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EMAL Dedicated To Excellence Aluminium Middle East Dubai, U.A.E Tuesday, April 23 rd, 2013.

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Presentation on theme: "EMAL Dedicated To Excellence Aluminium Middle East Dubai, U.A.E Tuesday, April 23 rd, 2013."— Presentation transcript:

1 EMAL Dedicated To Excellence Aluminium Middle East Dubai, U.A.E Tuesday, April 23 rd, 2013

2 Established in 2007 under the leadership and patronage of H.H. Sheikh Khalifa Bin Zayed Al Nahyan, President of the UAE. EMAL Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 2

3 On the completion Phase ll, EMAL will be the largest Greenfield, Single-Site Aluminium Smelter in the world Project aligned to 2030 Abu Dhabi strategic vision Flagship of the UAEs diversification and industrialisation strategy Investment Phase l $5.7B Phase ll $3.8B JV between MUBADALA and DUBAL To be built in 2 phase with a total capacity of 1.4M t/PA Developed in Khalifa Industrial Zone Abu Dhabi (KIZAD) - Aluminium Cluster. Allocated area of 6 sqkm. EMAL 3 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

4 EMAL Production Capacity Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 4

5 Thousands Regional Production Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 5

6 EMAL Phase I Construction 565,000 m 3 CONCRETE75,000 t. STEEL 500,000 m 2 CLADDING Over 2,000 EMPLOYEES 3,000 km of E. CABLES OVER 40 countries 44,000 t. Aluminium 24/7 hrs. WORK Over 60 Contractors 6 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

7 EMAL Dedicated to Excellence 7 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence FOUNDING Business Systems CONTINUOUS IMPROVEMENT Business Systems

8 EMAL OPERATIONS FOUNDATION BUSINESS SYSTEMS 8 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

9 Power Plant S hipment 4 Coke Pitch Alumina R eduction C asthouse anodes/cell, Replaced every 32 hrs Aluminium Production Process 9 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

10 Foundation Business Systems EMAL launched a number of Foundation Systems to transform from a massive construction site to an Operational marvel. These included: 1.ORP framework – October CEO Dashboard – May Defining and Living the Core Values – July The A3 initiatives – May 2009 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 10

11 1.0 Operations Readiness Plan (ORP) Framework 11 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence ORP Human Resources Production Management Conversion Cost Supply and Logistics Training Recruitment Induct Raw Materials Consumables Spares Identify Catalogue Store Categories Monitoring Budget Policies KPI SOP Order

12 2.0 CEO Dashboard Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 12

13 4.0 Living the Core Values Everything can be improved Investing in today for tomorrow Protection of the environment Safety first, last and always We respect individuals and their differences and value local culture Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 13

14 5.0 The A3 Initiative A3 is a strategically driven document where following points are articulated –Business Case –Present condition –Future Desired Condition (FDC) –Action Plan to move towards FDC. Strategic A3 articulates the Future Desired Condition (FDC) in terms of Balanced Score Card dimensions. All Divisions develop their Strategic A3 in line with the vision of the CEO. Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 14

15 5.0 The A3 Initiative BUSINESS CASE FUTURE DESIRED CONDITION (FDC) PRESENT CONDITION ACTION PLAN TO GET THERE Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 15

16 Power Plant 16 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 1 - Power Plant – Electricity Production Since commissioning the Power Plant has generated, 30 Billion kWh (30 Million MWh) which is equivalent to 8 days US domestic electricity consumption or 7 months state of New York domestic consumption. Likewise 30 Billion kWh is more than a Typical Development Countrys annual electricity consumption and more than 40% of UAE annual electricity consumption. As of 2012, 30 billion kWh is more than 80% of Dubai annual electricity demand and almost 50% of Abu Dhabi annual electricity demand. 2 - Power Plant – Water Production Achieved 800,000,000 IG of water production on March 4 th, 2013 and is targeted to reach 1 billion gallons by mid-September-2013, which will be significant milestone. The above has been achieved without single LTI in the Power Plant since the beginning of Operations in 2009.

17 Reduction Team EMAL achieved Steady State Operation, reached 1 million ton milestone on November 17, Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

18 Reduction In February 2013, EMAL achieved 2 million metric tonnes of hot metal. This is a unique achievement by EMAL, compared against,any other smelters. More importantly, not a single cell failed since the first cell started on December 2 nd, Major upgrade project completed in September 2012, when EMAL Potlines reached 380 kA operation. This took production capacity to 800,000 of hot metal per annum. The upgrade was achieved without compromising EMALs core values particularly safety of our workforce (both direct and contractors). 18 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

19 Cast House 19 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

20 Cast House Casthouse - Two Million Tonnes of Finished Production On February 24 th 2013, EMAL casted two millionth tonne of finished production. The aluminum product that realised this remarkable event was long length billet delivered to a local, UAE, customer who produces aluminum extrusions. To put it into perspective, two millions tonnes of aluminium could be used to make: –11,600 Airbus A380 aircraft –12.5 million automobiles –125 billion CDs –157 billion beverage cans EMAL has in a comparatively short time frame become a respected supplier of quality aluminum products to over 150 customers around the globe. EMAL is rapidly becoming a benchmark for the industry. This is a reflection of the commitment and dedication of the workforce and the quality of the leadership 20 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

21 Carbon, Lab and Port (CLP) One Millionth Anode The Millionth Anode casting was achieved on February 22 nd, A continuous effort by the whole CLP team is the major contributor for this achievement. Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 21

22 EMAL OPERATIONS CONTINUOUS IMPROVEMENT BUSINESS SYSTEMS 22 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence

23 Continuous Improvement towards Operational Excellence 23 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence EMAL continues to move towards Operational Excellence using Lean Manufacturing Principles. Programs already running successfully include: 1.Suggestion Scheme (11310 suggestions presented, 42% implemented, 85% participation rate) 2.Kaizen Event initiatives (15 Kaizen Events successfully organized in all areas) 3.Problem solving A3 (247 A3 Problem Solving effectively Opened, 135 closed) 4.WOT 2.0 – Time motion studies (32 SOPs reviewed and improved with Standard Times and waste elimination) 5.5S workplace organization and work design across EMAL (500 walkarounds conducted, 24 winners of the monthly 5S competition) 6.Lean Manufacturing techniques and tools– May TPM – September Asset Management (to be launched – 2014)

24 EMAL is awarded Gold Occupational Health & Safety Award Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 24

25 RoSPA Achievement Awards 25 Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence RoSPA is The Royal Society for prevention of Accidents; Patron Her Majesty the Queen-UK Achievement awards are International and non-competitive based on the organisation's individual occupational health and safety performance assessed against the judging criteria.

26 EMAL, through TPM principles and techniques, is principally focused on progression from Breakdown towards Proactive Maintenance. Operational Excellence - Last addition Time Emal Greenfield Startup and ramp upFocus on Operational and Maintenance Excellence Focus on System Optimisation Continuous Improvement System Design and Planning Asset Management (2014) Start up and Ramp up Steady State Cost Control Construction and Commissioning TPM Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E EMAL Dedicated To Excellence 26


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