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SPRING EDITION 2016 1
SPRING EDITION 2016
MOBILITY TAKING LEAPS
AND BOUNDS
GREEN BANNER SAVINGS
HEADS UP FORCHARITY
2 SPRING EDITION 2016
CEO message 3
Green banner savings make their mark 4
Heads up for charity 5
FEATURE STORY 6-8
MOBILITY TAKING LEAPS AND BOUNDS
Fun time had by all 9
Better quality and more of it! 10
Ingot chain automation leading the way 11
Beating the winter blues 12
Health & Safety Committee training day a great success 12
Celebrating years of service 13
Jeepers creepers, where’d you get those peepers? 13
Maintenance revolution 14
A brave new SAP world 15
Bash For Cash always a winner 16
Did you know? 17
60 seconds with... Nat Godwin 17
Six-year safety milestone 18
Tomago’s giving back 19
Welcome to Tomago’s new starters 19
Light aircraft champions 19
Tomago’s key performance indicators 20
CONTENTS
SPRING EDITION 2016 3
MATT HOWELL – CHIEF EXECUTIVE OFFICER
WELCOME TO THE SPRING EDITION OF TOMAGO NEWS, FEATURING SOME GREAT ARTICLES ON A NUMBER OF INNOVATIONS, SUCCESS STORIES AND SAFETY MILESTONES.
With the first half of the year
behind us we are well on track
for another very solid set of
results. At the time of writing,
we achieved a new quality
benchmark, with average iron
in metal falling to 803 ppm and
potline 3 at 758! This is new
ground for TAC and certainly
doesn’t happen by fluke. It is
the result of persistent focus
and attention to detail by all
of our people right through the
production chain. It is also being
noticed in the marketplace
with complimentary feedback
coming from our owners
and customers. In a global
commodities environment of
depressed prices and uncertain
futures, we are re-establishing
our reputation as a reliable
supplier of choice, one that
can be counted on to deliver.
Production performance has
been tremendous, with the
deficit in the first quarter of the
year fully recovered by the end
of June and now well on track
to finish the year ahead of
budget. Even better, our
controllable cost performance
has been commendable, and
we report on this in the article
featuring Luke Rankovich and
the success we are having
with the weekly $10k banked
cost reductions. Innovative
ideas from all departments
have resulted in more than
$1 million in savings across
the business, achieving the
annual savings target in almost
half the time anticipated. This
could not come at a better
time, as the Australian dollar
aluminium price is still at
historical lows and may not
recover for some time. We
need to make our own luck
and create our own future –
nobody else will do this for us.
You will also read about our
recent mobility expo where
our most creative minds have
been exploiting emerging
technologies to make it easier
and more efficient to do the
work we need to do – anything
from mobile approvals, tablet
computing to allow mobile
access to control room
functions and ‘smart’ WiFi
devices that can monitor
equipment condition and
performance, just to name
a few. We have been very
transparent that the future for
TAC involves more automation
and changing the way we do
things. The advantage we
have is by working together
and implementing changes in
a planned fashion, we do not
have to resort to the sort of
mass retrenchments that
many other manufacturing
and resources businesses
have been unable to avoid.
It is essential that we get the
best ideas on the table and
that means everyone has
a role to play.
Perhaps the best example
in recent times of people
working together to deliver
major change was the
successful SAP upgrade.
I have experienced a number
enterprise business systems
upgrades in my career, but
this was a textbook example
of how to get it right. Hats off
to the entire project team for
more than eight months of
planning and long days and
nights executing a major
upgrade in such a seamless
fashion. The new cloud-based
system will support our
innovation package as we
transform the business to be
the best it can possibly be.
If recent performances are
anything to go by, we have
a very bright future indeed
Enjoy this edition of TAC
news and to all our team
and the people who support
them, my thanks for your
considerable efforts.
Best regards,
Matt
Do you have an interesting
story to tell? If you have a
suggestion for TAC News
please contact Toni Lawson at
IT IS ESSENTIAL THAT WE GET THE BEST IDEAS ON THE TABLE AND THAT MEANS EVERYONE HAS A ROLE TO PLAY.
4 SPRING EDITION 2016
Innovative ideas from EMPLOYEES have resulted in almost $1 million in savings across the business, achieving the annual savings target in almost half the time anticipated.
Cost Accountant Luke
Rankovich said the savings
had been achieved in all
areas, thanks to some ‘great
innovative ideas’ and reviews
of processes and costs that
had been undertaken by
teams in each department.
“All of our teams have made
a real effort to look at the way
things had traditionally been
done in their departments
and to think about how they
could be done differently to
create savings of real value,”
Luke said.
“These improvements vary
from team to team, but each
of them demonstrate how new
thinking and a fresh approach
to things can make a huge
difference in outgoings –
as well as in efficiency and
outcomes.
“Every week we see teams
reporting on savings through
our $10K Green Banner
initiative, which is our way
of communicating new
processes and savings
across the plant.”
