ABB Automation & Power World - May 18-20, 2010    CRS-103-1    Maintenance Partnerships:    M i t        P t    hi    Wise...
•About Wise•What We Produce Wh t W P d•Our Mills / Processes•Why We Chose ABB? Wh W Ch•Our Alliance, Wise / ABB•Continuous...
•   Based in Muscle Shoals, Alabama•   100 acres under one roof•   Wise Alloys is the third-leading    producer in the U.S...
•   Founded in 1941, the    facility featured a 36,000-    f ilit f t d 36 000    ton hot mill to produce    sheet aluminu...
• Wise Alloys, Muscle Shoals, Alabama• One of the largest single employers inthe Muscle Shoals area withapproximately 760 ...
Aluminum can stock                   gfor food and beveragecontainersRigid ContainerTrailer roof
Commercial           Food Product            3%   2%            Beverage              95%
Reclaims UBC, class scrap and other common alloyscrap into molten aluminumEquipment:     1500 HP Shredder               Tw...
Electromagnetic (EMC) Casting Technology to produce    non-scalp ingot.        Non-Scalp Rate    90% N    S l R tEquipment...
Ingot Scalping to remove surfaceimpurities and to produce smooth finish.         10% EMC ingot scalped before         hot ...
Ability to hot roll multiple alloys including can body &end stock, food container, building p                             ...
The primary production mill for finishrolling D&I.A 4 hi h 3-stand mill, i  4-high, 3      d ill installed i              ...
The primary production mill for finish rollingD&I can stock, as well as most tab stock and someend stock.    stockA 4-high...
Considered the fastest coil coating line inthe world – 1200 FPMThe following takes place on the HSCCL:      • Leveled     ...
80.00%                                     70                        70.00%                                     60        ...
PartnershipJanuary 2007WiseWi made decision to i     d d i i t improve our maintenance                             i tJune...
•ABB is a technical / engineering based company•Providing long term technical solutions•Technical expertise and discipline...
Successful Transition•   Interview and Hire Effectively•   Organizational Structure•   Warehouse Management•   Provided Po...
Improvements NeededI         t N d d•   Delays (Reliability)•   Effective Supervision•   Training•   Overall Communication...
• ABB completed 2009 with no recordable injuries  ending year with a TIR of 0.• ABB h worked 800 workdays without a l     ...
•                                         training.    ABB conducted planner certification training•   ABB has redefined w...
•                          y                     p    ABB conducts monthly 5S Kaizen events in a specific    area of the m...
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
Wise Alloyts Case Study APW
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Wise Alloyts Case Study APW

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Full Service Case Study for a large Aluminum Rolling Mill

