Alcan Rolled Products UK, Rogerstone, South Wales, UK
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[Unfortunately the Remelt was demolished in 2009]
Process Control and Optimisation
Process Control and Optimisation
- I was a Member of 6-person team managing a 100,000 TPA melt-&-cast facility.
- Departmental keeper of ISO 9002 / ISO 14001 / Q1 systems.
- Responsible for control of prime metal and hardener inventories (£1M+) and consumables delivery planning.
- The initiator and driver behind the change of state of the art PPE – greater protection and wearability [PR97].
- Introduced networked video monitoring of blind spots reducing potential for incidents.
- Designed and introduced earth circuit based tap-hole run out detector.
- I was the leader of the operations teams for the specification, construction, commissioning and ongoing operation of Low NOx producing - gas fired aluminium melting furnaces and related equipment. The conversion from heavy fuel to natural gas being BAT for melting furnaces.
- Developed and implemented Electronic Data interchange with vendors which permitted return metal from the dross processor to be received into the melt preparation system with the actual chemical composition of each piece known. This resulted in the elimination of the sale of this metal which had been taking place at a significant discount (about 2,500 tpa).
- Introduced scrap tracking - including bin naming - with a project in progress at my departure for site wide Radio Frequency tagging.
- Reduced hardener (alloying additions) purchases by over 50%.
- Improved dross recovery by 15% through process monitoring and reporting.
- Developed systems so that the introduction of unmanaged autonomous shift teams – and the removal of shift experts did not adversely impact efficiencies