Recent Green Banners
included a new approach to
ingot mould cleaning, which
has saved the company $60k
annually. In the past, Cast
Products Operations had
always used contractors
to clean the ingot moulds
– a process that was labour
intensive, largely inefficient
and carried the potential to
damage equipment. The team
recently trialled an automated
cleaning machine that not
only eliminated the need for
contractors, but also required
very little operator input.
Additionally, the results
indicated the new cleaning
process produced a higher-
quality ingot.
Another $64,000 will be
saved annually in Liquid
Metal Operations (LMO),
where costs are being
reduced thanks to an
efficiency improvement in the
repairs of potline expansion
joints. Foot and vehicle traffic
over the tending aisles of the
potlines cause damage to the
expansion joints over time,
with these eventually
becoming a safety hazard.
During recent repairs it
became apparent that money
could be saved by reducing
the contractor involvement
and passing the management
to the LMO supervisor. At the
same time, the contractor also
came up with an idea that
reduced equipment hire costs.
Implemented together, these
two savings added up to
about $500 per repair – and
with 128 repairs remaining, the
total cost saving is $64,000.
‘We are so close to our target
– we’re only half way in and
we’ve already saved just
under what we set out to do,”
Luke said.
“It’s a great achievement
for everyone.”
Green banner savings make their mark
IT’S A GREAT ACHIEVEMENT FOR EVERYONE.
Ingot mould cleaning machine in Cast Products
SPRING EDITION 2016 5
It’s a no-brainer at Tomago Aluminium when it comes to supporting the Mark Hughes Foundation.
We love Beanie Day and once again we outdid ourselves
by raising over $3000 to fund research into brain cancer.
Not only was it a great chance to raise awareness for an
important cause, it also gave everyone an opportunity to
flaunt the ‘Mates Looking After Mates’ beanies given to
them in their Men’s Winter Health Care packages.
Money was raised at a morning tea, which was hosted at
the fire station, as well as through the sale of 100 Mark
Hughes Foundation beanies and tins resting at the front
gate. $1000 was donated by Tomago Aluminium Company.
A big congratulations to Danielle Harman who won a $50
gift card for her skill in the ‘Pin Stick the Beanie on Mark
Hughes’ competition.
Peter Petryk was also lucky on the day, winning a goodies
hamper for correctly guessing the Mark Hughes stats
– 161 First Grade Games for the Newcastle Knights from
1997-2005. Craig Jones bagged a home safety kit for
nailing Mark’s nickname – Boozy Hughesy.
Executive Assistant Nicki Harvey said a great day was
had by all.
“Everyone had lots of fun,” she said.
“This is a really great local charity, doing really good things.
It was a cold morning so everyone enjoyed the chance to
have a catch up, a hot cuppa and some sweets.”
“Thank you so much to everyone for their support and
a big thanks to Kristy Gately and the Security guys for
helping organise the event.”
Heads up for
charityMark Westbury and Andrew Thurlow
Peter Horsburgh and Brodie Fairhall
Dean Howard, Neil Lindus and Brett Timney
Andrew Thurlow and Kristy GatelyCharlie Saunders
A two-week Mobility Expo held at Tomago
Aluminium last month showcased the
enormous breadth and depth of innovation
being adopted across the plant as the
business leverages its use of technology.
Across the plant, staff are using commonly available IoT
electronics to build our own data sources to reduce unplanned
failures and, where possible, eliminate the need for manual
inspections.
Dennis said the Expo received extremely positive feedback from
the Tomago Aluminium board members and management team
who attended.
6 SPRING EDITION 2016
MOBILITY
“The feedback we had was so positive, we decided to leave the
Expo open for two weeks,” he said.
“Congratulations to all those involved – some great ideas through
Courage, Trust and Pride!”
Our innovations that are currently live include:
SAP Warehouse Manager
The warehouse inventory tracking system is now integrated into
SAP at the local bin level, meaning operators can maintain bin
movements without having to balance two separate systems.
By using a mobile device, the warehouse team is able to scan
bar codes and find stock without waiting to use a workstation.
Live access to SAP in the field
Previously maintainers only had access to SAP via desktop
computers and had to travel between the equipment they were
maintaining and their desktops to carry out inspections and
corrective work. Maintainers are now provided with a mobile
tablet providing access to all desktop systems (i.e. SAP work
SAP Warehouse Manager screen
used by Procurement Operators
Mick Tolhurst using SAP
Warehouse Manager
The Expo shone the spotlight on a number of projects that
have evolved from ideas within the business to automate,
simplify or improve tasks using technology and achieve an
increasingly mobile plant.
Most of these projects utilised our ever-improving Wireless
Network (WiFi) and reduced waste and inefficiencies for
simple, repetitive tasks.
IT Technical Supervisor Dennis Moncrieff said the project
ideas came from all areas of the plant.
“Mobility is now being used in Carbon, Cast Products,
Maintenance, Liquid Metal and the Services departments,”
Dennis said.
“In fact, there isn’t an area of the plant that isn’t involved
in a mobile project of some form.”
The Internet of Things (IoT) is the network of physical devices
– vehicles, buildings, etc – embedded with electronics,
software, sensors and network connectivity to enable them
to collect and exchange data.
