Challenges and Issues, Human Resources and Trends

OPERATIONS AND LOGISTICS IN PRACTICE

PRODUCTION

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Vertically Integrated

Organisation

• Billet caster overproduction

(750,000 tonnes p.a.)

• Rolling mill bottleneck

(400,000 tonnes p.a.)

• No domestic competition

MAINTENANCE

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Weekly maintenance

program

• 24 hour minimum

shutdown for Electric

Arc Furnace (EAF)

• Breakdown issues

MAINTENANCE

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Cleanup time for

Ladle Furnace

spillage- 27 hours

• Heavy maintenance

on furnace every few

years

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Strict Safety

Requirements

• High risks with heat,

fire and explosive

elements

• Noxious fumes

• Noise emissions

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Dealing with metal in

several stages- crushed

scrap, liquid, hot slag,

hot billets, cold steel

• Hazardous toxic

contaminants-lead,

copper

• Personal Protective

Equipment (PPE)

LOGISTICS

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Single use trucks for

inbound and outbound

transportation

• Export of excess billets

to Newcastle mill

• Inbound scrap quality

control

• Warehousing of

materials

MARKETING

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

REGULATION

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Council refused original

application in

September 1988

• Land and Environment

Committee appeal

• Strict Environmental

Regulations

ENVIRONMENTAL

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Air filtration of lead dust

and other contaminants

• Water treatment

• High power

consumption

• Carbon emissions

FINANCIAL

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Business cycle effect

(Boom, downturn, bust)

• Interest Rate charges

• Infrastructure

investment

• Ongoing maintenance

costs

FOREIGN

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• China and SE Asia

competition

• Currency exchange rates

• Offshore suppliers for

manufacturing equipment

OCCUPATIONAL HEALTH & SAFETY

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• Achieved with ‘zero’ work-related incidents

• Continually improve health and safety performance

• Comply with applicable health and safety laws

• Identify hazards, assess, control and monitor risk measures, and implement the appropriate mitigating actions

• Management of risks in the workplace

TRAINING AND DEVELOPMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• High investment in

training

• Graduate program- 2

years

• Mentor program

• Low turnover of staff

BENCHMARKING

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

• a

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander

WORKING ENVIRONMENT

Michael Monteleone, Vijayanarayana Karigiri, Michal Buchowiecki, David Alexander