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Wise Alloyts Case Study APW

  1. 1. ABB Automation & Power World - May 18-20, 2010 CRS-103-1 Maintenance Partnerships: M i t P t hi Wise Alloys Case Study© ABB Inc.June 5, 2010 | Slide 1
  2. 2. •About Wise•What We Produce Wh t W P d•Our Mills / Processes•Why We Chose ABB? Wh W Ch•Our Alliance, Wise / ABB•Continuous I C ti Improvementst
  3. 3. • Based in Muscle Shoals, Alabama• 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 company that relies heavily on recycled aluminum in the production of its can stock.• Plant founded in 1941 by Reynolds Metals• Purchased by Wise in April, 1999
  4. 4. • Founded in 1941, the facility featured a 36,000- f ilit f t d 36 000 ton hot mill to produce sheet aluminum.• Aluminum produced at the plant was used for military aircraft during World War II.• According to a 1946 article in Fortune magazine, W ld i F t i World War II was won with air power and aluminum.
  5. 5. • Wise Alloys, Muscle Shoals, Alabama• One of the largest single employers inthe Muscle Shoals area withapproximately 760 hourly and 210 pp y ysalaried employees.• There are four primary facilities p ycomprising the Muscle Shoals operations:the Alloys Plant, Alabama Reclamation,Sheffield Plant, and LTMC – ListerhillTotal Maintenance Center• Production Employees - USW p y
  6. 6. Aluminum can stock gfor food and beveragecontainersRigid ContainerTrailer roof
  7. 7. Commercial Food Product 3% 2% Beverage 95%
  8. 8. Reclaims UBC, class scrap and other common alloyscrap into molten aluminumEquipment: 1500 HP Shredder Two Delacquering Kilns Six 200K lb. Reverberatory Furnaces 20,000 lb. 20 000 lb Molten Transport Crucibles Two 150K Tilting Holding Furnaces One 4-Ingot DC Casting UnitScrap to Prime Ratio: i i 85% / 15% % %Transfers molten aluminum to Alloys Castingoperation or internal DC Casting operationCapacity: 660 mm lbs per year - molten 150 mm lbs per year – cast% to Capacity: 85% Molten Capacity l 80% DC Casting Capacity
  9. 9. Electromagnetic (EMC) Casting Technology to produce non-scalp ingot. Non-Scalp Rate 90% N S l R tEquipment:Melting Furnaces Five 220K Lb. Round TopHolding Furnaces Six 200K Lb. Tilting Five 6-Ingot Casting Pits State of the Art Metal Filtration SystemsIngot Sizes: Thickness – 26” Widths – multiple sizes from 55” to 69” Length – up to 240” Weights vary up to 40,000 40 000 lbs/ingotScrap / Prime Ratio: 75% / 25% (includes Prime Based Ingot Casting)Capacity: 1,200 mm lbs per year ingot% to Capacity: 83% Casting Capacity
  10. 10. Ingot Scalping to remove surfaceimpurities and to produce smooth finish. 10% EMC ingot scalped before hot rolling. 90% DC Casting ingot scalped % l d before hot rolling. Scalping Capacity of 100 ingot per day.Ingot Homogenizing Two - 40 ingot/load Pusher Furnaces Six - 10 ingot/load Soaking Pits Total Combined Capacity of 200 ingot per day (5.5 million lbs.)
  11. 11. Ability to hot roll multiple alloys including can body &end stock, food container, building p g products and multiple pcommon 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 SystemCoil Sizes: Gauges – multiple gauges from .100” up to .390” Widths – multiple sizes up to 116” wide Diameters – up to 90” Weights vary up to 30,000 lbsCapacity: 1,100 mm lbs per y p y p year% to Capacity: 83% Capacity
  12. 12. The primary production mill for finishrolling D&I.A 4 hi h 3-stand mill, i 4-high, 3 d ill installed i ll d in1941 as original hot mill, converted to acold 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”
  13. 13. The primary production mill for finish rollingD&I can stock, as well as most tab stock and someend stock. stockA 4-high, 5-stand mill, installed in 1968 withmajor upgrades in 1983, 1996 and again in 2006.Capable of fi i h rolling end stock in one passC bl f finish lli d t ki(improved recovery and quality).Every modern mill control except for continuousoperation capability. World class gauge andshape control control.Specifications: • Production rate: up to 4,400 FPM • Coil weight: up to 38,000 LBS. 38 000 LBS • Coil width (cold): 30.0” to 64.75” • Output gauge: 0.006” to 0.042”
  14. 14. Considered the fastest coil coating line inthe world – 1200 FPMThe following takes place on the HSCCL: • Leveled • Cleaned • Treated • Coated • Thermally Cured • Waxed • Trimmed to widthContinuous operation (non-stop exceptfor changeovers) 280 plus rolls contact the metal 3 accumulator towers 2 payoffs, 2 entry end reels
  15. 15. 80.00% 70 70.00% 60 60.00% 50 009% Increase Above 20 50.00% 40 40.00% 30 30.00% 20 20.00% 10.00% 10 0.00% 0 00% - 2009 Jan-10 Feb-10 Mar-10
  16. 16. PartnershipJanuary 2007WiseWi made decision to i d d i i t improve our maintenance i tJune – July 2007Presentations made by five maintenance providersAugust 2007 gDecision was made to go with ABBNovember 2007ABB assumes all maintenance at Wise AlloysABB hires all new work force – hourly – (No craftsmen from Wise)Wise salaried supervisors – Maintenance – Join ABB
  17. 17. •ABB is a technical / engineering based company•Providing long term technical solutions•Technical expertise and discipline from many worldwide locations•Focused importance of reliability efforts / engineering as well as effectivepplanning and scheduling 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.•Proven success record from other companies P df h i•Most overall effective maintenance long term
  18. 18. Successful Transition• Interview and Hire Effectively• Organizational Structure• Warehouse Management• Provided Positive Labor Situation• Productivity / Wrench Time / Utilization Rate
  19. 19. Improvements NeededI t N d d• Delays (Reliability)• Effective Supervision• Training• Overall Communication with Process Owners has improved• Engineering Support
  20. 20. • ABB completed 2009 with no recordable injuries ending year with a TIR of 0.• ABB h worked 800 workdays without a l has k d 800+ kd ih lost time i injury.• ABB team members have completed over 4700 Safety p y Observation Tours in last 16 months.• ABB compiled a site specific comprehensive Full 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 during 2009. d i 2009• ABB instituted a contractor safety process to ensure the safety of all our contractors working on site. y g
  21. 21. • training. ABB 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 orders. This allows us to code and track reliability work orders.• ABB plans all outages using Microsoft project project.• ABB leads outage critiques after outages to capture lessons learned.• ABB centralized planner’s offices to optimize effectiveness, t li d l ’ ffi t ti i ff ti uniformity and efficiency of planning team.• ABB established natural team meetings with both ABB and Wise t Wi team members for each area to enhance effectiveness of b f h t h ff ti f planning schedules.
  22. 22. • y p ABB conducts monthly 5S Kaizen events in a specific area of the mill.• ABB has returned 3500 parts to storeroom during these events at a value of over $900K t t l f $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 areas i a positive way. in iti• ABB’s 5S efforts have improved the safety conditions for their work and storage areas.

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