Attendees at the Mobility Expo
SPRING EDITION 2016 7
orders, asset information, drawings). This improves record-
keeping and gives maintenance crews live accessibility to SAP
maintenance systems and up-to-date work lists. It allows them
to track down parts as well as record and complete work on the
job without having to return to the office.
Live PLC adjustment in the field
Technical maintainers have also been equipped with mobile
tablets to give them access to all desktop systems while they are
in the field. Using the technology, technicians can now optimise
PLC settings at the site, meaning operators can see instantly if
the adjustments they are making are having the desired effect.
They are also able to do so with equipment operators present
to validate the optimisation.
Leave request – anytime, anywhere
This new mobile application allows all employees to request leave
when they are not on-site or in front of a computer. This shifts
accountability for leave entry from the supervisor to the employee
and allows for more accurate data in the payroll system.
ALPSYS on the go
The provision of buggies equipped with ALPSYS work station
capability in the pot room gives technical operators live access
to the control system. In doing so, workflow is more easily
planned, with live notification of abnormalities in the line saving
up to four hours of intervention time on each case.
ASH Tablet
Anode Stacking and Handling operators have previously been
able to monitor and control production from three limited sites.
This meant it wasn’t unusual for operators to walk between the
control room and a turntable six times to fault-find and correct
each problem, with every trip requiring walking up and down
six flights of stairs and more than 100 metres.
The mobile control station allows monitoring and control from
any location, saving travel time and labour intensity. It means
operators are also able to review and acknowledge alarms more
quickly, reducing downtime and correcting problems on the spot.
Pictured above, the Liquid Metal ALPSYS Buggy using tablet for
Pot feedback in the Potline instead of going back to office
TAKING LEAPS AND BOUNDS
8 SPRING EDITION 2016
MOBILITY TAKING LEAPS AND BOUNDS
F1 Citect Tablet
Portable Citect tablets allow F1 operators to control
equipment from anywhere a WiFi connection is available.
Benefits include:
• A reduced need to stop and leave the forklift to
manually intervene, in turn reducing equipment
downtime;
• A decreased risk of slips and trips by reducing the
frequency of ingress and egress events from forklift;
• Equipment troubleshooting and resetting can be done
at the source; and
• New opportunities offered by live video feeds of
equipment.
360° Camera
The use of a 360° camera puts Tomago Aluminium right
on the cutting-edge of site-specific training and creates
an immersive experience for trainees.
The camera allows trainees to be introduced to the
working environment and their potential interaction
with other plant equipment and vehicles without
exposing them to hazardous areas.
It also allows for review and critique of a trainee’s
performance once they have begun operating on the plant.
Our innovations that are in the pipeline include:
Approvals anytime, anywhere
This is a new mobile application that will allow supervisors
to approve all leave requests, purchase requisitions, DMS
documents and capital projects on any mobile device,
including phones. The new system reduces delays in
document/process approvals, and in turn, production.
GTC Citect Mobile Access
Still in the pipeline pending maximised WiFi coverage, this
will give users the capability of operating equipment in the
field with a mobile tablet, as opposed to operating in pairs
or returning constantly to the control room. Once rolled out,
the system will increase efficiency, improve response time
and increase capacity with less operators required.
FTA Tablets
This tablet application is being developed to enable FTA
operators to access their schedules, enter their work,
administration data and downtime via a paperless system.
Data will be live and centrally stored, removing double
handling of information and generating instant machine
reliability and performance data.
Anode Hauler Pre-flights
New anode haulers give us the opportunity to set the standard
with electronic pre-flight checks. In this light, we are developing
a tablet application to enable operators to check the pre-flight
electronically, with the data saved into SAP.
This will enable SMS and emailing of deficiencies and missed
checks to supervisors; and the future integration of issues
into the SAP notification/work order system to immediately
begin the issue resolution process.
Anode Hauler Pre-flight Inspection on Tablet
SPRING EDITION 2016 9
IT WAS ALL HANDS ON DECK AT THE FUME TREATMENT CENTRES (FTCS) RECENTLY FOR A MONUMENTAL CLEAN-UP ORGANISED BY THE BAKE OVENS TEAMS.
Called the Fun Time Clean-up (FTC) in honour of
the FTCs, the day brought together employees from
a range of areas within the department, as well as
a number of contractors.
The 5s system was used to identify redundant
material and manage the area to ensure it could
be well maintained into the future.
Carbon Manager Andy Robbins, said the day had
been very successful and had been followed by
a catch-up and sausage sizzle.
“It was really great to see the commitment from
people to ensure our work area is looking at its
best,” Andy said.
Good housekeeping leads to a more productive
and safe working environment.
A big “well done” to Megan Scollay, Martin Nicholls
and Kristy Gately from the Bake Ovens for organising
the clean-up, getting people on board and ensuring
bins, cleaning tools, equipment and PPE was available.
Fun time HAD BY ALL!
Sweeping the top level of FTC 1
Marek Bartczak, Ryan Bromley and Nicole Armistead cleaning up FTC 1
Sweeping behind FTC near the diesel fan
10 SPRING EDITION 2016
Tomago Aluminium has added another notch to the belt of records the business has broken over the past three years.Since 2012 the business has improved
annual output by more than 40,000
tonnes, taking production from 547,000
tonnes four years ago and heading
towards 590,000 tonnes in 2016.
