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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


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

[email protected]

IT IS ESSENTIAL THAT WE GET THE BEST IDEAS ON THE TABLE AND THAT MEANS EVERYONE HAS A ROLE TO PLAY.


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


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.


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


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


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


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


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.


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


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


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.


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


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


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


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


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


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


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.

banner savings - tomago.com.au€¦ · spring edition 2016 3 matt howell – chief executive...

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