Meet the team exporting specialties to the world Delivering value for customers
Alicante resumes casting
Aludium Magazine June 2018 | Issue 07
CODE OF CONDUCT
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Index
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Welcome
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COO news
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Meet Mario Allet
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Code of Conduct
10 Specialties Team in the spotlight 16 Re-opening the cast house in Alicante 18 Product innovation 19
June 2018 | Issue 07
Colophon Editorial staff: Elsy Aelvoet, Maite Etxeita Gorritxategi, Bob Van Cauwenberghe, Dan Smith Contributors: Arnaud de Weert, Manuel Ruano, Christiane Huber, Mario Allet, Bertrand Corgie, Brigitte Darmigny, Agathe Tranchand Pagazaurtundua.
Your opinion counts! Please email your suggestions or comments to: marketing@aludium.com
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Local News
Supporting sustainability
Welcome to the latest edition of Aludium Today. In this issue we take a close look at Aludium’s Specialties team. This dedicated group of people, led by Christiane Huber, is rapidly growing the market for Aludium’s bright and specialty products. And it’s not just in Europe – Asia and the Americas are increasingly important
export markets for Aludium’s premium aluminium offer. This issue also looks at Aludium’s efforts to increase our sustainability. Beginning in 2016 with the installation of a new rotary furnace in Amorebieta, we have made a conscious decision to increase our ability to melt post-consumer scrap. In addition to the rotary furnace, we are also investing €20 million to install a new multi-chamber furnace in Amorebieta and €7 million to reopen the Alicante cast house. These investments will further increase Aludium’s ability to close the recycling loop with customers and cut our carbon footprint significantly. Later this year we will publish Aludium’s first Sustainability Report as part of our efforts to be transparent about our social, economic, and environmental sustainability. The Report is part of our commitment to the Aluminium Sustainability Initiative (ASI), which aims to address the sustainability of the aluminium value chain. During the first half of 2018, Aludium has renewed its commitment to our local communities with events such as our annual Charity Race. As well as sporting events and entertainment for employees and their families, these events have a serious side – collecting provisions for local food banks. Thanks to the events held in Alicante, Amorebieta, and Castelsarrasin, over 5,000 kilograms has been donated by Aludium, our staff, and partners. As this issue goes to press we are busily preparing Aludium’s presence for the Aluminium 2018 trade fair to be held in Düsseldorf (Germany) this October (booth 13G40). The fair is one of the most important for our business and is a great opportunity to meet with existing and potential customers. It’s an ideal chance for customers to meet the Aludium management team, R&D experts from Cindal, and the sales team. We’ll also show a selection of Aludium’s latest products. For those of you who are looking forward to summer holidays, I wish you a restful break with your family and friends.
Arnaud de Weert, Aludium CEO Today
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Interview with
Manuel Ruano, COO
2017 was another strong year for Aludium as the company consolidates its position as one of Europe’s leading aluminium suppliers. In this interview with Manuel Ruano, COO of Aludium, we take a look back at last year’s performance and the challenges facing the business in 2018 and beyond. Aludium Today (AT): At the end of 2017, Aludium completed its third full year of trading as an independent company. How is the business performing? Manuel Ruano (MR): Very positively I’m pleased to say! Compared to 2014, Aludium has achieved 28 percent growth over the three years to the end of 2017. And we’re expecting to grow by another four percent this year compared to 2017. AT: What is driving the growth? MR: The increase is mainly being driven by demand for our distribution, building and construction, and foil stock products. But we have also seen a big growth in the specialties sector with much higher deliveries to automotive trim manufacturers. Aludium is also seen as a key supplier by customers now. We work closely with them to see how we can improve our products and our reputation as a supplier. One thing that is highly valued by all customers – large and small – is that we have kept them informed of movements in the LME price for aluminium. This has been particularly volatile over the past few months.
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AT: Which plants have contributed the most to the increase? MR: All three plants have made positive contributions to our growth in terms of both production volume and sales. For example, Amorebieta has increased its output significantly compared to 2014, but the value of the products the mill produces is higher still. This reflects the success of our strategy to reduce operating costs and concentrate on our core markets to achieve long-term growth. AT: What about investments? MR: We have made huge investments in Aludium’s facilities since the company was formed. By the end of 2018 we will have spent over €50 million to increase our capacity, remove bottlenecks in production, and increase our ability to recycle scrap in our own facilities. What do we get for that money? In Amorebieta we’ve installed the rotary furnace and work on the new multichamber furnace has begun. In May we also announced that we would reopen the cast house in Alicante. This €7 million
investment will allow us to produce slabs and coils. While the slabs will go to Amorebieta for further processing, the continuous cast coils will be used in Alicante. We’ve also been revamping the existing equipment at all three mills. That’s included upgrading our levelling lines, slitters, the Amorebieta hot mill, and the cut-to-length (CTL) line in Castelsarrasin among others. AT: The globalisation model pursued by many countries over the past two decades is under threat – particularly from the US. How is this likely to affect Aludium and are there opportunities for the business? MR: The US government has taken several steps to protect its internal markets. While some of these measures target specific countries such as China, others have more widespread impact. For example, the US government announced a 10 percent tariff on aluminium imports from any country. The outcome of these actions is likely to be a shortage of aluminium in the US market. For Aludium there will be opportunities despite the additional tariff. On the other hand, we are likely to see cheap aluminium from Asia enter the European market. For Aludium this is not a huge concern as we focus on providing premium service. Asian countries are not able to match our level of service. This is one of the key reasons why our exports to Asia are growing quickly.
