Cement Energy & Environment

24 Beyond Automation: Aligning People, Processes and Leadership for Sustainable Cement Manufacturing Dr S B Hegde Former President – Manufacturing (Cement), Professor, Department of Civil Engineering, Jain College of Engineering and Technology, Hubballi, India and Visiting Professor, Pennsylvania State University, USA ABSTRACT Over the last three decades, the cement industry has undergone one of the most significant transformations in its history. From advanced process control and robotics to artificial intelligence (AI), digital twins, and low- carbon material innovations, technology has reshaped how cement is manufactured. Yet, despite these impressive strides, many plants continue to operate below their potential. . The core challenge does not lie in technology itself but in the degree to which people, organizational processes and leadership cultures are aligned to use it effectively. This article examines the global and Indian cement industries through this lens, showing how a mismatch between technological investment and human capability often constrains performance. It integrates benchmark data, case experiencesand actionable strategies to demonstrate that the future of cement manufacturing will depend as much on leadership vision and culture as on automation and artificial intelligence. 1. INTRODUCTION Cement remains the backbone of modern civilization. With global production exceeding 4 billion tons annually, it is indispensable to infrastructure, housing, and industrial growth. India, the world’s second-largest producer, contributes significantly to this global footprint. In recent decades, the industry has seen an accelerating wave of technological adoption. The late 1990s marked the rise of programmable logic control (PLC) and early process automation. The