titan group profile - amcham bulgaria€¦ · in 2004 zlatna panega cement was acquired by titan...
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TITAN Group in numbers: � 13 countries� 14 cement plants� 44 quarries� 148 Ready mix plants� 5.640 direct employees� 73 million € for environmental investments since 2008
TITAN Group Profile
since 2008
TITAN’s fourTITAN’s four--pronged Strategypronged Strategy
•• Geographical Diversification Geographical Diversification -- We extend our business through acquisition We extend our business through acquisition
and and greenfieldgreenfield development into attractive new markets, to build production development into attractive new markets, to build production
scale and spread the risk of overscale and spread the risk of over--reliance on too few marketsreliance on too few markets
Governing Objective
scale and spread the risk of overscale and spread the risk of over--reliance on too few marketsreliance on too few markets
•• Continuous Competitiveness Improvement Continuous Competitiveness Improvement -- We implement new efficiencies We implement new efficiencies
throughout our business to reduce costs and compete more effectivelythroughout our business to reduce costs and compete more effectively
•• Vertical Integration Vertical Integration -- We extend our business into other product areas in the We extend our business into other product areas in the
cement value chain, gaining greater control over our markets and accessing cement value chain, gaining greater control over our markets and accessing
new profit opportunitiesnew profit opportunities
•• Focus on Human Capital and CSR Focus on Human Capital and CSR -- We develop and continuously improve We develop and continuously improve
our good relationships with all internal and external stakeholders for mutual our good relationships with all internal and external stakeholders for mutual
respect and understandingrespect and understanding
� In 2004 Zlatna Panega Cement was
acquired by TITAN Group
� TITAN implemented a long-term
modernization plan with total investments
exceeding EUR 85 million to enhance
operation efficiency and environmental
performance
� More than 230 people are currently
employed by TZP and the majority (88%)
� The first cement in Bulgaria was
manufactured in Zlatna Panega village in
1907. An Italian company built a small
cement factory next to the river, in
operation until 1923
� The cement was of good quality and
was used in the construction of the Sofia
Market Hall, the port of Varna, St.
Alexander Nevski Cathedral ... employed by TZP and the majority (88%)
are local citizens
� In 2004 - ISO 14001
� In 2004 - ISO 9001
� In 2009 - OHSAS 18001
� In 2010 – IMS ISO 9001:2008, ISO 14001:2010 & OHSAS 18001:2007
Training procedure - comprises a part of the documentation of the Integrated
System for Management of Quality, Environment and Health&Safety at
work, implemented in accordance with the requirements of standards BDS EN
ISO 9001:2008, BDS EN ISO 14001:2010 and BS OHSAS 18001:2007
“We aim to grow as a multi-
regional, vertically integrated
cement producer, combining an
entrepreneurial spirit and
operational excellence with respect
for people, society and
environment.”
TITAN Group Values and Governing Objective
Our Values:
� Integrity
� Know-How
� Value to the customer
� Delivering results
Business Priorities:
� Health & Safety
� Sustainable Development
� Community Relations
� Integrity & Transparency
� Delivering results
� Continuous self-
improvement
� Corporate Social
Responsibility
� Focus on Internal training programs and technical competences
development
TITAN recognizes the importance of people development. It is a way to
retain our people within the company, but it also helps employees to
keep up with a changing environment thus we ensure our future and we
are ready for the forthcoming challenges.
developing
people
changing
behavior
growing
business
1.Goals setting & planning
Performance improvement is an ongoing process aiming at
employee improved performance and professional
development through the appropriate support from
supervisors, in line with company objectives.