COO News
Aludium Incident Rates
Investments 2015-2018 (M€)
LWDR
TRR
2.500
25 20+6
2.006 2.000
20
23
1.497 1.500
15
1.102
11
1.187
1.115
1.006
1.058
1.000
8
10
1.225
5
0.333
0.315
0.500
5
0.175 0.000
0.159 0.000
0.000
2013
2014
0.000
0.000
0 2015
2016
2017
2018
AT: You mentioned volatility in the price of aluminium. What is behind this? MR: On 6 April this year the US government announced sanctions against the owner of Rusal, Oleg Deripaksa. They are set to take effect from 23 October and have caused huge volatility in the market as Rusal is the second largest supplier of primary aluminium globally. Oleg Deripaksa has said that he will reduce his shares in Rusal to below 50 percent. The US Treasury indicated that it may lift the threat of sanctions if that happens. We’re seeing positive signs from Rusal. And as an indication of this positivity, Aludium and Rusal have agreed to qualify the metal from Siberia as originally planned at the beginning of this year. AT: We are hearing a lot about Industry 4.0. Can you explain how Aludium is preparing for this next evolution in business? MR: Industry 4.0 is part of a global trend to gather information using sensors on equipment and in workspaces and to use that data to improve or automate our response to events. We’ve been piloting Aludium’s Industry 4.0 project in Alicante. Here we have already installed a control system to gather process and product data and sensors have been installed on almost every piece of equipment. The information is stored in a database and used to produce statistical studies in real-time. The system can generate an alert if a potential problem is identified – essentially if there is a deviation from what is ‘normal’ in our operating environment. This helps our process engineers to be more proactive and to
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take corrective actions before production is interrupted or product quality is affected. The next step is to automate the Gant output diagrams used on the shop floor This will help control production through daily management, a balanced scorecard, or by automatically calculating metrics. Our plan is to expand the number of quality and production indicators and implement a link between them by the end of this year. The implementation has gone very well in Alicante and we’ve started implementing the system in Amorebieta. Castelsarrasin will be next. AT: Since Aludium was formed, there has been a strong focus on safety. Is the investment in safety bearing fruit? MR: Absolutely. In 2017, Aludium had the best total recordable rate (TRR) of incidents since 2014. Our lost work day rate (LWDR) was zero. These are impressive results for a company of Aludium’s size. We are continuing to invest in safety and in October we will hold our third annual Safety Week to stress the importance we place on working safely. AT: This year Aludium has announced a few personnel changes. Can you tell us more about the people in these key positions? MR: Firstly, Mario Allet was appointed head of our Cindal R&D Centre effective from 1 February this year. As you know, Mario has been head of Programs and CAPEX since he joined the company in 2015. He holds on to this position as well as taking up his responsibilities as Head of Cindal. Mario’s extensive background in
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aluminium, together with his ability to drive and collaborate on different initiatives to grow the company make him the ideal person for both roles. In his new position Mario will focus on strengthening the current activities of Cindal, but there will not be a change in strategic direction. We have also appointed Markus Plakolm as Director of Growth Projects. He has 24 years of experience in plant management, lean manufacturing, and operations leadership. In this new role, Markus will manage the investment projects which are enabling Aludium to become more independent with respect to metal supply. As well as overseeing the installation of the multi-chamber furnace and the restart of the Alicante cast houses, Markus will supervise improvements to increase the capacity of Amorebieta’s hot mill. We’re also looking at several new appointments to the sales team. The goal here is to ensure we have people in place to cover for colleagues who are retiring in the near future. AT: Looking ahead to the second half of 2018 and beginning of 2019, what are the key challenges for the Aludium management team? MR: We need to bring our investments in melting capacity onstream as quickly as possible. We’re on track and have Markus Plakolm in place to supervise this important work so I’m confident we will succeed. Our second major focus is to continue improving our IT infrastructure to develop our customer portal and ready Aludium for Industry 4.0. We also need to develop people from within the business so we can continue on the strong growth path we have established. ■
Today
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Cindal
Meet
Mario Allet
On 1 February 2018, Mario Allet was appointed as R&D Director of Aludium’s Cindal R&D centre. In addition to his new responsibilities, Mario will remain as Aludium’s Programs and CAPEX Director, a position he has held since 2015. He will continue to report directly to Manuel Ruano, COO of Aludium. With Cindal as one of the world’s leading centres of excellence in aluminium research, Aludium Today spoke with Mario to find out more about his vision for the future.
Aludium Today (AT): Can you start by telling us a little bit about your background? Mario Allet (MA): I’ve worked in the aluminium industry since I graduated from the University of Science and Technology (ETH) in Zürich (Switzerland) with a PhD in physics. I started my career at Alusuisse where I gained practical experience in R&D, smelting, casting, extrusion, and rolling. Due to mergers and spin offs, I’ve also held operational and corporate roles over the years at Alcan and Novelis in Europe and in North America. I speak four languages fluently and now I am working on my Spanish. In my free time I enjoy skiing and mountain biking. AT: In 2015 you joined Aludium, what have been your major projects since then? MA: I’ve been developing projects and initiatives to grow Aludium’s business. One of the most important has been the development of our cutting-edge Recycling Unit. That’s included the
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Mario Allet has been appointed R&D Director of Aludium’s Cindal R&D Centre
installation of a new rotary furnace in the Amorebieta cast house, and our recent investment in the multi-chamber furnace. While these projects underline our commitment to reduce our carbon footprint, they are also the basis of a sustainable future for Aludium. Recently we also have decided to reopen the cast house in Alicante. This was approved by the Aludium Board in mid-May. The cast house in Alicante was closed 10 years ago and the assets have been idle since then. The plan is to revamp the four furnaces and to reopen the direct casting and continuous casting lines. The furnaces will be charge with run-around scrap from Alicante and we
will also convert third-party scrap into sheet ingots and hot bands. This is line with Aludium’s strategy to become more independent of third party metal suppliers. AT: What will your new responsibilities entail? MA: As R&D Director I’ll be working with the Cindal team to understand the needs of Aludium’s customers, and our main markets. We will explore how Aludium can fulfil those ambitions with our existing resources including people, processes, and equipment. But we will also be developing appropriate investment plans which will expand and enhance Aludium’s product portfolio to meet market demand.
Cindal
“Process and material development are often connected. We’re fortunate that Cindal’s laboratory includes a full set of pilot plants which can simulate our operational processes. ”
AT: What are the most recent trends in the industry and how can Cindal anticipate them? MA: One of the megatrends in the world today, and especially the aluminium industry, is sustainability. That doesn’t just mean improving our own recycling capabilities. It includes initiatives to help our customers lightweight their products for example. We’re also seeing a trend for consumers to demand products which are more individualised to their lifestyles. Here Aludium is well-positioned as we can create individualised surfaces for specific applications. Another major trend is the speed of change in the world. As a business we have to be able to react quickly to these changes. We must use Cindal’s knowledge and experience to understand what solutions our customers need, and to deliver those solutions on-time and accurately so that we deliver value for our customers and for Aludium. AT: What is your strategy for Cindal’s future? MA: Cindal must continuously improve so that is a relevant business partner for Aludium and our customers. That involves creating a portfolio of products which meet the needs of Aludium’s targeted markets. To help us with this we need committed partners. Our plan is to select appropriate customers that are willing and able to move forward with us. We are envisaging strategic partnerships with long-term commitments on both sides. AT: What are Cindal’s main strengths? MA: Cindal has experience in a wide range of markets and products and has a complete lab setup. We also have some of the most knowledgeable aluminium
experts in the world. These advantages enable Cindal to provide expert advice to customers, Aludium’s plants, and increasingly suppliers and other business partners. AT: You are an expert in process technology. Where can Cindal make the difference in this area? MA: Process and material development are often connected. We’re fortunate that Cindal’s laboratory includes a full set of pilot plants which can simulate our operational processes. We use these plants to optimise our process routes. An example is downgauging. Here we adapt the alloy so that its mechanical properties are maintained, even when it is used in a thinner gauge. AT: Cindal is also known as a centre of excellence for materials development. How can this knowledge be used to help customers? MA: It can be time consuming to develop a new alloy, its surface, and the related process. At Cindal we are already working on new alloys to solve problems for our customers. The launch of our new 55AT™ alloy is a good example. Our expertise has enabled us to develop and commercialise this alloy which has significant cost advantages. We are also developing tailor-made surfaces which can help customers create truly unique products. Texturandum® is a perfect example. It has applications in a wide range of sectors including automotive trim, building and construction, packaging, and consumer products. I am happy to see that one of our Asian customers has started to actively promote Texturandum®.
