Hydro Aluminium, Kurri , NSW

To increase profitability of the plant, Hydro Aluminium Smelter in Kurri, NSW initiated a performance-based contract, challenging their maintenance provider to increase the efficiency of the plant by reducing the down time of each pot, which would increase the production of aluminium. ATIVO was engaged in 2002 due to their demonstrated experience in effectively managing maintenance in the manufacturing industry and their willingness to work closely with Hydro.

Scope

An important part of the aluminium smelting process is the conversion through electrochemical process of aluminium oxide to molten aluminium, which is carried out in huge smelting pots. These pots ultimately break down, needing repair. Hydro out sources the maintenance of the 360 pots (3 lines of 120) to ATIVO.

ATIVO manages most related maintenance activities, a maintenance crew, spares inventory, materials and specialist sub-contractors.

Crew

ATIVO coordinates a core maintenance crew of 45 that cover three shifts per day, five days per week. ATIVO. is able to supplement the workforce when required to ensure Hydro experiences minimum downtime.

Efficiency Outcomes

ATIVO achieved such efficiencies allowing Hydro to maximise their productivity, through:

  • The appointment of an onsite planner and manager who both work closely with Hydro and subcontractors to manage workflow; and
  • Specialist OHS management reducing LTI’s 
  • Through the removal of duplicate tasks, multi skilling and effective planning

reducing production downtime by 34% and ensuring a higher profitability for Hydro ‘s Australian operations. 

ATIVO’s Shutdown Service is a tailored solution designed to meet client’s specific needs. All shutdown managers, planners, supervisors, and tradesmen undertake the ATIVO Accreditation Program which ensures that our crews are competent to work safely and productively with zero harm to people, plant and environment.