Abstracts - Management Issues Track
Click on the abstract title to see the author name(s) and description.
| MI017 Extrusion Optimization at the Profile Level |
MI101 Breakthrough Sustainable Innovation: The Journey behind the Development of a 90-Minute Fire Rated Door |
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| MI018 A Self Planning Matrix for Extruders - Benchmarking Extrusion Operations |
MI112 Modern Maintenance Concepts: Strategic Approaches, Benefits and Trends |
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| MI019 What Matters? Pixie Dust is Not an Extrusion Optimization Strategy |
MI113 Efficient Recycling |
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| MI021 From Past to Present in the Extrusion Industry: A Personal Family Story of 100 Years |
MI133 Past, Present and Future Safety Hazards in the Extrusion Industry |
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| MI041 Aluminum Extrusion Sales Price Determination & Process Monitoring |
MI167 Use of Manufacturing Execution Software in the Aluminum Extrusion Industry |
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| MI049 Die Shop Management and Its Location |
MI176 Paperless Production: the Benefits of Two-Way Real-Time Communication within the Plant |
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| MI052 ADAM - Advanced Data Acquisition & Management |
MI183 Benefits of Integrated Extrusion-Specific Quoting |
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| MI065 BENCHMARKING |
MI191 Innovative Approaches to Occupational Health and Safety Management Systems by Select Extrusion Companies |
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| MI071 Green Aluminum Extrusions - Breakthrough Development in Sustainability from UAE to the World |
MI192 To Cast or Not to Cast, That is the Question |
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| MI076 A Novel Methodology for Optimization of Properties, Costs and Sustainability of Aluminum Extrusions |
MI197 Defining Our Modern Metal |
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Extrusion Optimization at the Profile Level Craig R. Werner, Kaiser Aluminum, USA
The author has written extensively regarding optimization techniques for the aluminum extrusion industry, in ET ’08, ET ’12, Light Metal Age magazine and other venues. These techniques are proven in industrial settings. Many of the past optimizations focus on the global optimizations possible through evaluating multiple profiles, for equipment decision support, corporate asset capacity utilization/cost (linear programming), log length optimization, etc. The new optimization technique is more locally focused on the profile (local optimization), answering the question: “On what press should this profile be tooled, with what number of holes, using what run practice in order to minimize the $/lb conversion cost? If this isn’t desired, what would be the next most beneficial decision?” The model is based on the concepts disclosed in the author’s 2012 Management Issues award-winning paper (“Is Operational modeling Worth the Effort?”) dealing with equipment decision support and optimization. In this case however, the model is equipped to evaluate which of 12 different possible presses, with which of 12 different number of holes and 7 different run practices (1 billet per runout, ½ billet per runout, 2 billets per runout, etc.) will provide the optimal solution. A Self Planning Matrix for Extruders - Benchmarking Extrusion Operations Craig R. Werner and John A. Funai, Kaiser Aluminum, USA
The authors have developed a classification/self-planning matrix to facilitate assessment, rating, understanding and communicating how extrusion operations are set up and operated. The system currently utilizes a series of 42 “Attributes”, each of which is given an Importance Rating and is then given a Rating based on a set of Descriptions for each attribute, which would suggest a particular rating. The attributes are associated with seven Categories (Safety, Quality Systems, Data, Extrusion Tooling, Extrusion Process, Equipment and Miscellaneous), which gather the effects of the 42 attributes, subcategorizing the effect that they have on the seven categories. Management systems such as this help extruders to internally, and to a degree externally, benchmark their operations and can help them to understand and focus on the portions of their company requiring additional focus, guiding them to specific attributes to improve, depending on their goals. What Matters? Pixie Dust is Not an Extrusion Optimization Strategy Craig R. Werner, Kaiser Aluminum, USA