AT: What is the added value of Cindal’s technical support? MA: Even though our core business is aluminium rolling and casting, Cindal has competencies which exceed that scope. Our infrastructure allows us to provide advice and support on additional issues including metallography, metallurgy, surface corrosion, and lubrication among others. And our assets are optimised to serve the needs of customers and our own operations. Lastly, we have ISO 17025 certification which allows us to undertake third-party services in these areas. AT: Are you looking forward to Aluminium 2018 in October? MA: For a company such as Aludium, this biennial tradeshow is the place to be. This year we will again present Aludium’s latest innovations and product portfolio on our booth. It’s a great opportunity to meet new and existing customers and suppliers. And the show is also a source of inspiration and an opportunity to meet old friends. I’ve been participating in this show for more than 25 years and I still enjoy it immensely. AT: What is your personal target for 2018? MA: To be successful at Cindal and to integrate it even better into Aludium’s business. I also want to open up its competencies to the market. AT: And finally, what makes you happy in your job? MA: Completing a challenging task successfully or achieving a milestone, particularly if there have been issues or roadblocks. That really gives me a kick and spurs me to go further. ■
Today
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Code of Conduct
Winning without cutting corners During 2018, Aludium is taking its first steps to establish an ethics and compliance programme which will help the company mitigate risks and prevent illegal activities. As part of the programme, Aludium has prepared a Code of Conduct, internal procedures, and a risk map.
CODE OF CONDUCT
Published in early 2018, the Code of Conduct provides guidelines and basic instructions to ensure that all of Aludium’s people undertake our corporate activities in an ethical and lawful manner. The goal is to achieve the best results for the business without affecting our ethics, safety, or the quality of the products we produce.
Ethical values defined The Code defines four key values which are at the centre of Aludium’s ethics philosophy: People First: Safety is the foundation of Aludium’s strategy. But the company is also committed to creating a diverse and inclusive work culture where everyone is valued for the contribution they make. The Code includes specific policies on gender equality and protocols to eliminate any form of harassment or discrimination. Performance Excellence: Aludium aims to sustainably outperform our competition in a transparent way. Employees are also encouraged to take the initiative and react quickly to challenges and customer requests. Personal Integrity: The Code reminds Aludium’s people that morals have a place in business and that the company has zero-tolerance of bribery and corruption. The golden rule is to win without cutting corners. Passion: Aludium personnel are encouraged to be passionate about engaging with our local communities, protecting the environment, and following through on the promises we make our customers, suppliers, and partners. This value also recognises that Aludium’s products and services must be of the highest quality and that this is critical for the ongoing success of the business.
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The Code of Conduct applies to all Aludium employees, as well as external or freelance workers hired by the company. Over the coming months, every employee will be asked to sign the Code of Conduct to indicate that they agree with its provisions.
Implementation by end 2018 As part of the compliance project, Aludium has also prepared several specific procedures relating issues such as whistleblowing. Employees are encouraged to use the whistleblowing channel to report any breaches of the Code of Conduct. In case of a breach, any employee can send an email to employee.channel@aludium.com A Compliance Committee has also been established to oversee the Code of Conduct and its implementation. The Committee includes Alberto Ruiz, Pedro Escudero, and Thijs Visser. By the end of June, the Code of Conduct will be signed by the company directors, Works Council, and all employees. Training and specific tools will also be rolled out to all relevant personnel. The compliance project is scheduled for review in July. Progress and future actions will be included in Aludium’s Annual Report which is scheduled for publication at the end of 2018. For more information about the Code of Conduct visit: www.aludium.com/aludium/ mission-vision-values/ ■
Company News
Ready to roll Aludium will continue supporting the Formula Student Bizkaia (FSB) racing team from the University of Bilbao as a Platinum sponsor. Aludium’s support for the team began in 2017. The FSB team is making extensive use of aluminium in its 2018 prototype – to be known as FSB2018. Aluminium is present in every assembly of the car thanks to its excellent strength-to-weight ratio. The FSB team is continuing to explore new techniques which will enable them to optimise components and the manufacturing process with aluminium. One new application is the use of alloy 5005 to manufacture the moulds for the car’s carbon fibre rims. The alloy is very easy to machine and has a very similar expansion coefficient to the carbon fibre. The moulds can also be reused to create several rims as they do not deteriorate as quickly as the foam
moulds which are traditionally used in this application. Although it appears to be made completely from carbon fibre, the vehicle’s monocoque also makes extensive use of aluminium honeycomb to minimise its weight. An aluminium honeycomb structure has also been deployed in the vehicle’s impact attenuator, which is designed to absorb energy in a frontal collision. The car’s aerodynamic devices use the same aluminium honeycomb which is laminated. In 2018, the Bizkaia Racing team will take part in Formula Student races in the UK and Spain. The UK race will take place at the world-famous Silverstone track from 11 to 15 July, while the Spanish race will be in Montmeló from 22 to 26 August. ■
For more information on Formula Student Bizkaia visit: www.fsbizkaia.com
Aludium to publish first Sustainability Report During the second half of 2018 Aludium will publish the company’s first Sustainability Report. The Report is part of Aludium’s long-term strategy to quantify and reduce the impact of our operations on the environment, improve our health and safety performance and secure the company’s profitability. Aludium’s Sustainability Report is a key part of our programme to become an accredited member of the Aluminium Stewardship Initiative (ASI). ASI’s Performance Standard defines environmental, social, and governance principles and aims to address the sustainability of the aluminium value chain. Aludium’s accreditation to ASI is the
responsibility of Marta Alvarez Marquez. The Sustainability Report will provide reassurance to Aludium’s customers that the company is focussed on improving our sustainability. By being completely transparent with them we will ensure that Aludium remains a trusted supplier for the long term. ■
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Team in the spotlight
Exporting specialty flat rolled products to the world
Meet Christiane Huber Christiane Huber gained a master’s degree in International Trade from the University of Linz (Austria) before joining Alcoa (now Aludium) in 2002. As well as being Director of Aludium’s Specialties team, Christiane also leads the company’s overseas export activities. She is also actively involved in the daily business and enjoys direct contact with the customers, having met most of them personally over her career. Christiane speaks five languages including English, French, German, Italian, and Spanish. She is very involved in her local community and serves as a member of her municipal council. She enjoys skiing, travelling, and spending time with her family.
