Cold Mill Audit at Hulamin

Background

Hulamin, situated in Pietermaritzburg, South Africa, is an independent producer of semi-finished and fabricated aluminium products. Their rolled products division manufactures a range of sheet, plate and foil alloys and is focused on high specification, tight tolerance products which it supplies to customers throughout the world.

Last year Hulamin contacted us to carry out an audit of their six-high cold rolling mill. They asked us to assess the general capability of the mill, and to comment on its performance relative to other mills producing similar products. Dan Miller, who is part of our Process Improvement team, visited the plant in Pietermaritzburg.

How we were involved

cold mill audit at Hulamin

Hulamin’s S6 cold mill control room

During his visit Dan audited the rolling operations, assessed the recorded machine centre metrics and carried out detailed analyses of the process data. He measured the performance of the cold mill against its capability and against the requirements of world class quality and performance. Dan then divided his recommendations from the audit into two parts: those that would help to improve mill performance immediately, and those which should be considered longer term improvements. He then worked closely with the team at Hulamin to prioritise the recommendations.

The visit also proved a good opportunity for Dan to mentor Hulamin’s engineers and operators to enable them to implement his recommendations themselves, as well as to transfer the techniques to other operations in the plant.

Outcome

Following the cold mill audit, we’ve been delighted to continue working with Hulamin by supporting their new foil mill installations. This has included a study on the lubrication requirements for the mills, as well as training in foil rolling and defect analysis for the lead operators.

Services Involved

This case study appears as an article in the 2009 edition of ‘innform’; the newsletter of Innoval Technology.

Dan Miller

Dan is one of our Process Improvement consultants and a recognised expert in aluminium rolling. He’s worked in most of the former Alcan rolling operations across the globe, as well as a huge number of plants since Innoval was formed.

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