2. •About Wise
Wh t W P d•What We Produce
•Our Mills / Processes
Wh W Ch ABB?•Why We Chose ABB?
•Our Alliance, Wise / ABB
C ti I t•Continuous Improvements
3.
4. • Based in Muscle Shoals, Alabama
100 acres under one roof• 100 acres under one roof
• Wise Alloys is the third-leading
producer in the U.S. and world of
aluminum can stock for the beverage
and food industries.
It is an environmentally friendly• It is an environmentally friendly
company that relies heavily on
recycled aluminum in the production
of its can stock.
• Plant founded in 1941 by Reynolds
MetalsMetals
• Purchased by Wise in April, 1999
5. • Founded in 1941, the
f ilit f t d 36 000facility featured a 36,000-
ton hot mill to produce
sheet aluminum.
• Aluminum produced at the
plant was used for military
aircraft during World Waraircraft during World War
II.
• According to a 1946 article
i F t i W ldin Fortune magazine, World
War II was won with air
power and aluminum.
6. • Wise Alloys, Muscle Shoals, Alabama
• One of the largest single employers in
the Muscle Shoals area with
approximately 760 hourly and 210pp y y
salaried employees.
• There are four primary facilitiesp y
comprising the Muscle Shoals operations:
the Alloys Plant, Alabama Reclamation,
Sheffield Plant, and LTMC – Listerhill
Total Maintenance Center
• Production Employees - USWp y
7. Aluminum can stock
for food and beverageg
containers
Rigid ContainerRigid Container
Trailer roof
9. Reclaims UBC, class scrap and other common alloy
scrap into molten aluminum
Equipment: 1500 HP Shredder
Two Delacquering Kilns
Six 200K lb. Reverberatory Furnaces
20 000 lb Molten Transport Crucibles20,000 lb. Molten Transport Crucibles
Two 150K Tilting Holding Furnaces
One 4-Ingot DC Casting Unit
i i % / %Scrap to Prime Ratio: 85% / 15%
Transfers molten aluminum to Alloys Casting
operation or internal DC Casting operation
Capacity: 660 mm lbs per year - molten
150 mm lbs per year – cast
l% to Capacity: 85% Molten Capacity
80% DC Casting Capacity
10. Electromagnetic (EMC) Casting Technology to produce
non-scalp ingot.
90% N S l R t90% Non-Scalp Rate
Equipment:
Melting Furnaces Five 220K Lb. Round Top
Holding Furnaces Six 200K Lb. Tilting
Five 6-Ingot Casting Pits
State of the Art Metal
Filtration Systems
Ingot Sizes: Thickness – 26”
Widths – multiple sizes from 55”
to 69”
Length – up to 240”
Weights vary up to 40 000Weights vary up to 40,000
lbs/ingot
Scrap / Prime Ratio: 75% / 25% (includes
Prime Based Ingot Casting)
Capacity: 1,200 mm lbs per year ingot
% to Capacity: 83% Casting Capacity
11.
12. Ingot Scalping to remove surface
impurities and to produce smooth finish.
10% EMC ingot scalped before
hot rolling.
% l d90% DC Casting ingot scalped
before hot rolling.
Scalping Capacity of 100 ingot per
day.
Ingot Homogenizing
Two - 40 ingot/load Pusher
Furnaces
Six 10 ingot/load Soaking PitsSix - 10 ingot/load Soaking Pits
Total Combined Capacity of 200
ingot per day (5.5 million lbs.)
13. Ability to hot roll multiple alloys including can body &
end stock, food container, building products and multipleg p p
common alloy products.
Equipment: 170” Reversing Breakdown Mill
130” Intermediate Breakdown Mill
120” 4-Stands Finishing Mill
Automatic Gauge Control
State of the Art Automatic Sheet
Inspection System
Coil Sizes: Gauges – multiple gauges from
.100” up to .390”
Widths – multiple sizes up to 116”
widewide
Diameters – up to 90”
Weights vary up to 30,000 lbs
Capacity: 1,100 mm lbs per yearp y p y
% to Capacity: 83% Capacity
14. The primary production mill for finish
rolling D&I.
A 4 hi h 3 d ill i ll d iA 4-high, 3-stand mill, installed in
1941 as original hot mill, converted to a
cold mill~ 1960.
Specifications:
• Production rate: up to 3,100
FPM
• Coil weight: up to 37,000 LBS.g
• Coil width (cold): 32.0” to
73.5”
• Output gauge: 0.007” to
0.070”
15.