Aluminum extrusion is a complex system defined and influenced by the profile, equipment, customer requirements, quality and process requirements, and other characteristics. Extrusion equipment can be expensive and competition with other extruders and materials drives the need for optimization. This paper combines the “What If” modeling techniques of the author’s ET2012 Management Issues award-winning paper (“Is Operational Modeling Worth the Effort?”) with a philosophical review of how to best manage extrusion operations, as well as incorporating connections to the Aluminum Extruders Council’s 2013 “Key Indicators Report”. The author synthesized performance metrics from the Key Indicators Report and utilized a previously modeled extrusion operation to set a base profile “mix”. Profile scrap requirements and extrusion velocities were adjusted to achieve the results for a “typical” and “90%” 8-inch press from the study. This model was then used to show the productivity, yield and resultant total cost effect of modifying various process and equipment parameters, bridging the gap from the “typical” to the “90%” extruder, answering the question “What Matters?” From Past to Present in the Extrusion Industry: A Personal Family Story of 100 Years Yair Levin, Profal Ltd., Israel Aluminum Extrusion Sales Price Determination & Process Monitoring Markus Dobler, Manufacturing Consulting Establishment, Principality of Liechtenstein Die Shop Management and Its Location Sutanay Parida, Taweelah Aluminium Extrusion Company (TALEX) LLC, UAE
Every successful extrusion company is backed up with successful die shop performance. Being the heart of the process, the die shop plays a major role in whole company performance. Die shop management can be broadly divided into:
If all the above points are collectively taken in to consideration and worked-out in such a manner, a cross-link function can be established which will ultimately result in a cost-effective die shop. Location of the die shop is equally important, especially in large companies. In conventional die shops the etch tank is located inside the die correction shop. To have better access to the Waste Water Treatment Plant (WWTP), it is always advisable to locate the pickling shops closer to WWTP. Location of the die correction shop is usually closer to the press. This creates a logistical issue and has a substantial impact on the dies and die shop performance. Optimum organizational management of the die shop will result in the lowest cost die production. Gulfex has developed and proven that die shop organization, streamlined procedures and work instructions provide the lowest cost options.
ADAM - Advanced Data Acquisition & Management Davide Turla and Luca Fogliata, Turla srl, Italy BENCHMARKING Roger A. P. Fielding, BENCHMARKS and The Virtual Company, Inc., Canada
Although the practice of competitive benchmarking is attributed to Rank Xerox who,in 1976used it to reduce overheads, improve quality, and speed new copying machines to market, Alcan's European extrusion businesses already employed a system of competitive benchmarking that was presented to and adopted by the Company and its affiliate extrusion operations in 1969. During the following 25 years the company's extrusion businesses developed and expanded the monthly exchange of press data and, at the periodic meetings of teh Extrusion Business Center managers, added comparisons of financial, employment and operating costs pertaining to their die making, extrusion, finishing, and recycling operations. The author employed benchmarking in teh selection of the CAD/CAM systems that linked Alcan's Canadian customers to product and shape design, die design and manufacturing in 1977. And later, the author used benchmarking in the design of a remelt and casting system producing up to 90 million pounds of 120 combinations of alloy and billet diameter annually – just -in-time. From January 1987 – as manager, extrusion technology – the author applied competitive benchmarking in over 100 workshops, operations audits and technology reviews involving over 1000 managers, technical and operating staff. By 1994, when Alcan exited the business, the practice had shown how to improve the performance of 43 extrusion businesses located in 20 countries worldwide. BENCHMARKS was formed that same year, 1994, with the name being suggested by Colin Jardine, then president of Alcan Price Extrusions Limited located in Calgary, Alberta, Canada. This paper discusses the benchmarking of extrusion and related operations. Green Aluminum Extrusions - Breakthrough Development in Sustainability from UAE to the World Modar AlMekdad, Mansoor Ali Khan, and Arvind Kumar Sivakumar, Gulf Extrusions Co. LLC, UAE