Aludium’s Specialties team consists of a highly diverse group of experts who support customers in all corners of the globe. Led by Christiane Huber, Sales Director of Specialties, the team is actively growing Aludium’s sales in sectors ranging from automotive trim to lithography plate. And they’re working closely with the Cindal R&D Centre to develop new products which meet customer requirements for special surfaces combined with specific mechanical properties. Aludium Today spoke with Christiane to find out more about the Specialties market, Aludium’s offer, and her team of dedicated professionals. Aludium Today (AT): Firstly Christiane, can you tell us what the term ‘specialties’ covers? Christiane Huber (CH): Speciality products include aluminium alloys which are typically used in niche markets. These materials are highly technical. That means they have been specifically developed to provide different surface or drawing properties and are often applied to high purity or customised alloys. The main applications for Aludium’s specialty products are in decorative automotive trim for interior and exterior parts, cosmetic and pharma packaging, lighting, solar absorbers, semi-rigid containers, food cans, closures, and lithography plate. Essentially anything which requires a specific surface and/or perfect formability. AT: What is special about Aludium’s offer for these applications? CH: Aludium has some unique capabilities which are not available from any other aluminium mill in Europe – and in some cases, the world. That includes our knowledge of bright products and surfaces and our ability to combine those surfaces with different mechanical properties. It’s very challenging to achieve deformation while maintaining good surface properties, but this is something that Aludium excels at. Aludium is also fortunate to have our inhouse Cindal R&D Centre. The Cindal team includes some of the world’s leading experts in aluminium forming and processing. They can also offer our customers co-engineering capabilities to help them achieve the specific surface and mechanical properties they require for their products. Cindal is also responsible for enlarging Aludium’s surface range with the development of Decorandum® and Texturandum®. AT: What makes Decorandum® and Texturandum® so different? CH: While our Decorandum® range mimics the look and feel of stainless steel (but without the weight and cost disadvantages), Texturandum® is a truly unique product. We can recreate almost any pattern - geometrical, organic, or logos - on the aluminium’s surface. Aludium is the only rolling company which has successfully industrialised this process and can offer it
Interior trim with decorandum® 10
Today
Team in the spotlight
“Aludium has some unique capabilities which are not available from any other aluminium mill in Europe – and in some cases, the world. That includes our knowledge of bright products and surfaces and our ability to combine those surfaces with different mechanical properties.” cost efficiently direct from the mill. It’s a great alternative to the usual embossing processes if used for higher volumes.
AT: You mentioned Aludium’s ‘unique capabilities.’ Can you explain what you mean? CH: In Alicante, Aludium has a unique combination of equipment including a continuous annealing line, degreasing line, and pre-treatment system. This is essential for sectors such as packaging. For example, our pre-treatment system helps packaging producers to achieve
Aludium has some unique capabilities which are not available from any other aluminium mill in Europe.
A coil of bright aluminium in our factory in Castelsarrasin.
good lacquer adhesion on the final product. Aludium’s continuous annealing line also guarantees uniform mechanical properties along the length and width of a coil. In our mill in Castelsarrasin we have developed extremely sophisticated processes to roll bright products. For example, we can roll brighter surfaces than anybody else, even below 0.2 mm. We can also maintain the extremely tight mechanical property ranges specified by the customer while obtaining a smooth and defect-free surface. This is unique.
AT: Are Specialties a strategic focus for Aludium? CH: Absolutely – our goal is to grow significantly in these markets. We are achieving this goal by offering excellent support at every stage from product development to full production and logistics. Customer focus is not just an empty promise. The sales team takes every request from a customer seriously, investigates it with their colleagues in the mill, and tries to find a solution. Our short-lead time concept is also very popular with customers.
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Team in the spotlight
“Customer focus is not just an empty promise. The sales team takes every request from a customer seriously, investigates it with their colleagues in the mill, and tries to find a solution.”
AT: What are the major trends in Specialties? CH: There are both positive and negative trends in the Specialties market. On the positive side, the market for aluminium wine closures has been growing consistently over the past few years, but we believe there is even further room for growth. Demand for aluminium in automotive trim applications is also growing, particularly for interior trim in the premium car segment. Aludium is actively promoting solid metal-trim parts for the mass market by offering cost efficient solutions like Texturandum® and Decorandum®. One of the negative areas is in lighting. Here LEDs, which require much
less bright material for the reflectors, have rapidly replaced fluorescent lighting solutions over the past few years. AT: How has the decline in lighting applications for aluminium affected Aludium? CH: The market for lighting has fallen by 20 percent every year since 2012. That’s a huge drop for a relatively small company like Aludium. But we’ve actually grown our volume of speciality products over the same period. Some of that growth has come from new customers in new markets, but a lot of it is down to increased demand from existing customers. That’s largely because Aludium’s customer base recognise us as a reliable partner. AT: Lithography was a key market in the past. Does Aludium have a plan for this sector? CH: Some years ago, our previous owners made a strategic decision to limit our lithography plate sales to our home market. But we have never stopped producing lithographic sheet. Aludium has the perfect equipment and expertise to produce the very demanding surfaces required for printing. And that equipment has been enhanced significantly over the past few years. With our new overseas export team, we are now able to explore lithography markets around the world. We can also offer our lithography products to European players again.
AT: You mention Aludium’s export department. What’s driving the export demand for Specialities? CH: Aludium’s customers are embracing two major trends that are shaping the world now – globalisation and consolidation. We’re increasingly seeing customers which are headquartered in one region but operating plants around the world. Aludium can support these customers with material direct from our plants. While our main market remains Europe (particularly Germany, Italy, and Spain), we are seeing strong demand from Asia, and the Americas. Countries such as Chile, China, Mexico, and the US are becoming increasingly important for Aludium. During the qualification process with these new customers, the support of our Cindal team is extremely important. That includes material analysis, product recommendations, and process definitions for the mill. AT: Do you work regularly with Cindal? CH: Specialties have a big project list including qualifications, new alloys, new processes. Our connection with Cindal is extremely important – both for Aludium’s plants and our customers. Today, our big customers just expect this level of support and innovation. But I think many more of our customers could benefit from Cindal’s offering. For example, material characterisations and training are highly appreciated by those customers who have already tried them. AT: How is the Specialties team organised? CH: Account managers in the team are responsible for one particular market. It might be a region such as Asia which is looked after by Eddie Chou. Alternatively, it Aludium is leading supplier for the closures industry.
The Specialties team of Aludium.
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Team in the spotlight
“The account manager becomes our expert on their market and the players involved in it. That enables Aludium to follow customer and market developments around the world.”
