Leadership Journey

Phase 3 of the Leadership Journey® (Transformation Program) targets to achieve the next structural profitability improvement of Aperam.

This new phase of the Leadership Journey® aims EUR 200 million of annualized gains by the end of 2020. During this phase, the Company wants to further transform the business to improve our production costs as well as accelerate the adoption of the latest technological breakthroughs, automation and digitisation needed to create a fully-connected organisation ready to address the next generation needs of our customers.

 

 

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Industry 4.0 proposes a major paradigm change in the way companies work. In this vision of the future, there is a complete decentralisation of the control of productive processes and a proliferation of intelligent interconnected devices throughout the production and logistics chain. To prepare ourselves to always be ahead of the competition, Aperam has made Industry 4.0 a reality in its operations around the world. 

Use of drone to inspection and maintenance

For Aperam, Industry 4.0 concerns the adoption of industrial automation and IT technologies. The drone, for example, is already being used to inspect industrial roofs at the Timóteo plant in Brazil. By using a done, we can prevent exposing our employees to the risks of working on heights, in addition to making maintenance more agile and assertive.

There are plans to also use drones for inspecting chimneys, sheds and power lines, detect fluid leaks, and even to measure the volume of iron ore in stockpiles.

Water Treatment Plant

Our water treatment plant in Timoteo, Brazil, existed since the founding of the plant in 1944. In order to optimise its operation, the Company switched old engines to new high-performance ones, installed frequency inverters (equipment that varies engine speeds as needed) and a supervisory system to control the station process, which involves automated sensors and processes. As a result, there was an overall increase in the reliability of the water treatment plant, along with a 19% reduction in energy consumption and a 3% decrease in the need for water uptake.

Robot

Aperam has developed a robot to perform the task of staging high-voltage internal transformers. Due to the high voltage (13.8 kV equipment/3.8 thousand volts), there is a great risk  to the operators. Phasing requires physical connection by means of "sticks", and inaccuracies or failures can lead to serious incidents.

The robot does the service and physically connects the bats. Commanded at a safe distance by the operator, using a tablet and digital controls, the robot has a camera, emits alerts and has laser sights to ensure precision in the fittings.

Thermal Camera Equipment Inspection

Equipment inspections and heat sources at Aperam have gained greater agility and accuracy. The company recently incorporated the innovative CAT S60 device into its activities. The device combines three main functions into one: hand held (which marks the maintenance route), thermographic camera and cell phone. In addition to the practicality of this unique and easily mobile equipment, the teams have gained agility in obtaining information and in the automated sending of this information to the management systems. The inspection time has been optimised by about 10%.

Aperam BioEnergia’s Furnaces Automation

The project “Automation of the carbonisation furnaces of Aperam BioEnergia” has the objective of monitoring the temperature and controlling the oxygen input in an automated way. The work guarantees more accurate data and optimises the processes. The project was also recognised for representing gains in standardisation, quality and cost of charcoal produced by the Company in Brazil.

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