Background
- Service: O&M
- Industry: Cement
- Country: Liberia
Plant Supervision has supported cement plants with installation services globally for more than 15 years. In recent years, we’ve seen a growing need in operation and maintenance (O&M) support. However, full-scale O&M outsourcing remains rare in emerging cement markets like India, Liberia, and Indonesia.
Many clients prefer to retain internal control over core personnel while outsourcing technical support and daily operations to minimize headcount, meet compliance obligations, and manage costs. That’s why Plant Supervision has developed a lighter O&M model as a deliberate alternative to traditional full-scale outsourcing—an approach that has proven particularly effective in regions where companies seek cost-efficient solutions and lack the in-house competencies to operate and maintain their sites.
Challenge
In Liberia, we’ve worked with two clients who required long-term, on-site support to manage daily cement grinding operations.
Both sites faced a fundamental challenge: they did not have the required technical competencies in-house and found it difficult to source skilled personnel locally. At the same time, a full O&M takeover was neither financially viable nor aligned with their long-term strategy.
They needed a partner who could step in quickly, stabilize operations, and build local capabilities—without creating long-term dependency or significantly increasing operational costs.
Our solution
Plant Supervision India and Denmark implemented a tailored lighter O&M model designed specifically for the Liberian context.
Rather than assuming full control, our approach focused on providing cost-effective technical expertise through our Indian workforce—combined with structured knowledge transfer to local teams. This allowed the client to build internal capabilities while maintaining stable production.
At the same time, our back office managed all compliance and logistical aspects, including payroll, visas, travel, and housing. This is a key differentiator, as many providers avoid these projects due to the administrative complexity.
Our flexible setup also enabled the client to combine their existing workforce with Plant Supervision personnel—creating one integrated and cooperative team.
Our O&M service included
- Initial staffing of 17–18 supervisors per plant, gradually reduced to 10–12 as the team matured
- On-site training, QA/QC, and continuous production oversight
- Support during commissioning and achievement of performance guarantees
- SOP development for both mechanical and electrical systems
- Coordination with client sales and procurement teams
- Safety training and HSE compliance, including regular mock drills
Each site was anchored by Raghavendra Navali, an experienced Plant Supervision Project Manager, who trained the team, monitored performance, and supported daily operations through regular follow-ups and troubleshooting.
Site one, Liberia:
Equipment: Φ3.2×13m close-circuit ball mill (50 TPH), 1500T silos, 8-spout packer (100 TPH), truck loading (120 TPH)
Start: 2022
Model: Joint O&M with local staff and UAE-based partner
Site two (CLC), Liberia:
Equipment: Loesche LM24.2 mill (40 TPH), dual-grade cement output (42.5 & 32.5), twin silos (600T each), 2 packers, 8x 500KVA gensets
Start: 2023
Model: Joint O&M with CLC management and local consultancy recruitment
Results
Across both plants, Plant Supervision has delivered stable, efficient operations while steadily scaling down the number of expat supervisors—demonstrating the strength of a transitional O&M approach:
- Successful performance guarantees achieved within two months of commissioning
- Local teams trained and upskilled to take on increasing operational responsibility
- Gradual transition toward client self-sufficiency with continued remote and on-site support
- Flexible, low-cost service structure aligned with local compliance requirements
- Increased client confidence through structured reporting and KPI tracking
This model enabled the clients to employ and develop local personnel while relying on Plant Supervision for critical expertise during the most demanding phases of operation.
Our light O&M model provides meaningful technical support where full outsourcing is not yet feasible, positioning Plant Supervision as a trusted and flexible partner in Africa and Asia’s evolving cement sector.