Cindal, worldclass support in formability and surface optimisation.
can be a product sector such as cosmetic packaging which is the responsibility of Silvia Ruiz. The account manager becomes our expert on their market and the players involved in it. That enables Aludium to follow customer and market developments around the world. AT: What has been the biggest success of the Specialities team? CH: There are many but one that stands out is Aludium’s recent qualification as a supplier of aluminium for human and pet food containers which was achieved in record time. A packaging customer approached us with a request to outsource volume to Aludium. From the time we received the first email, it took us just four weeks to develop and cast the new alloy. Cindal drove the development of the hot rolling and thermal treatments we needed
to meet the customer’s specifications. We had to scrap some material and repeat the process, but that was relatively easy because we had prepared to fail. Because we knew it would be difficult to get the process right, we had additional slabs available. In just six months we completed all three qualification steps for a complex and demanding product. This success was down to the great cooperation we had between the mill, the sales team, the customer, and Cindal. We have never completed such a complex qualification process in such a short time. I’ve got to say we surprised ourselves. AT: What’s your professional goal for the Specialties team in 2018? CH: I would like us to accelerate the growth of Specialties even more this year and increase our volume of overseas exports. And within the team I’d like to provide more training and fill one or two vacant positions, so we can respond even more effectively to our customers. AT: And for Aludium as a company? CH: We are improving our recycling and sustainability with investments in the new rotary and multi-chamber furnaces. But we need to communicate this to customers, particularly with regard to Aludium’s carbon footprint. Like us, they will be pleased to know that Aludium is working more sustainably and increasing
its autonomy regarding metal supply. This year we will publish Aludium’s first sustainability report and we’re hoping that will help to bridge this knowledge gap. AT: What is the best thing about working for Aludium? CH: It would have to be seeing what is happening within the business. Our owner has expressed immense trust in us. And the improvements that have been implemented have created an excellent working atmosphere. It is very satisfying being part of this team. AT: What makes you smile at the end of the day? CH: Many things – I’m very happy in my job. But it is really special when someone in my team says thanks for your help and support. And although you need to be patient – qualification processes are long – it is worth it when you hold the first regular order in your hands. AT: Will you be at Aluminium 2018 this October? CH: I’ll be in Dusseldorf from the first to the last minute of the show. I’m looking forward to meeting with customers, many of whom I know personally. And Aludium’s CEO and COO will be there – so it will be a good chance for customers to meet them. We’ll also be showing Texturandum® and our other new products. ■
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Eddie Chou Asia Based in Asia, Eddie is Aludium’s account manager for the region. He joined the company in 2016 after running a successful aluminium business with Constellium (formerly Alcan). After studying for a bachelor’s degree in Taiwan, Eddie gained a master’s degree in industrial and system engineering in the United States. Eddie is now responsible for Aludium’s sales in China, Korea, and several other Asia countries. His main focus is the automotive trim market. However, he is also developing Aludium’s exports to Asia in the cosmetic packaging sector, and with coil anodizers and distributors. Working closely with Aludium’s customers Eddie ensures fast reactivity to fulfil customer demand and develop new projects. Eddie speak Chinese and English. His favourite hobby is tennis.
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Account Manager
Based in Germany, Musa has over 20 years of experience in the aluminium industry. He joined Aludium from Alcoa in September 2015 and took responsibility for Aludium’s commercial strategy in the European industrial market. His focus is automotive components and trim. Over the years, Musa has demonstrated a very strong track record for creating commercial growth. His goal is always to develop long-term partnerships and create new products which meet the needs of Aludium’s customers. Musa speaks English, German, and Turkish fluently and is currently learning Spanish. He enjoys working with people from different cultures both at Aludium and our customers.
Silvia was born and raised in Barcelona where she gained a degree in translation from the Autonomous University of Barcelona (UAB). She completed studies in marketing and quality at a number of different business schools before completing a post-graduate degree in negotiation and sales management at the University of Barcelona (UB). Her career in the aluminium industry began in 1993 when she became an assistant product manager for a major aluminium producer. In 2010, Silvia joined Aludium (then Alcoa) where she took care of industrial strip sales to France, Portugal, and Spain. When Aludium was formed she joined the Specialties team. She is now responsible for European sales of pharmaceutical and cosmetic packaging, and lithography. A keen ballroom dancer before becoming a mother, Silvia now destresses with outdoor activities such as mountain climbing and padel (a racquet sport popular in Spanish-speaking countries). She speaks English, French, and German, as well as Catalan and Spanish.
Luigi Barbella Closures Luigi joined Aludium in September 2015 with twelve years of experience in the aluminium market. Prior to starting his career, Luigi graduated from the University of Cassino and Southern Lazio (Italy) with a bachelor’s degree in economics and business. While Luigi’s focus is packaging customers, particularly in Eastern Europe, he is also increasing his involvement in the South American market. He believes that Aludium’s short lead time concept and the support of the Cindal R&D Centre set the company apart from the competition. A devoted Juventus fan, Luigi also enjoys jogging, live concerts, and has recently taken up tennis lessons. He speaks Italian, English, and has been improving his Spanish since joining Aludium.
Export Manager
Silvia Ruiz Cosmetic Packaging and Litho
Account Manager
Sales Manager
Musa Barlasakli Industrial Europe
Account Manager
Meet Aludium’s Specialties team
Account Manager
Team in the spotlight
Michael Brandner Overseas Exports Michael studied international business administration with focus on industrial management at the University of Vienna (Austria). Following an Erasmus exchange at the University of Alicante in 2004, Michael joined Alcoa in 2006. In 2007 he took a position in Austria before re-joining Alcoa in 2010 as an Account Manager for bright and packaging products in Europe. When Aludium was formed at the beginning of 2015, Michael took responsibility for building the company’s Exports department from scratch. He is now responsible for sales outside Europe and is the single point of accountability (SPA) for continuous anodizers and solar absorbers. He also supports Eddie Chou, Aludium’s account manager for Asia, and some customers in Germany and Austria. One of Michael’s biggest professional challenges came in 2016 when he made his first trip to China alone to promote Aludium. Together with Eddie Chou and the Cindal team, Michael has helped to grow Aludium’s sales in Asia from zero to a significant volume in a very short time. In his spare time Michael enjoys running, mountain biking, hiking, and a range of other sports. He speaks English, French, and Spanish.
Simone Vaine Closures and Strips Born in Italy, Simone gained a bachelor’s degree in engineering before starting his career. He joined Aludium (then Alcoa) in 2004 and is now Sales Account Manager for closures and strips. Simone is based in Italy where his main customers are located. However, he also supports Aludium customers in other parts of the world. Simone believes that Aludium is an attractive partner thanks to its extensive experience and product knowledge, and fast reaction times due to its lean structure. Simone is in regular contact with the Quality and Product Development teams in Alicante to ensure the plant does not miss a chance to develop an innovative product. As well as playing tennis regularly, Simone enjoys mountain bike riding, reading, and enjoying time with his family.