16. The primary production mill for finish rolling
D&I can stock, as well as most tab stock and some
end stockend stock.
A 4-high, 5-stand mill, installed in 1968 with
major upgrades in 1983, 1996 and again in 2006.
C bl f fi i h lli d t k iCapable of finish rolling end stock in one pass
(improved recovery and quality).
Every modern mill control except for continuous
operation capability. World class gauge and
shape controlshape control.
Specifications:
• Production rate: up to 4,400 FPM
Coil weight: up to 38 000 LBS• Coil weight: up to 38,000 LBS.
• Coil width (cold): 30.0” to 64.75”
• Output gauge: 0.006” to 0.042”
17. Considered the fastest coil coating line in
the world – 1200 FPM
The following takes place on the HSCCL:
• Leveled
• Cleaned
• Treated
• Coated
• Thermally Cured
• Waxed• Waxed
• Trimmed to width
Continuous operation (non-stop except
for changeovers)for changeovers)
280 plus rolls contact the metal
3 accumulator towers
2 payoffs, 2 entry end reels
21. PartnershipPartnership
January 2007
Wi d d i i t i i tWise made decision to improve our maintenance
June – July 2007
Presentations made by five maintenance providers
August 2007g
Decision was made to go with ABB
November 2007November 2007
ABB assumes all maintenance at Wise Alloys
ABB hires all new work force – hourly – (No craftsmen from Wise)
Wise salaried supervisors – Maintenance – Join ABB
22. •ABB is a technical / engineering based company
•Providing long term technical solutions•Providing long term technical solutions
•Technical expertise and discipline from many worldwide locations
•Focused importance of reliability efforts / engineering as well as effective
planning and schedulingp g g
•Successful conversion of “in-house” maintenance to third party / ABB
•Providing lower maintenance costs
•Increase productivity / decrease downtime
•Favorable long term labor situation
•Chance to retain a large majority of Wise maintenance employees
•Provide most effective warehouse management, PdM, etc.
P d f h i•Proven success record from other companies
•Most overall effective maintenance long term
23. Successful Transition
• Interview and Hire Effectively
• Organizational Structure
• Warehouse Management
• Provided Positive Labor Situation
• Productivity / Wrench Time / Utilization Rate
24. I t N d dImprovements Needed
• Delays (Reliability)
• Effective Supervision
• Training
• Overall Communication with Process Owners
has improved
• Engineering Support
25. • ABB completed 2009 with no recordable injuries
ending year with a TIR of 0.
ABB h k d 800 kd i h l i• ABB has worked 800+ workdays without a lost time
injury.
• ABB team members have completed over 4700 Safetyp y
Observation Tours in last 16 months.
• ABB compiled a site specific comprehensive Full
Service Site Safety Manual for Wise Alloys Site.Service Site Safety Manual for Wise Alloys Site.
• ABB improved OHS 18001 audit score 48% in 2009.
• ABB implemented first phase of NFPA 70E plan
d i 2009during 2009.
• ABB instituted a contractor safety process to ensure
the safety of all our contractors working on site.y g
26. • ABB conducted planner certification trainingABB conducted planner certification training.
• ABB has redefined work order priority codes in the CMMS to
improve work order prioritization and backlog management.
• ABB has established a work code in CMMS for reliability work• ABB has established a work code in CMMS for reliability work
orders. This allows us to code and track reliability work
orders.
• ABB plans all outages using Microsoft project• ABB plans all outages using Microsoft project.
• ABB leads outage critiques after outages to capture lessons
learned.
• ABB t li d l ’ ffi t ti i ff ti• ABB centralized planner’s offices to optimize effectiveness,
uniformity and efficiency of planning team.
• ABB established natural team meetings with both ABB and
Wi t b f h t h ff ti fWise team members for each area to enhance effectiveness of
planning schedules.
27. • ABB conducts monthly 5S Kaizen events in a specificy p
area of the mill.
• ABB has returned 3500 parts to storeroom during these
t t l f $900Kevents at a value of over $900K.
• ABB will involve 100% of their team members in these
events during 2010.g
• ABB’s 5S events have greatly impacted the
effectiveness and appearance of their work and storage
i itiareas in a positive way.
• ABB’s 5S efforts have improved the safety conditions
for their work and storage areasfor their work and storage areas.