This transformation has been no fluke.
The drastic improvement in anode
quality, combined with a step change
improvement in work standards, has
enabled Tomago to operate at world
benchmark level.
The plant-wide stability generated
through the focus on operational
drumbeat, along with the unwavering
commitment of our maintenance and
support crews, has also been a real
enabler for these results.
Booster engineer Darryl Frew said not
only was the business setting production
records month after month (in May, TAC
produced more than 50,000 tonnes), but
was doing so while also producing record
quality materials.
“Our average potline iron has improved
from 1213ppm in 2013, to 999ppm in
2015, to an annual average iron so far
of 957ppm in 2016,” he said.
Darryl said everyone at Tomago Aluminium
should be extremely proud of the way the
plant was being operated.
“Tomago Aluminium’s future is looking
bright and the journey ahead is one to
look forward to,” Darryl said.
BETTER QUALITYAND MORE OF IT!
EVERYONE AT TOMAGO ALUMINIUM SHOULD BE EXTREMELY PROUD OF THE WAY THE PLANT WAS BEING OPERATED.
SPRING EDITION 2016 11
LEADING THE WAYINGOT CHAIN AUTOMATION
Cast Products Operations (CPO) is breaking new ground with the implementation of the plant’s first comprehensive automation project.
Aimed at increasing
throughput, improving quality
and reducing the cost of
production, the Ingot Chain
Automation Casting system is
well on its way to becoming a
reality, with all the groundwork
laid, drawings finished and
engineering complete.
Automated Casting Project
Leader Erin Brown said the
implementation of the camera
monitoring systems was almost
finished and Ingot Chain 6 would
be initiated and commissioned
soon. The process would then
be rolled out to the remaining
ingot chains.
The automation at the casting
section of the ingot chains
optimises the existing
automatic features and
enables an automatic start
of the cast, automatic furnace
changeover, a camera system
for remote operation and an
increased launder depth.
The new system will also allow
for consistent, predictable
operation and consistency in
ingot size at the beginning of
the cast.
All four ingot chains will be
controlled from one central
control room by a team of
operators, minimising exposure
to hot metal and manual tasks
at the front end of the chain.
The camera will monitor all
phases of the operation,
including the hot metal aisle,
from the control room.
A recent visit by a team from
CPO to Boyne Smelter in
Gladstone QLD, where an
automated casting system is
already in operation, gave the
team a taste of things to come.
Erin said the trip had given
TAC operators a ‘real-life’
working perspective on
what could be expected and
provided the team with some
constructive learnings on best
practice and how the TAC
team could achieve the
highest standard of casting.
“It’s always a great opportunity
to visit other smelters and gain
a new perspective on how
different people and plants
operate,” he said.
“Our automatic casting project
will bring TAC into the future
and ensure we are at the
forefront of ingot chain
technology.”Shift 4 Ingot Chain Operator
Phil Bartlett at Boyne Smelter
Barry Gardiner and Andrew Ripley
inspecting launders at Boyne Smelter
The team at Boyne Smelter
12 SPRING EDITION 2016
Tomago Aluminium’s newly formed Health and Safety Committee recently came together for a highly successful training and planning workshop, held to assist members in their new roles.The committee, made up of
members from all levels and
departments across Tomago
Aluminium, was addressed
by an external trainer who
presented information about
the Work Health and Safety
Act, and the subsequent roles
and responsibilities of
committee members.
The information helped the
committee gain a clearer
understanding of the legal
framework of the Act, as well
as their Duty of Care to workers
at all levels of the organization.
The workshop highlighted the
key functions of an effective
health and safety committee.
Group activities, brainstorming
sessions, problem solving and
ideas on how to improve site
safety culture were also part
of the day’s activities.
Committee Chairman Neil
Lindus said the workshop
resulted in some great ideas.
“It set the ball rolling on new
goals we are setting to ensure
the committee can be more
involved than ever in supporting
everyone and creating a safer
place to work,” Neil said.
“The committee will keep
everyone informed about
future events and promotions
at which we can share
information and ideas across
the business.”
The committee includes:
Neil Lindus
Dan Lines
Trish Rapley
Neil Morgan
Nat Godwin
Andrew Shadwell
Greg McLoughney
Grant Duggan
Phil Carpenter
Ben Henshaw
Johan Kruger
Liam Sims
Tim Mason
Brad Hickey
Daran Emmett
Greg Kinniard
Simon Mitchell
Mark Westbury
Mal Muddle
HEALTH & SAFETY COMMITTEE
TRAINING DAY A GREAT SUCCESSBEATING THE
WINTER BLUESMood boosting during the winter chill was the idea
behind handing out Winter Care Packages recently.
Employees have been well armed for the cold with these
special Winter Care Packages filled with goodies and advice
to help keep the blues at bay.
Handed out during International Men’s Health Week, the
packages included items intended to boost the mood and
keep the winter chill away.