Team in the spotlight
Support from Cindal
Product Leader Closures and Food Packaging
Product Leader
Product Engineer
The Specialties team is ably supported by the Cindal R&D team. The main support comes from David Bravo, Dr Catalina Fernandez, and Ignacio Gil. David Bravo Born in León (Spain), David first joined the Cindal team in 2010 through a national scholarship. He became a permanent member of staff in 2011. Reporting to Dr Catalina Fernandez, he now works as a metallurgy product engineer specialising in bright products for cosmetic packaging and automotive trim. Through meetings with customers and visits to their facilities, David gains a deep understanding of their aluminium needs. The information is shared within the Aludium team to ensure everyone is aware of the customer’s reaction to our products. In the Specialties market, David believes customers are looking for specific surface properties. By manipulating the internal microstructure of the alloy, the desired properties can be achieved while maintaining the formability properties the customer requires. In his free time David enjoys cycling and watching football. He also loves spending time with his family. David speaks English and Spanish and is improving his French.
Dr Catalina Fernandez Dr Catalina Fernandez is Product Leader for the Bright, Cosmetic and Automotive Trim market segments. In this role, she provides support and technical leadership to both Aludium and our customers. Catalina holds a PhD in materials science from l’Institut National Polytechnique de Lorraine (France) and a bachelor’s degree in mine engineering, specialising in metallurgy. She joined Cindal in 1990 as metallurgist before becoming Project Leader for bright products and processes in 1994. Since 2008, Catalina has been Chief Metallurgist with responsibility for the metallurgical quality of Aludium’s products. In this role she oversees casting practices, hot and cold rolling, bright finishing, and quality between Aludium’s plants. Catalina is instrumental in leading improvements to processes and the development of new products in collaboration with Aludium’s mills, customers, and suppliers.
Ignacio Gil Ignacio Gil joined Cindal in 2011 as a Senior Metallurgist specialising in casting, rolling, hard alloys, and special products. He leads technical projects relating to quality, process improvement, and new product development for Aludium’s mills and customers. Ignacio also holds the position of Product Leader for the closures and food packaging segments where he provides support and technical leadership. Ignacio holds a bachelor’s degree in Physical Sciences. Following his degree, Ignacio became Metallurgical Manager at Compañía Valenciana de Aluminio Baux, a position he held for ten years. Ignacio then joined the Spanish National Centre for Metallurgical Research where he made a major contribution to the development of new processes, alloys and applications.
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Spot on Alicante
Alberto Ruiz, Plant Manager at Aludium Alicante
Aludium to resume aluminium casting in Alicante A decade after they closed, the cast house at Aludium Alicante is being readied to resume aluminium melting in 2019. The decision to reopen the cast house will increase Aludium’s ability to recycle aluminium and reduce the company’s environmental footprint at the same time. Aludium Today spoke with Alberto Ruiz, Plant Manager at Aludium Alicante, to find out more about the project and the drivers behind the decision to reopen the idle facilities. Aludium Today (AT): Why did the cast house close in the first place? Alberto Ruiz (AR): The decision to mothball the cast house was made back in 2008, at the height of the economic crisis. The Alicante mill’s former owners were facing a major slump in demand for aluminium. So, it was a logical decision to reduce capacity at the time. AT: Why reopen them now? AR: There are two major reasons. The
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re-opening of the cast house will give us extra capacity to continuously cast aluminium. This is vital for Aludium to continue our growth path. The second major reason is that Aludium’s strategic plan is to grow the business sustainably over the long term while reducing our material costs, cutting our environmental footprint, and limiting our dependence on external sources of metal. Having the cast house available will allow us to meet all of these objectives.
“We expect to reduce our energy consumption by 150 kWh annually, which will reduce carbon dioxide emissions by around 150,000 tonnes per year.”
Spot on Alicante
“The re-opening of the cast house will give us extra capacity to continuously cast aluminium. This is vital for Aludium to continue our growth path.”
AT: What are the major drivers behind demand for Aludium’s products? AR: The economic crisis affected the aluminium industry quite badly. After a long period of stagnation, the economies of our most important markets are growing again and there is a lot of pent-up demand. Thanks to the investments Atlas Holdings have made in Aludium, we’re able to take advantage of that growing market. And as Aludium, we made an important decision to focus on our key markets while other aluminium producers abandoned them for the lucrative automotive and aviation markets as a way of coping with the crisis. Our long-term customers have appreciated our decision to stick with them and are continuing to work with Aludium as their markets recover.
AT: What effect will the reopening have on Aludium’s sustainability? AR: From the business perspective it will reduce our dependence on external sources of aluminium. This is significant and a key part of our strategy. From an environmental perspective, it will enable us to increase the amount of aluminium Aludium recycles by 10 percent. As you know, melting recycled aluminium products requires just five percent of the energy needed to produce aluminium from raw materials. We expect to reduce our energy consumption by 150 kWh annually, which will reduce carbon dioxide emissions by around 150,000 tonnes per year. This is significant for a company of Aludium’s size.
AT: How will the cast house be organised? AR: One production line will cast slabs which will be sent to Aludium Amorebieta for further processing. The second line will use continuous casting technology to produce coils which will be finished in Alicante. AT: What is involved in getting them up and running again? AR: We need to completely revamp the cast house to make it fully operational again. That work will cost around €7 million. We hope to commission both lines by the end of this year. The goal is to have the cast house in full production in the first quarter of 2019. AT: Will there be extra jobs? AR: Yes – we expect to employ an additional 23 people in Alicante. That will take our total workforce in Alicante to around 400 people. We will hire new people according to Aludium’s HR values and respecting diversity. We want all new employees in the cast house to become leaders in safety, quality, total preventive maintenance, and productivity. People who take responsibility and ownership seriously. ■
Alundi: a voice for everyone Aludium is about to implement Alundi – a new social networking app which gives every employee a voice. Alundi will ensure that every employee can communicate with their colleagues, regardless of whether they have a company email address or not. All that you need is a smartphone which supports either the Android or iOS operating system. The implementation of Alundi is supported by Arnaud de Weert (CEO) and Manuel Ruano (COO) as a way of ensuring the voice of every Aludium employee is heard.
Communication made simple The app is managed by Community Builders at each site including: • Igor Cacho Marin in Alicante • Maite Etxeita Gorritxategi in Amorebieta • Brigitte Darmigny in Castelsarrasin.
Alundi includes four main communication channels which allow users to share messages, videos, images, and documents across teams and throughout the company: Alerts; Bulletin Boards; Libraries; and Messages. Aludium will begin the rollout of Alundi when the project team completes its first tests in Alicante and Amorebieta at the end of May. Final testing will be complete in June. In July, the first phase of the rollout begins in Alicante and Amorebieta. By September the rollout will be completed in Alicante, Amorebieta, and Castelsarrasin. As we tailor Alundi to Aludium’s specific requirements, the project team would like to hear from any employee who has an idea about how the app can contribute to their professional life. Send your ideas to your local Community Builder today.
