Post on 29-Mar-2015
EMAL
Dedicated To Excellence
Aluminium Middle East
Dubai, U.A.E
Tuesday, April 23rd , 2013
2EMAL Dedicated To Excellence
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
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 UAE’s 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
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4EMAL Dedicated To Excellence
EMAL Production Capacity
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
5EMAL Dedicated To Excellence
Thousands
Regional Production
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
EMAL Phase I Construction
565,000 m3 CONCRETE2 Emirates Palace
75,000 t. STEEL6 Eiffel Towers
Cover 66 Soccer Fields500,000 m2 CLADDING
Over 2,000 EMPLOYEES
Recruited for EMAL operations
More than 50 nationalities
All backgrounds (Engineering, business, management)
Highly experienced (Dubal, Alcoa, Rio Tinto,…)
Smelter to Istanbul3,000 km of E. CABLES
Supplying equipments and machineries
OVER 40 countries
44,000 t. Aluminium160 Airbus A380
~ 90 Millions Man-Hours
24/7 hrs. WORK
Local and internationalOver 60 Contractors
6Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
EMAL Dedicated To Excellence
7EMAL Dedicated To Excellence
EMAL Dedicated to Excellence
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
FOUNDING Business Systems
CONTINUOUS IMPROVEMENT
Business Systems
EMAL OPERATIONS
FOUNDATION BUSINESS SYSTEMS
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EMAL Dedicated To Excellence
9EMAL Dedicated To Excellence
Power Plant
Shipment4
Coke
Pitch
Alumina
Reduction Casthouse1 2 3
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36 anodes/cell, Replaced every 32 hrs
Aluminium Production Process
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
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 2007
2. CEO Dashboard – May 2008
3. Defining and Living the Core Values – July 2008
4. The A3 initiatives – May 2009
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
EMAL Dedicated To Excellence
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1.0 Operations Readiness Plan (ORP) Framework
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
EMAL Dedicated To Excellence
ORPHuman
Resources
Production Management
Conversion Cost
Supply and Logistics
Training
Recruitment
Induct
Raw Materials
ConsumablesSpares
IdentifyCatalogue
Store
Categories
Monitoring
Budget
PoliciesKPI
SOP
Order
2.0 CEO Dashboard
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
EMAL Dedicated To Excellence
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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
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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
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5.0 The A3 Initiative
BUSINESS CASEFUTURE 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
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Power Plant
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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 Country’s 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 4th, 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.
Reduction Team
• EMAL achieved Steady State Operation, reached 1 million ton milestone on
November 17, 2011.
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EMAL Dedicated To Excellence
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 2nd, 2009.
• 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 EMAL’s core values particularly safety of our workforce (both direct and contractors).
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EMAL Dedicated To Excellence
Cast House
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EMAL Dedicated To Excellence
Cast House
Casthouse - Two Million Tonnes of Finished Production• On February 24th 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
20Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
EMAL Dedicated To Excellence
Carbon, Lab and Port (CLP)
One Millionth Anode• The Millionth Anode casting was achieved on February 22nd, 2013.
• 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
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EMAL OPERATIONS
CONTINUOUS IMPROVEMENTBUSINESS SYSTEMS
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EMAL Dedicated To Excellence
Continuous Improvement towards Operational Excellence
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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 SOP’s 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 2010
7. TPM – September 2012
8. Asset Management (to be launched – 2014)
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EMAL is awarded Gold Occupational Health & Safety Award
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
25EMAL Dedicated To Excellence
RoSPA Achievement Awards
Tuesday, April 23rd, 2013 Aluminium Middle East, Dubai, U.A.E
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.
26EMAL Dedicated To Excellence
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 up Focus on Operational and
Maintenance Excellence
Focus on System Optimisation
Con
tin
uou
s
Imp
rovem
en
t
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