial digital arms race may not be as deleterious as one might first think.

Turkey: The Turkish Cement Manufacturers' Association (TÇMB) has appointed Tamer Saka as its president. He has been the president of Sabancı Holding Cement Group since early 2018.

Saka holds a doctorate from the School of Business at Istanbul University. He worked as the Manager and Senior Manager of Arthur Andersen and Ernst & Young companies, respectively, and he was in charge of Risk Management Consulting Services and then he joined Sabancı Holding family in 2004 as the Risk Management Director. He served as the Executive Director responsible for business development operations of nearly 20 countries, including Turkey, at Willis London in 2010 and 2011. In August 2011, he was appointed as the Strategy and Business Development Coordinator of Kibar Holding and then he was appointed as the Head of Automotive and Corporate Functions Group in May 2012 and as the Kibar Holding Board Member. Tamer Saka became the CEO of Kibar Holding in 2014.

India: Basant Kumar Birla, chairman of BK Birla Group, has died at the age of 98 in Mumbai. He is survived by his grandson Kumar Mangalam Birla, the head of Aditya Birla Group, the owner of UltraTech Cement, amongst many other family members, according to the Times of India.

Part of the influential Birla family of industrialists, Basant Kumar Birla originally started working at Kesoram Industries before turning the business into a conglomerate with concerns in cement, engineering, medium-density fibreboards, pulp and paper, rayon, shipping, tyres, tea, chemicals and other sectors. BK Birla Group reported a turnover of US$2.4bn in the 2018 – 2019 financial year. At present the group now comprises five major companies - Kesoram Industries, Century Textiles & Industries, Century Enka, Mangalam Cement and ECE Industries - and several smaller subsidiaries.

Image of Basant Kumar Birla by Biswarup Ganguly CC BY 3.0

India: The National Company Law Tribunal (NCLT) in Mumbai has approved Dalmia Bharat’s offer for debt-laden Murli Industries, subject to conditions intended to stop the company going into liquidation. The tribunal has given Dalmia Bharat until 12 July 2019 to decide if it wants to proceed, according to the Economic Times newspaper. The conditions include forcing the buyer to reinstate lapsed mining leases related to Murli Industries itself and removing clauses allowing Dalmia Bharat to modify or withdraw its plans at any stage. Dalmia Bharat bid around US$60m to buy Murli Industries’ 3Mt/yr cement plant in Maharashtra in late 2017.

Philippines: Big Boss Cement has reportedly stopped plans to build a new grinding plant at Bamban in Tarlac province following a series of protests by local residents. Local mayor Jose Feliciano said the cement producer had withdrawn its US$117m investment, according to the Philippine Daily Inquirer newspaper. The project was going to be built an agricultural land around 0.5km from a school with 4000 students. However, Feliciano noted that the loss of the factory would reduce local municipal funds.

China: Jidong Cement and its subsidies have received US$30m in subsidies from the Chinese government in the first half of 2019. It said that the subsidies were related to its daily activities, according to Reuters. The cement producer said that its estimated profit nearly doubled to US$134m in the reporting period following restructuring the company. Its cement and clinker sales volumes by 15% year-on-year to 45.76Mt.

El Salvador: Holcim El Salvador is marking its 70th anniversary with the launch of a 42.5kg limited edition bag for its Fuerte cement brand. The new bag features the traditional red and black colours and landmark buildings constructed with Holcim’s cement product packaging, such as Torre Futura, the San Salvador Metropolitan Cathedral and the Divino Salvador del Mundo monument, according to the El Mundo newspaper. The new limited edition bag will be sold until the end of 2019.

Saudi Arabia: Najran Cement has renewed its clinker export licence. It is valid for one year from 9 July 2019.

France: Lafarge France has launched its Lafarge 360 initiative. The scheme aims to aid specifiers, contractors and builders make low-carbon structures through reducing CO₂ emissions, preserving natural resources and responsible innovation. It will start the initiative by proving a Lafarge 360 score on its associated digital platform to allow customers to assess the environmental impact of Lafarge’s products. By providing a rating of A to D the tool will offer information on the concrete types.

Switzerland: LafargeHolcim has launched a four-year industrial automation plan called ‘Plants of Tomorrow.’ It includes Industry 4.0 concepts such as automation technologies and robotics, artificial intelligence, predictive maintenance and digital twin technologies for its entire production process. The plan is expected to show 15 – 20% operational efficiency gains. It also claims that the initiative is, “one of the largest roll-outs of Industry 4.0 technologies in the building materials industry.”

“Transforming the way we produce cement is one of the focus areas of our digitalisation strategy and the ‘Plants of Tomorrow’ initiative will turn Industry 4.0 into reality at our plants. These innovative solutions make cement production safer, more efficient and environmentally fit,” said Solomon Baumgartner Aviles, Global Head Cement Manufacturing.

The building materials company is presently working on more than 30 pilot projects covering all regions where the company is active. The company’s integrated cement plant at Siggenthal in Switzerland will be a trial site where the integration of all relevant modules will be tested.

One examples of where LafargeHolcim has started the plan include a partnership with Swiss start-up Flyability to use drones to increase the frequency of inspections at plants while simultaneously reducing cost and increasing safety for employees by inspecting confined spaces. The concept is being rolled out to several markets, including Switzerland, France, Germany, the UK, the US, Canada, India and Russia. It is also using a subsidiary, Maqer, to identify technology startups with promising technology. It aims to harness the potential of this through new partnership models with both manufacturing and software companies.

LafargeHolcim has already launched technology to track performance centrally and allocated resources to support the plant network in real time. More than 80% of LafargeHolcim’s cement plants are already connected to its Technical Information System that provides data transparency at plant, country, regional and global level. Some country operations have more than a decade of historic technical data available. Other systems allow the remote control of certain parts of the operations through online condition monitoring systems. Since its implementation in 2006, this system has saved over Euro70m and an additional 3Mt of cement sold through fewer breakdowns.