The Winter Care Packages contained the Mates Looking After
Mates beanie, a soup/coffee mug, a sachet of either porridge,
soup or hot chocolate, hand sanitiser, tissues and hints and
tips on staying well and healthy during the cold months.
Executive Assistant Nicki Harvey said the packages were
‘happily received’ on two ‘very chilly mornings’.
“It’s been great to see so many people wearing their beanies!”
Pictured below are (from left) Anthony “Cookie” Cook, Gordon
Wilson, Nicki Harvey, Leigh-anne Ruch, Nigel Shalimov and
Peter Roberts.
Pictured above are (from left) Phil Carpenter, Simon Mitchell, Greg Kinniard,
Johan Kruger, Neil Morgan, Trish Rapley, Tim Mason, Neil Lindus, Greg
McLoughney, Dan Lines and Ben Henshaw
SPRING EDITION 2016 13
Congratulations to our employees celebrating milestone years of service from May to the end of August 2016.
10 yearsMitchell Keen Liquid Metals
Steve Dines Cast Products
Matthew Hession Carbon
Kate Curtis Business Services
Wayne Rigelsford Carbon
20 yearsPeter Petryk Liquid Metals
Andrew Auchterlonie HSEC
Neville Crompton Cast Products
Bradley Mace Cast Products
25 yearsDaryl Stirrat Maintenance
30 yearsLarry Hickey Cast Products
Grant Ellis Carbon
Brett Mason Liquid Metals
CELEBRATING
YEARS OF SERVICE
JEEPERS CREEPERSWHERE’D YOU GET THOSE PEEPERS?Innovative redesign of peephole covers in the Bake Ovens
is set to save Tomago Aluminium $100,000 annually.
There are about 4,000 peephole covers across the three bake
ovens, half of which need to be replaced every year at a cost $150
each. Two major failure components of the previous covers were
the gasket replacement and the internal cylinder, which together
were worth almost half the entire cover price.
Carbon Process team members Francois Ordronneau and Ryan
Bromley broke down the design and came up with a new cover
that required significantly less metal, reducing the cost of each
cover by $100. By removing the bottom metal plate, which
was preventing more than one refurbishment of each cover,
the design allows for in-house casting, as well as an easy
system of replacing the gasket in-house.
The Refractory team was an integral part of this project, adding
the job to their core work and delivering a constant supply to the
Bake Ovens.
Hand-in-hand with the new covers came the design of a casting
table to facilitate the production by the Refractory team of 24
moulds at a time.
Bake Ovens Improvement Leader Megan Scollay said the new
design allowed for an innovative way to reduce costs by bringing
casting of the peephole covers in house.
“This cost saving could not be achieved without the help of our
Refractory Team. Thanks to everyone who worked on this project,
from the initial design, table design and the casting of the
peephole covers!”
Refractory team members Garry Beaven (far left) and Matthew Wind (third from right) in the process of casting new peepholes using the custom moulds and casting table.
14 SPRING EDITION 2016
MAINTENANCE REVOLUTION
PTA 12 WEEKLY INSPECTIONS
PLC ADJUSTMENT ON INGOT CHAIN
The introduction of mobile tablet devices at Tomago Aluminium provides valuable in-the-field access to SAP and plant control systems for maintenance.Our Recent SAP upgrade included the
implementation of a product called SAP
Work Manager (SWM). This SWM is a
software application for accessing and
using SAP on mobile devices. It supports
maintainers by providing access to SAP
whilst on the job and in the field and so
improves access to information for the
maintainer both for inspection and
breakdown work.
With the mobile tablet, the maintainer can
immediately access information about the
job as well as logging and recording the
problem, repair or inspections on SAP
notifications and Work Orders. Using SWM
a SAP notification can be created in the
field including attached photos. A Work
Order can be accessed for viewing work
instructions, making component reservations
and completing work as it is done.
The roll-out of mobile tablets with SWM
has begun by assigning a small number
of tablets to an initial group of maintainers
to seek, test and share their experience.
Some new advantages are already being
discovered and the plan is to continue to
capitalise on the advantages of mobile
devices in conducting maintenance
functions.
Maintenance Process and Systems
Leader Peter Philipson said the SWM
mobile tablets used for SWM have the
computing power at least equivalent to
the desktop PCs and the increased WiFi
coverage across the site had been a
“game changer” for tablet users.
“The PC power capability of the tablets
and the increasing WiFi coverage of the
plant has meant a maintainer can access
the maintenance systems directly from
the tablet in most areas of the plant,”
Peter said.
“This has meant additional to SWM on the
device, most of the PC applications can be
used on the tablet in the field as the job is
being done. We have seen early gains from
this mobile PC access”.
Peter said the rollout was off to a fantastic
start, and next steps included:
• ramping up access and usage to more
maintainers
• widening the WiFi coverage allowing
usage in all areas and workshops
• discovering and sharing mobile
capability advantages
• helping each other on the culture
and mindset changes.