Two key steps:
Performance improvement
process
2.Monitoring & feedback
3.Acesses performance
4.Rewards & performance recognition
Two key steps:
� Assessment of employee annual performance
� Elaboration of development priorities
(development plans) based on the assessment
Total number of man hours
training distributed during 2012 –
12 201
� Training activities focused on
Health & Safety – more than
7000 man hours
� Technical Know-How and core
competencies development –
1235.5
1451
1050.5
7094
1195
145 30Management / Managerial Skills Technical Know-How and Core Competence Non-Technical Skills & Specialization Health & Safety training
Environment training
Foreign Languages
Other
Distribution of training hours per subject 2012
Total: 12201
hours
competencies development –
1451 man hours
� Environmental training - 1195
man hours provided
For Q1 of 2013 the total training
hours are 3 028
88.5
428
128.5
2291
24 34 34
Management / Managerial Skills
Technical Know-How and Core Competence
Non-Technical Skills & Specialization
Health & Safety training
Environment training
Foreign Languages
Other
Total: 3028 hours
Distribution of training hours per subject Q1 2013
� By implementing Cmentors program in Zlatna Panega we are aiming to support our
key employees to become excellent professionals and highly-valued Cement mentors
� Develop the capability of our people and plant teams to achieve our business
objectives
The three pillars of Industrial Competencies Development Program are:
Industrial Industrial Competences Competences FrameworkFramework
Plant team Plant team assessmentassessment
Industrial Industrial EducationEducation
Job profiling, elaboration of INDUSTRIAL COMPETENCIES FRAMEWORK
and benchmark a couple of plant positions
FOUNDATION AUTOMATION TECHNOLOGY
SKILLS/ COMPETENCIES ON THE JOB
� Basis of the main points of process measurements in a cement plant - temperature, pressure, flow, level, power, etc.
� Basis of the main principles of measurements in temperature, pressure, flow, level, power etc.
� Basis of Dosing systems and scales
� Gas analysis in basic. Extractive and In Situ (in position) types of measurement
� Automated systems. What is PLC control,
� Understanding of flow sheets
� Using of HMI in CCR and archives information about process, analyses of data collected and alarams for malfunctions
� Using of environmental emission evaluation software
� Automated systems. What is PLC control, control loops and how we can optimize productivity and decrease expenses
� Environmental emissions evaluation systems
Development of INDUSTRIAL COMPETENCY MATRIX
Safety Mining Production Process Environment Quality
Maint.
Methods
Mech.
Technology
Elect.
Technology Automation
Eng./
Designs Proj. Mgmt
Maintenance
Maintenance Manager
Mechanical Maintenance managerLevel II Foundation Level I Level II Level II Foundation Level I Level II
Head of Mech. Maint. Kilns & Coal Mill SectionLevel I Foundation Level I Level II Level II Level I
Head of Mech. Maint. Crushers & Raw Mills SectionLevel I Foundation Level I Level II Level II Level I
ZLATNA PANEGA Industrial Competencies Matrix
Head of Mech. Maint. Cement Mill & Packing SectionLevel I Foundation Level I Level II Level II Level I
Head of Maintenance Planning and Reliability groupLevel II Foundation Foundation Foundation Foundation Level II Level II Foundation Foundation Level I Level II
Preventive maintenance - plannerLevel II Foundation Foundation Level II Level I Foundation Foundation Level I Level II
Electrical Maintenance managerLevel II Foundation Foundation Level I Level II Foundation Level II Level II Level I Level II
Head of Power Supply & Distribution and electrical repairsLevel II Foundation Foundation Foundation Level II Level II Level I Level I Level II
Electrical engineerLevel II Foundation Foundation Foundation Level I Level II Level I Level I Level II
Head of Process Automation & Instrumentation SectionLevel I Foundation Foundation Foundation Level I Level I Level II Level I Level I
Plant team assessment steps:
� Plant teams complete their self-assessment booklets
� Assessment is submitted for validation by a Committee
Plant Profile
1What is the age of the plant ? Original construction year ? Year of most recent addition or renovation ?
2What is the average age of production line equipment ?
Getting to know the cement plant
Maintenance:
2
3
Number of kilns ? Process Type ? In operation ? Rated capacity versus actual production rate ? Clinker
cooler type ?
4
Kiln gases vent (baghouse /precipitator) specifications ? Cooler vent (baghouse/ precipitator)
specifications ? Number and type of mills ? In operation ? Rated capacity versus actual production rate ?
6Obtain a copy of the plant layout / flow sheet.