This paper will showcase our journey with Masdar Green City, Abu Dhabi UAE, where we embarked together to actively develop sustainable building materials and processes to reduce the total carbon footprint of aluminum extrusions and provide a replicable commercial resource. The paper will demonstrate how we worked with the Masdar Supply Chain team to analyze the entire product life cycle of aluminum extrusions in particular. This involved extensive studies where carbon savings can be made, analysis of more efficient production processes, logistic plans, producing locally wherever possible and by introducing more recycled material and renewable energy into the production process. The objective was clear - to find a sustainable material of choice which will have low carbon emissions and less embodied energy consumed for production. The Middle East region posed a very interesting challenge for us to embark on this journey - Low energy costs which supported extraction and production of aluminum in the region and lack of available aluminum scrap segregation centers to secure post-consumer/end of life aluminum. In this abstract, we will showcase the process, supply chain strategy, alloy strength study of recycled aluminum and the meticulous steps taken by our Research team to identify the right production strategy for “green” aluminum extrusions. Furthermore, we will highlight the life cycle analysis study we conducted using a third-party agency to verify the methodology used and validate the efforts into developing “green” aluminum extrusions. A Novel Methodology for Optimization of Properties, Costs and Sustainability of Aluminum Extrusions Ole Runar Myhr, Hydro Aluminum, R&D; Rune Østhus, SINTEF-Raufooss Manufacturing; Jostein Søreide, Norsk Hydro, Corporate Climate Office; and Trond Furu, Norsk Hydro, Corporate Technology Office, Norway This paper describes an innovative methodology that has been developed for optimization of product properties, production costs and environmental impact in fabrication of aluminum alloys. The main idea is to represent each operation along the process chain by predictive models, which include material, mechanical, cost and sustainability models. A multi-objective optimization platform is used to combine the models into a common software environment, which allows fully automatic simulations to be carried out. The optimization tool runs the models in sequential iterations until user-defined acceptance levels on properties, costs and sustainability indices are obtained. In this paper, the methodology has been applied for fabrication of 6xxx series aluminum extrusions. As a demonstration of the practical relevance, the software tool was used to optimize mechanical properties and electrical conductivity by manipulation of microstructure characteristics like grain structure, precipitates, dispersoids and solid solution concentrations. At the same time material and production costs, as well as emissions of CO2, along the value chain were kept at minimum levels. The models used for these optimizations range from physically based material models and Finite Element (FE) codes, to models for raw-material and processing costs as well as CO2 footprint. Breakthrough Sustainable Innovation: The Journey behind the Development of a 90-Minute Fire Rated Door Modar AlMekdad and Arvind Kumar Sivakumar, and Gulf Extrusions Co. LLC, UAE
Globally, approximately 6 million people are seriously injured in fire accidents per annum and more than 500,000 die. Approximately 80- 85% of deaths are mainly due to smoke inhalation and not by burns. The smoke kills faster than fire. Studies from recent fire incidents have shown that 57% of people killed in fires are not even in the room of the fire's origin. There has also been an increase in the fire incidents in the Gulf Cooperation Council (GCC) region where the entire façade had been burned down. We had to address this problem and decided to engineer a solution which can be sustainable, locally available and easily sourced. The challenges were obvious, aluminum is conventionally understood as a metal which deforms at about 600°C and the air temperature during a fire can reach up to 900°C in a room. However, aluminum has significant properties such as lightweight, recyclable and high strength-to-weight ratio. These properties cannot be achievable in any other metal. So we had to design a system that had to be innovative and had to maintain the integrity for at least 60 minutes. In the paper, we will show how we had to maintain the integrity of the door in temperatures of 900°C by designing two special barriers -- internal and external. Both needed to be highly insulated in order to prevent the heat and smoke to transfer from inside to outside. The design had to function as an entire system and maintain its integrity for more than one hour under conditions of extreme fire and smoke. Further, in the paper we will explain the process in conducting the fire test and the results which had come through as per the British EN Standards. The system eventually passed a fire rating of 90 minutes. This is indeed a breakthrough development as now we are able to present the aluminum door as a sustainable fire-rated material of choice and replace the use of non-sustainable fire-rated material such as stainless steel and wood. Modern Maintenance Concepts: Strategic Approaches, Benefits and Trends Jim Gates, SMS Technical Services LLC, USA