Mick demonstrating the
SWM tablet in the workshop
Scott Bubb goes mobile
Scott Bubb at desktop PC
Mick Jackson working at desktop PC
SPRING EDITION 2016 15
Tomago Aluminium has
successfully implemented a
leading-edge, plant-wide SAP
(System Applications and
Products) upgrade, bringing
with it efficiencies and
streamlined processes to keep
the business competitive and
at the forefront of system
technology in the years ahead.
Commissioned after eight
months of planning by the
13-strong project team, the
upgrade was the result of a
partnership between Tomago
Aluminium and specialist SAP
company UXC Oxygen for
both the delivery and
maintenance of the new
cloud-based solution.
Thanks to cooperation across
the site to enable April end-of-
month to occur on a Sunday
(the first time ever at TAC), the
upgrade went live as planned,
followed closely by the
implementation of the new HR
learning management system
(Success Factors). Both
projects were delivered on time
and jointly under budget.
SAP Upgrade Project Manager
Lesley Anne Clifton said the
previous system had been
working hard for the business
for 10 years, but had started to
slow down in the last couple.
“The old systems were all
in-house, so we took a huge
leap of faith when we decided
to move to a Partner Managed
Cloud (PMC) partnering with
UXC Oxygen. I believe
cloud-based systems are the
way of the future and we need
to be on the front foot with our
technology,” Lesley Anne said.
“The TAC project is the largest
implementation of this
technology in Australia to date.”
Where new functionality was
being introduced, training was
rolled out over the site and the
change-over occurred almost
seamlessly, with minimal
issues and minor defects, none
of which interrupted work flow.
New functionality of SAP
includes Warehouse
Management, which now
occurs in real time; Simple
Finance; Employee/Manager
Self Service; and SAP Work
Manager, which has also been
rolled out on mobile devices.
SAP Work Manager has been
rolled out to a pilot team of 13
users, with plans in place to
expand to another 145 users.
Lesley Anne said that the
project team had worked
tirelessly, spending from
October last year to May this
year in an isolated demountable
on-site working on the project.
“While we had a core project
team, we often had to call upon
other subject matter experts in
the business and I’d really like
to thank everyone who put
so much time and effort into
making the project a success.
We now have a leading-edge
system that will keep the
business on the front foot
for years to come,” she said.
The core project team included:
• Lesley Anne Clifton
• Charmain Underwood
• Amanda Gill
• Janelle Daley
• Steve Macnamara
• Donna McCormack
• Peter Philipson
• Steve Mahoney
• Zoran Grabic
• Deborah Chen
• Tom Miller
• Ian Macdonald
• Dennis Moncrieff
A BRAVE NEW SAP WORLD
THE TAC PROJECT IS THE LARGEST IMPLEMENTATION OF THIS TECHNOLOGY IN AUSTRALIA TO DATE.
The Project Team in the SUP demountable
The Project Team on-site
16 SPRING EDITION 2016
Four intrepid TAC employees had the time
of their lives off the beaten track again this
year during the 2016 Variety NSW Bash.
Supported by Tomago Aluminium, which has
generously supported the event for many
years, our very own Tony Lewis, Rod Lewis,
Peter Roberts and Vic Cochrane hit the high
road again in May for the annual event.
The Variety Bash (in support of Variety –
The Children’s Charity), is an adventure that
takes friends and families driving pre-1976
cars through regional NSW to isolated
places not often visited.
Designed for those with a sense of humour
and adventure, who love cars, don’t mind
getting a little dirty and want to make a
difference to the lives of Australian kids, the
Variety Bash takes participants through tiny
outback towns, where children and families
line the streets to enjoy the spectacle.
TAC Security’s Tony Lewis said this was his
tenth year on the Bash, and as far as he
was concerned, the more ‘dirt and mud
involved, the better’.
“It’s always such a great experience, but the
most important thing is helping the kids,”
Tony said.
“I always come away from the event feeling
incredibly humbled and rewarded.”
Tony drove car OV8 First-Aid with his
brother Rod, who has completed 11 bashes.
Vic Cochrane and his wife Brooke took to
the road in Car 8 – a Hillman Minx; while
Peter and Jacquie Roberts, who were on
their first Bash with a couple of friends,
were in Car 1½ – a Mercedes station wagon.
After experiencing two days of mechanical
problems, Peter and his crew really got into
the swing of things and won an award for
the Most Enthusiastic Virgin Bashers.
Tony said he became involved with the
Bash after going and seeing a retired TAC
workmate (Laurie Reiffel) off when he
participated.
“It always looked so exciting and in 2007 I
was asked by Newcastle Variety to help out
as an official. I’ve been hooked ever since,”
he said.
“The track takes you into outback NSW to
places you’d probably never go otherwise
– tiny towns with little schools and very
small populations.
“Nearly the whole town turns out to see the
cars drive by, and of course we stop along
the way to visit schools and spend some
time with the kids.
“It’s an incredible experience and I’d like to
say a big thanks to Tomago Aluminium – the
company has always supported the Bash
and we are very grateful.”
The 2016 Variety Bash travelled more than
2,700 kilometres through regional NSW,
making more than $40,000 worth of pledges
to rural schools and families with sick or
disadvantaged children. In total, the event
raised more than $850,000.