5 Number and type of mills ? In operation ? Rated capacity versus actual production rate ?
Name: John Smith
Position: Automation engineer
Department: Maintenance
1. Safety
2. Mining
3. Production
4. Process
5. Environment
Industrial CompetenciesDevelopment Priorities
X
X
X
X
X
H
H
H
15
5. Environment
6. Quality
7. Maintenance Method
8. Mechanical technology
9. Electrical Technology
10. Automation
11. Eng./Designs
12. Project Management
My profileRole Profile
X
X
X
X
X
X
H
� Classroom training
Create the ‘right’ blend of learning tools, in the ‘right’ order
� Self-study
� Networking & coaching
� All new comers and engineers with experience up to 4 years will go through
Foundation level & acquire solid knowledge of Cement
production, operation, maintenance, as well as H&S and Environment
protection
� Recognize top experts and create a pool of internal trainers, further develop
communication and presentation skills to become Cement Mentors and
transfer K-H within the Group
� Identify, motivate and give opportunity to individuals, eager to learn and
grow to become a Group asset
� Keep and transfer K-H in the Group
� Retain our Key People
� Reduce training cost
� Increase operation efficiency
� Leading indicators for Safety Performance
� Risk assessment of all jobs and activities
� Data Collection to measure performance & progress vsKPIs agreed (# of tools Safety Audits findings, Stop Cards, Near miss reports)
Health & Safety
TRAINING
KPIs
Risk Assessment
Procedures development
miss reports)
� Procedures development
Step by step to improve the safety at work and radically to change the Safety Performance
Assessment
Performance assessment
development
Leading Indicator2011 Matrix Weight
Factor
Jan2011
Feb2011
March
2011
April2011
May2011
June2011
July2011
August
2011
September
2011
October
2011
November201
1
December201
1
Annualy
Green area Yellow area Red area
1. Number of UA reported in the audit+Stop card /working hours x 1000
<1 1-3 >3 1 3 4 5 5 4,5 3 3,6 3,24 4 4,67 4,79 5 4,15
2. Number of UC closed(m&h)/ UC(m&h) found per month
90-100% 70-90% Less than 70%
2 34% 4% 1% 12% 25%11,1% 10%7,24% 12,3% 20% 28,57% 17,3% 15,2%
3. Percentage of audit completed / audit planed
85-100% 70-85% Less than 70%
2.5 100% 100% 92% 108% 100% 93% 108% 108% 125% 125% 108% 100% 105%
4. Percentage of NM 80-100% 65-80% Less than 1 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%4. Percentage of NM Investigated/close/ NM total per month
80-100% 65-80% Less than 65%
1 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100% 100%
5. Number housekeeping findings 0-50 50-150 >150 1 48 73 58 69 54 40 51 47 49 69 49 39 53,8
6. Number of STOP cards filled rigtly
>50 50-40 <40 2 77 119 137 99 50 112 126 61 67 75 81 32 86,3
7. Number of safety training/person hours x 1000
>5 3-5 <3 2 4 6 13 22 5 5 3 23,46 7,87 18,29 6,21 10,6 10,36
8. Number of NMR/month Above 30 20-30 Less 20 2 31 20 39 52 24 31 39 25 46 13 60 53 36
9. Number of contractors incident 0 1-3 More than 3
1 1 3 2 2 1 0 0 0 0 0 0 1 0,8
10. Summary >47.8 47,8-38.8 <38.8 14.5 47.9 50.2 53,8 56,5 42.6 47,9 53,8 45,07 50,5 50,9 53,5 42.8 49,47
Environment awareness program - joint project with
Regional Environmental Center (REC).
Aim:
� Development of integrated approach towards
environment protection on company level by
introducing training for all ZLP employees
� Stakeholder engagement through introduction of
extended environmental educational program in
local schoolslocal schools
Results:
� Tailor made, 10 modules program
developed, more than 50 employees trained
during 1st phase
� Training of teachers in schools of Lovech
municipality to use Green Pack tool (developed
by REC); Printing and submitted of 1000 copies
funded by the Ministry of environment and Titan