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Product Innovation
Aludium releases 55AT™ – the cost-effective alloy for automotive decoration Aludium has launched its newest alloy for automotive trim – 55AT™. Developed by Aludium’s Cindal R&D centre in cooperation with a customer, 55AT™ is a high quality and cost-effective alternative to 5505. The new alloy offers clear cost and productivity advantages for solid, metal trim parts used on the exterior of vehicles. 55AT™ has already been deployed on Alfa Romeo’s new Stelvio model. 55AT™ was developed by Aludium specifically for exterior automotive trim applications which require the highest quality bright finish. These include window frames, roof rails, sunroof trim, roof racks, B- and C-pillar decoration, and other exterior decorative parts of premium vehicles. For exterior trim application, 55AT™ is cost-effective both in terms of its initial cost and yield. It has a level of cleanliness not found in any comparable alloy thanks to the advanced filtration system Aludium uses during casting. This guarantees consistently perfect anodising and brightening results. With 55AT™, there is no need for labourintensive mechanical polishing and high productivity guaranteed.
55AT™ is a part of Aludium’s family of automotive trim products which also include Decorandum®, Texturandum®, the high purity alloy 5505 for premium vehicles, and a wide portfolio for interior trim.
For more information about 55AT™ visit: www.aludium.com/55AT ■
New focus on lithography Aludium Alicante has been a leading producer of alloys for the lithography industry since the 1960s. Although the activity in this market has been reduced in the last years, Alicante has significantly improved the production facilities used to create our lithography alloys. Those improvements have included a complete overhaul of the fast-speed finishing line at Aludium Alicante. This enables us to guarantee the accurate gauge, shape, flatness, and surface quality of our lithographic alloys. A new X-ray gauge control system has also been installed at the line’s entry and exit points, allowing Aludium to guarantee the uniform thickness of the final sheet. This is critical to manage the produced sheets after graining, to minimize lithographic plate
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wear and ensure consistent ink transfer during printing operations. Aludium’s offer for the lithographic sector includes two main alloys: • 1050 for standard printing applications. • 1020 for high speed processing lines. This patented alloy, developed by Aludium’s Cindal R&D team, offers better wear resistance and higher mechanical performance than 1050.
With our increased focus on overseas export markets, Aludium is now also targeting lithographic customers around the world. New opportunities are being investigated in North and South America.■ More details about Aludium’s lithographic offer can be found at: https://aludium.com/markets/ equipment-and-devices/lithography/
Site News
Second annual Charity Race takes place in Alicante This year, more than 280 people from Aludium, including employees and their families, took part our second annual Charity Race on 14 April. Participants were asked to donate food to the Alicante Food Bank. Aludium quadrupled the amount of food donated while the Federation of Metal Entrepreneurs in Alicante (FEMPA) added another 237 kilograms. In total, 3,126 kilograms of provisions were donated to the Food Bank.
Soli II Carrera 1 Kil
dium daria A4lu de Abril
nto - Em o de Alime
1
pleados y
familiares
de Aludiu
m
MARCHA A PIE
5 KM
CARRERA A PIE DE
Several sporting events were arranged on the Porquet grounds adjacent to Aludium’s Alicante plant. These included an eight-kilometre hike and a 15-kilometre mountain biking route. Adults and children were also invited to take part in a non-competitive ‘Solidarity Walk’ of four kilometres. In addition to the sporting events and entertainment, a feast was prepared for
The Charity Race mountain bike event covered 15 kilometres
the participants. A highlight was the ‘Alicante rice’ which was cooked onsite and served to all attendees. The event was attended by Fernando Marcos, a councillor from the City of Alicante; Luis Rodríguez, Secretary of FEMPA; Juan Vicente Peral, Director of the Alicante Food Bank; Gerson Morales, Director of the ASEPEYO Assistance Centre; and representatives from the UGT and CCOO unions. ■
8 KM
CARRERA MTB
15 KM
9:30
bienvenida, recogida de dorsales y donación de alimentos
Actividades para los más pequeños
Paella Gigante
Trofeos para los ganadores
INSCRIPCIONES
Hasta el 29 de Marzo mediante mail a agathe.tranchandp@aludium.com y elena.povedagarcía@aludium.com, o través de tu Team Leader o Supervisor.
More than 3,000 kilograms of food was donated to the Alicante Food Bank by participants and Aludium
Aludium employees take part in eHealth Challenge Aludium has fielded several teams in the 2018 international eHealth Challenge. This month-long competition took place in 32 countries and involved 1,088 team from 77 companies including Aludium. In total the 13,146 participants covered over 1.3 million kilometres! Aludium participated in the Big Companies category for businesses with more than a thousand employees. Our participation was part of Aludium’s Salud Para Siempre (Health Forever) programme. Promoted by Aludium Alicante’s EHS department, Salud Para Siempre aims to
ensure Aludium’s retired employees remain in perfect health after retirement. The Aludium team placed third overall in the mountain bike race. The 467 employees who took part in this competition covered almost 15,000 kilometres in the month. ■
Salud para siempre Healthy for ever
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Site news
Amorebieta First QBR of 2018 in Amorebieta On 17 and 18 January, Aludium Amorebieta played host to the first Quarterly Business Review of 2018. Aludium’s directors gathered at the plant to review the 2017 results and set Aludium’s targets for the new year. As part of each QBR a town-hall style meeting is held with employees. In Amorebieta, the company’s performance was discussed as were the challenges for 2018. Employees also had the opportunity to raise concerns with both Arnaud De Weert and Manuel Ruano. After the meeting, an event was held to recognise Amorebieta employees who have made an outstanding contribution to Aludium’s safety and productivity. They included: • The hot mill modernisation team who improved the mill’s productivity. • A cross-functional team who have enhanced Aludium’s service level for customers in the building and construction sector • The maintenance team who worked over the Christmas shutdown to carry out essential works. The work was completed without any safety issues. ■
The hot mill modernisation team with their awards. From left to right: Eduardo Lorca, Oscar Parra, Manuel Ruano, Aitor Abril, David Bermejo, Ander Arias, and Crispin Olaizola. Jon Ariznabarreta and Antonio Brao were also recognised but were unable to attend the presentation
The building and construction service team with their awards. From left to right: Aida Villoriego, Arnaud De Weert, Omar Arias, Alfredo Redondo, Aritz Irakulis, Philippe Barraud, Natalia Garcia, Joaquín Rodríguez, and Endika Zarandona. Other team members who were unable to attend the event include Alberto Del Hoyo, Igor Orue, Andoni Recio, Iñaki Mozo, Gabino Peral, Aitor Velez, Iñigo Larizgoitia, Iván Fernández, Ekaitz Goikoetxea, Jorge Luis Alvarado, Francisco Javier Gamero, and Aitor Tudanca
The Christmas maintenance team. From left to right: Pedro Escudero, Jose Félix Garcia, Joaquin Rejano, Jose Antonio Ramos, Manuel Ruano, Jose Ramón Gómez, Pedro Maria González, Jesus Maria Izurza, José García, Francisco Javier Uriarte, Jose Javier Fernández, and Eduardo Lorca. Jesus Parra, Josu Barroeta, Antonio Brao, David Hernando, Oskar Gil, Jose Miguel Flores, and Jose Martin Intxausti were also recognised but were unable to attend the event.
