Report: Observations, Initiatives, and Revival Strategy for WACEM: West African Cement S.A.

Introduction

I joined WACEM: West African Cement S.A. as General Manager - Works on 3rd November 2024. The plant, with two clinkerization units installed in 1970, was taken over by Diamond Cement Group, India. It reached its peak production levels in 2005 but has been on a decline since then, particularly after a fatal blast in 2015, which led to the loss of several lives. By 2023, the plant’s production had hit its lowest point.



The workforce comprises local permanent employees and a handful of Indian expatriates managing plant operations.

Observations Upon Joining

  1. Organizational Challenges

    • Lack of trust, motivation, and enthusiasm among employees.
    • An overarching atmosphere of pessimism.

  2. Operational Deficiencies

    • Absence of preventive maintenance for machinery.
    • Poor housekeeping and a lack of cleanliness.
    • Negligence in the inspection of equipment.
    • Unmanaged inventory leading to inefficiencies.

  3. Security Issues

    • Frequent and significant incidents of theft.

  4. Human Resource Challenges

    • Aging expatriates contributing minimally, primarily passing time.
    • Young expatriates lacking the required skills and experience.

Initiatives Undertaken

  1. Team Building and Motivation

    • Began building a team of positive-minded individuals and guiding them to take leadership roles.
    • Initiated daily morning talks with a small team, which has gradually grown to include more participants.

  2. Safety and Operational Improvements

    • Launched safety awareness campaigns and 5S activities to improve housekeeping and cleaning.
    • Conducted condition appraisals of plant equipment and started preparing a refurbishment plan.

  3. Maintenance and Engagement

    • Established a strict weekly maintenance regime.
    • Increased involvement of local employees in operations and maintenance tasks.

Revival Strategy and Action Plan

  1. Restoring Trust and Motivation

    • Continue team-building activities to instill a sense of purpose and belonging.
    • Recognize and reward good performance to boost morale.

  2. Enhancing Operational Efficiency

    • Implement a robust preventive maintenance program.
    • Conduct detailed equipment inspections and refurbish critical machinery based on priority.
    • Organize training sessions for young expatriates to improve their skills and confidence.

  3. Improving Safety and Security

    • Strengthen safety protocols and regular safety audits to prevent accidents.
    • Collaborate with security agencies and implement surveillance systems to curb theft incidents.

  4. Optimizing Human Resources

    • Redistribute responsibilities to maximize the potential of experienced expats.
    • Mentor local employees to take on key operational roles, reducing dependency on expatriates.

  5. Addressing Housekeeping and Inventory Management

    • Establish a cleaning and inspection schedule for all plant areas.
    • Digitize inventory management to ensure better control over materials and spares.

  6. Fostering Community Engagement

    • Engage with the local community to create goodwill and develop a pipeline for skilled local hires.
    • Promote collaborative initiatives like skill development programs for locals.

Conclusion

The challenges at WACEM are significant but not insurmountable. By implementing these strategies and fostering a culture of safety, efficiency, and trust, I am confident that the plant can regain its former glory. The journey towards revival requires persistence, strategic planning, and the active involvement of every member of the organization.

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