Extrusion presses have to be able to withstand severe mechanical stress, while simultaneously achieving the highest possible productivity and product quality levels. Regular maintenance is of major importance to ensure that the machine produces consistently. However, direct maintenance costs add up to several billion dollars per year. Thus, those responsible for modern maintenance management are constantly challenged by the necessity for high plant availability, well-trained and knowledgeable personnel, and cost-conscious behavior. The right strategic mix is vital to overcome this challenge successfully. This paper attempts to exemplify effective methods of modern maintenance, such as Reliability Centered Maintenance (RCM), Total Productive Maintenance (TPM) or Lean Management. Benefits, current trends and the implementation of a modern maintenance strategy for extruders will be evaluated in more detail, as well as the possibility to measure its success with the help of previously defined Key Performance Indicators (KPIs). Efficient Recycling Roger A. P. Fielding, BENCHMARKS and The Virtual Company, Inc., Canada
In 2013, about two million tons of aluminum scrap requiring the expenditure of 28TWhrs of electricity—more than the annual capacity of the Canadian generators at Niagara Falls, was exported from North America. Recycling that quantity of aluminum requires about five percent of the energy, or 1.4TWhr. And, much of that scrap was undoubtedly suitable for recycling into extrusion log. Large systems exist to efficiently recover the heat generated when recycling shredded aluminum cans. But, the systems used for recycling coated extrusions tend to be relatively small, and questions surround the alternative methods employed for processing this contaminated scrap. Although there has recently been a dramatic rise in recycling of clean extrusion scrap, inefficient practices are still employed in many recycling centers. Time and energy are wasted handling and charging extrusion scrap into furnaces, in attempting to recycle scrap by submerging it in molten aluminum, and specifically when employing casting furnaces as 'melters'. Little use is made of electromagnetic stirring to reduce melt times. Modern furnace construction, and particularly modern charging systems, extend the time between major repairs. But poorly engineered furnace strcutures and doors, improper selection and operation of regenerative burners and recuperators add to downtime. Opportunities exist for delivering recycled products just-in-time without inventories. Past, Present and Future Safety Hazards in the Extrusion Industry Alex W. Lowery, Wise Chem LLC, USA Use of Manufacturing Execution Software in the Aluminum Extrusion Industry John Stenger, Foy, Inc., USA
Continuing advances in computer technology require extruders to stay up-to-date on their Manufacturing Execution Software in order to remain competitive. As an example, newly enhanced features and capabilities of the EPICS software from Foy Inc. will be reviewed. This paper will highlight the latest upgrades, demonstrating how new technology such as handheld devices, wireless equipment, and touchscreens can be used in the modern extrusion facility. Interfaces with third-party and customer-designed applications will be described. Paperless Production: The Benefits of Two-Way Real-Time Communication within the Plant Kevin Rahe, KRAHE InfoSystems, Inc., USA
Extrusion production is a hybrid of the static routing of an assembly line and the dynamic routing of a package delivery business. Effectively developing and executing a schedule for the modern extrusion plant requires tools that can manage processes with different kinds of capacity constraints and adapt to needs that can vary significantly and quickly depending on product mix, customer priorities and unforeseen product or equipment issues. Ensuring that production personnel have the latest information regarding the products being produced, the jobs in process and the schedule of upcoming jobs requires a move toward a more paperless operation, not only for collecting data from the plant floor, but also for pushing schedule and job status information out to presses and post-extrusion operations. Tools that facilitate these advancements will be discussed, and additional benefits such as real-time monitoring of jobs in process and various plant productivity and profitability metrics will be demonstrated. Benefits of Integrated Extrusion-Specific Quoting Kevin Rahe, KRAHE InfoSystems, Inc., USA
Innovative Approaches to Occupational Health and Safety Management Systems by Select Extrusion Companies Greg Lea, Rio Tinto Aluminium; Howard Somers, Service Center Metals; Rob Morret, Pennex Aluminum; and Tim Myers – Bonnell Aluminum, USA
To Cast or Not to Cast, That is the Question Jim Madgett, Almex USA Inc., USA
Defining Our Modern Metal John Weritz and Ladan Bulookbashi, The Aluminum Association Inc., USA |
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