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Installation of multi-chamber furnace begins Work to install the new multi-chamber furnace in the Aludium Amorebieta cast house has begun in earnest. The team is already modifying the roof of the cast house. This work is expected to be completed in June. An internal reorganisation of the cast house to accommodate the furnace is also underway and should be finalised in July. The project is on schedule for full completion by mid-March 2019 when the first slab will be cast. In this period, existing equipment will be removed, the holding and multi-chamber furnaces will be installed, and the new casting pit will be completed. The furnace has a capacity of around 275 tonnes per day and will primarily use postconsumer scrap as its source material. ■
Full work schedule Works
Scheduled completion date
Preparation phase
15 August 2018
Removal of existing equipment
15 September 2018
Installation of multi-chamber furnace
15 December 2018
Completion of the casting pit
31 December 2018
Installation of the holding furnace
15 January 2019
Cold, dry, and hot tests
15 February 2019
Installation of the new casting pit
15 March 2019
Casting of first slab
15 March 2019
Start of production (70 percent capacity)
15 April 2019
Full production (100 percent capacity)
15 July 2019
Amorebieta launches AMO 3000 project to improve quality culture and customers satisfaction Amorebieta’s AMO 3000 project was launched in February with the goal of reducing customer claims and improve our metal usage (recovery increased). Aludium recognises that quality is a key reason why customers choose one aluminium supplier over another, not been the cheapest one. Reducing rejections to an absolute minimum is key to ensuring their satisfaction and Aludium’s profitability. Several different actions were launched at the project’s kick-off in February. All employees received training about the project and its goal of reducing the amount of internal scrap produced at Amorebieta to less than 3,000 tonnes annually. Key processes were improved: LF5 cold mill including welding in intermediate passes or new wrapper device, LF6 scrapping process and special focus in acceptance criteria in finishing processes. Since the launch, a number of other activities have been started. A weekly AMO 3000 newsletter is now sent to all Amorebieta employees with the company’s 7 Días (7 Days) newsletter. The AMO 3000 newsletter features ‘STOP stories’ which detail issues which can affect product quality. 1st quarter results already shows good trend with an increase of more than 0,5% points in recovery and reduction in claim rate of 10 % versus previous year. ■
Alicante QBR and Town Hall meeting held in Alicante The second Quarterly Business Review (QBR) for 2018 was held at Aludium Alicante on 17 April 2018. In keeping with Aludium tradition, the day included a town hall style meeting with selected employees from the plant. The main topic of the town hall meeting was to be aware about the business environment and how it affects the Alicante plant’s operations. The QBR and town hall meeting were chaired by Manuel Ruano, and attended by Arnaud de Weert (CEO), Gert Karenbeld (CFO), and all members of the Aludium Board. The Alicante Lead Team also attended the QBR. ■
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Site News
Alicante Recognitions at QBR During the April QBR, Aludium’s management recognised several teams and individuals who have made a significant contribution to the plant’s operations. Best Suggestion – 2017 The award for best suggestion in 2017 went to Oscar Sánchez Beas and Alejandro García Espinosa for their idea to install more efficient pumps in the basement of the L95 machine. The new pumps are over 75 percent cheaper than the existing solution, and maintenance costs are 77 percent lower. In addition, the time to change the pumps has been reduced from three-hours to just 20 minutes. Energy costs are also 78 percent lower. Since the new pumps were installed there have been no pump failures and acid leakage has been eliminated.
Ramp-up of L95 Following the installation and commissioning of the L95 machine in summer 2017, a team of people worked to ensure the equipment operates to its full potential. This involved training of operators and maintenance personnel, and the definition of new procedures, recipes, and standards. Thanks to the optimisation work the team carried out, L95 was able to achieve the quality level required on schedule. The following people were recognised at the QBR for their commitment and successful coordination of the different teams involved in the project: Laura Rodríguez Gomis, Daniel López Martínez, Antonio Sirvent López, Manuel Torregrosa Conesa, Ángel J. Valdés Navarro, José Manuel Márquez Arjona, Alejandro García Espinosa, and Juan Carlos Rives Sempere.
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Improvement in quality of fine grain surfaces for cosmetic applications
Improvement of quality indicators
David Bravo Espinosa was acknowledged during the recognition event for his contribution to improving the quality of Aludium’s fine grain material for cosmetic applications. David developed a new process which reduced the rate of rejection by customers significantly. David’s improvements are estimated to have saved Aludium over €130,000 annually.
During the QBR, Marcos Gómez Parres was recognised his work to improve the quality of material for our customers on the L95 line. By optimising parameters and processes standardize for levelling, rolling, slitting, annealing, and packaging, Marcos was able to improve product quality and reduce the claim rate. ■
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Castelsarrasin First Kaizen event leads to quality improvements As part of efforts to improve the quality of the products it makes, Aludium Castelsarrasin held its first Kaizen event in April. Kaizen is a methodology which aims to continuously improve quality by identifying issues in the production process. The event was attended by Aludium’s COO Manuel Ruano, members of the Amorebieta logistics team, and operators, quality technicians, and logistics personnel from Castelsarrasin. During this first event, the team worked to define new processes which could accurately control upstream metal quality, shipments from Amorebieta, and etching- and rolling-line processes. Over a full week, the Kaizen team redefined procedures and physically tested them on the shop floor. Five weeks later, the benefits of the Kaizen event are being seen with product quality improving significantly.
Some of the quality issues have been fully resolved, while others are still being resolved. Each team in the plant has been trained on the new product flow developed during the first Kaizen event. Aludium Castelsarrasin is also collaborating closely with Amorebieta to control the raw material flow and this is now a routine part of operations. A second Kaizen event was held in Castelsarrasin to apply the methodology to products for another major customer. “The implementation of Kaizen in Castelsarrasin is ushering in a new era of maturity with regards to problem solving,” notes Manuel Ruano. “The plant is already seeing improvements in the quality of its products and operational metrics as a result.” ■
Using Kaizen principles, the team examined all processes and identified improvements
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“Working together for a better, brighter future�
ACR II Aluminium Group cooperatief U.A. Prof J.H. Bavincklaan 2-4 1183 AT Amstelveen The Netherlands +31 20 7237 218 www.aludium.com
Aludium Amorebieta Barrio Ibarguren s/n E-48340 Amorebieta, Vizcaya Spain +34 944 887 500
Aludium Alicante Avda. de Elche, 109 E-03008 Alicante Spain +34 965 989 500
Aludium Castelsarrasin 294 chemin de Lavalette 82100 Castelsarrasin France + 33 5 63 32 80 00
Cindal R & D Avda. de Elche, 109 E-03008 Alicante Spain +34 679 518 645