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