Tony and Vic will take it up a notch at the
end of October for the 2016 Newcastle
Variety Postie Bike Dash. The event sees
50 CT110 Honda’s travel more than
1,300kms around regional NSW raising
funds for children.
BASH FOR CASH ALWAYS A
WINNER
Vic Cochrane, Rod Lewis, Tony Lewis
and Peter Roberts
Peter and Jacquie Roberts with their support crew
Peter and Jacquie Roberts in Car 1½
SPRING EDITION 2016 17
DID YOU KNOW TOMAGO EMPLOYEES HAVE ACCESS TO A UNIQUE RANGE OF CORPORATE HEALTH CARE COVERS WITH HCF?
New members to HCF or other fund members that transfer to HCF who take out hospital and extras cover will have the usual 2 and 6 months waiting periods waived on over 20 health benefits.
This means no waiting for:
• DENTAL CHECKUPS, SCALES, CLEANS,
FLUORIDE TREATMENTS AND FILLINGS;
• EYEWEAR, INCLUDING FRAMES,
LENSES AND CONTACTS;
• PHYSIOTHERAPY, CHIROPRACTIC, GYM
MEMBERSHIPS AND REMEDIAL MASSAGE
AND MORE.
Tomago employees looking for more information can contact their HCF Corporate Sales Representative Jeff Bell on 0414 559 735 or [email protected]
DID YOU
KNOW?
Special Offer to all Employees of Tomago Aluminium.
HCF has developed a new range of unique corporate products for our corporate
partners and they are available now.
Take out HCF hospital and extras cover through your HCF Corporate Sales
Representative before 30th April 2015 and he will waive the usual 2 & 6 month
waiting periods on over 20 health benefits.
Contact me today and enjoy the benefits of HCF cover straight away! You can claim immediately on over 20
Dental checkups, scales, cleans, fluoride treatments and filings.
Eyewear, including frames, lenses and contacts.
Physiotherapy, chiropractic, gym memberships and remedial massage.
And more much more.
Offer only available to new members taking out Hospital and Extras cover. Waiver does not apply to waiting periods of
more than six months, including 12 months for pregnancy and birth-related services, pre-existing ailments and
conditions. Psychiatric, rehabilitation and palliative care services, which have a two month waiting period, are also
excluded from this offer.
You get more with HCF
Not-for-profit
Consistently returns more in benefits
Save on hospital excess payments
Save with more fully covered services
FREE health coaching
WHAT IS YOUR CURRENT ROLE?Cast House Shift Fitter.
FINISH THIS LINE: WHEN I’M NOT AT WORK... I’m annoying someone,
somehow, somewhere
– it’s my specialty.
IF YOU HAD $100 TO SPEND ON YOURSELF WHAT WOULD YOU DO WITH IT? Spend it at a nightclub with my
mates, you know the places
where your feet stick to the
floor from all the spilt drinks,
and they are pumping out
retro tunes like crazy (they’re
the best clubs).
BIGGEST REGRET?Not taking up my singing
career in Tokyo karaoke bars.
Just kidding, not learning more
languages, I like to talk.
FAVOURITE FOOD?Any Asian food, especially
with seafood or the magical
animal (pork).
WHAT WERE YOUR FIRST THOUGHTS OF TOMAGO?Big place, how am I going to
meet everyone here! I have
given it my best shot though.
WHAT’S THE BEST PIECE OF ADVICE YOU’VE BEEN GIVEN?Laugh every chance you get
and live life to the second,
it could be your last.
Aluminium FactAluminium powder was used as the primary fuel for the
space shuttle’s solid rocket boosters.
NAT Godwin
18 SPRING EDITION 2016
IT IS THE FOCUS ON UNDERSTANDING WHAT HAS TO BE DONE AND WHEN – UNDERSTANDING THE HAZARDS AND RISKS INVOLVED AND WORKING TO MITIGATE AND CONTROL THOSE RISKS – THAT UNDERPINS A WHOLE OF LIFE APPROACH TO SAFETY.
WorleyParson-Tomago Engineering Alliance
Years of detailed planning,
education, training and
teamwork culminated in a
significant safety milestone in
April for the engineering alliance
between WorleyParsons and
Tomago.
The team celebrated six years
of engineering-based and
construction projects at
Tomago Aluminium without
a recordable injury, a
remarkable achievement
given the complex and often
hazardous nature of its work.
SIX-YEAR SAFETY MILESTONE
The Engineering Alliance
has delivered 700,000 hours
of site-based project work
(including construction),
including high-voltage
switchyard work; working
at heights on stacks and
towers; working in confined
spaces; and around-the-clock
support of TAC’s 24/7
operation.
Engineering Manager Brian
Crossingham said safety was
of paramount importance to
the team.
“This is a great achievement but
what we are also celebrating is
all the hard work, planning and,
very importantly, our teamwork
with Operations, Maintenance
and the TAC contractors that
goes in to make a result like
this possible,” Brian said.
“Safe delivery of projects does
not happen by itself or at any
single phase of a project – it
is built in from the very start
in the way projects are
conceived within the business
and the approach to safe
operations; how safety is
designed into equipment and
installation construction
processes; how access and
outages are planned; how we
engage the right people at the
right time to deliver a safe
installation; and how that
installation is operated and
maintained safely for years
to come.
“It is the focus on
understanding what has
to be done and when –
understanding the hazards
and risks involved and working
to mitigate and control those
risks – that underpins a whole
of life approach to safety.”
Brian said the milestone
could not have been achieved
without the leadership of
Construction Manager Mick
Byrne and his team of
construction coordinators,
as well as the ‘high level’ of
cooperation and teamwork
established with key
contractors which include
Downer Electrical ; Rabcon;
Rig; Programmed Facility
Management (Thomas and
Coffey); Fives (ECL); Boom;
and Instant Success.
Tomago Aluminium CEO Matt
Howell congratulated the team
and said the alliance was highly
regarded by Tomago
Aluminium management.
“The team is a valued partner
in our success and this is a
first-class effort from a team
that knows the very essence
of Mates Looking After Mates,”
Matt said.
Brian Crossingham, Matt Howell, Simon Mitchell and Mike Philipson
SPRING EDITION 2016 19
Congratulations to Peter ‘7’ Horsburgh, Tomago’s Reliability
Engineer on his achievements at the Australian Light Aircraft
Championships.
Formation team members Dave Kunkel, Peter Horsburgh and
Gordon Southwood took out gold in the formation flying event.
Peter also won bronze in the forced landing event and ended up
taking out the overall championship. It has been 23 years since a
Royal Newcastle Aero Club member won the overall championship.
LIGHT AIRCRAFT
CHAMPIONS
Beyond Blue, Life Line and the Special Olympics are just a few of the organisations
receiving support from Tomago Aluminium during April to July this year.
Tomago donated over $11,000 to 12
organisations during the period taking
the yearly tally to over $20,000.
Tomago’s HR Officer Keiran Turner said
the sponsorship program was Tomago’s
way of giving back to the community.
“Each year we support local charities and
community groups that are trying to help
the less fortunate in our community. This
is one of the ways we like to give back
and it’s always fun to get involved and
see the great outcome for these
organisations,” Keiran said.
If you have a worthwhile charity that
needs support contact Keiran Turner
on 4966 9293.
beyondblue
Shane Newell Golf Day
Immune Deficiency Foundation Australia
Variety the Children’s Charity
Mt Kanwary Public School
Mark Hughes Foundation
Life Line
Mattara Festival
Hunter Valley Research Foundation
Stroke & Disability
Special Olympics Sponsorship
City2Surf
Personnel Personnel Area Date
Steven Mulley Rodded Anodes Operations 04/04/16
Alexander Deacon Maintenance 18/04/2016
Danielle Beale Rodded Anodes Operations 02/05/2016
Taylor Callen Human Resources 09/05/2016
James Malley Cast Products 09/05/2016
Craig McIntosh Cast Products 08/06/2016
Personnel Personnel Area Date
Mitchell Fulton Cast Products 14/06/2016
Kenneth Felton Cast Products 14/06/2016
Andrew Darr Maintenance 04/07/2016
Dean Pond Maintenance 11/07/2016
Shannon Szmynec Rodded Anodes Operations 08/08/2016
WELCOME TO TOMAGO’S NEW STARTERS
Tomago’s Giving Back
Shane Newell Golf Day
beyondblue Blue Tie Ball
20 SPRING EDITION 2016
Tomago’s Key Performance Indicators
41,000
40,000
42,000
43,000
44,000
45,000
46,000
47,000
48,000
49,000
50,000
51,000
52,000
p
2014 2015 Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Oct-16 Nov-16 Dec-16 2016YTD
Jul-16 Aug-16 Sep-16
Yearly ActualEffective Metal Production (Tonnes/Mth) Monthly Actual 2016 Budget
47,002
48,376 48,913
49,32949,639
48,137
50,130
48,567
50,139
46,482
The Effective Metal Production is the total amount of hot metal tapped from the pots. It includes both hot metal tonnes delivered to Cast Products plus any reclaimed cold metal.
Energy Consumption measures how much power we use to make one tonne of aluminium. The lower this number the better!
13,250
13,300
13,350
13,400
13,450
13,500
13,550
13,600
13,650
13,700
13,750
2014 2015 Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Jul-16 Nov-16 Dec-16Aug-16 Sep-16 Oct-16 2016YTD
13,800
13,850
DC Energy Consumption (kWh / tAl)
13,900
Yearly Actual Monthly Actual 2016 Budget
13,535 13,522
13,600
13,57313,553
13,565
13,610
13,525 13,528
13,494
17
15
0
2
4
6
8
10
12
14
16
18
DC
kW
h/t
Al
20
22
24
26
28
30
2014 2015 Jan-16 Feb-16 Mar-16 Apr-16 May-16 Jun-16 Jul-16 Nov-16 Dec-16Aug-16 Sep-16 Oct-16 2016YTD
Hazard Event Ratio Yearly Actual Monthly Actual 2016 Target
19 19 19
24 24
19
18
16
The Hazard Event Ratio measures the number of injuries in proportion to the number of safety related events.