Ever since its inception, Sohar Aluminium, with its smelter located in one of the energy-rich regions in the world, has been adopting a culture of productivity effectiveness and efficiency while continuously maintaining a quality-driven mindset. The smelter is eyeing to become a global benchmark smelter through consistently enhancing and optimising its systems, and processes all the while maintaining environmentally conscious operations. In order to maintain its quality operations and competitive advantage in a dynamic and ever-changing market, Sohar Aluminium uses a systematic approach of lean manufacturing principles and capital improvement projects to significantly advance its productivity through waste reduction efforts, efficiency, cycle time and material costs. Because the company truly believes that development and innovation are dynamic and ongoing, the smelter has been witnessing continuous improvements driven by its visionary leadership and dedicated workforce. As the smelter approached its 10th anniversary in 2019 having achieved operations and systems stability, the company embarked on a journey of transition towards progressive growth and sustainability. A new business strategy was launched that saw the introduction of innovation and growth as a new strategic pillar focusing on building new sustainable, innovative and breakthrough opportunities, as well as optimization of efficient and alternative clean energy resources.
Smelter of the Future
With rapid change across traditional industries, Sohar Aluminium continuously seeks to harness the transformational potential of advancements of the technology to position itself as a ‘smelter of the future’. The company has, since its formation in 2004, implemented automation and robotics within the smelter’s Casthouse’s operations in order to achieve the highest levels of efficiency and error-free operations. Most importantly, these systems contribute vastly to minimising the interaction of human operator with unsafe material and therefore reducing the risk of accidents and injuries. Robotic cranes, for example, assist in the stacking of refined metal bundles and applying labels.
Leveraging IoT
Potential key game-changers for Sohar Aluminium are the Internet of Things (IoT), Machine Learning (ML) and Artificial Intelligence (AI). By combining these advancement, the smelter is able to automatically record, network and use numerous machine and system parameters to plan downtime, increase productivity and drive quality. Historical data is used to forecast equipment failures and process deviations, allowing room for proactive improvement of uptime, efficiency, safety, as well as resources optimization.
Revamping Systems
The project of upgrade to version 15 of the ALPSYS, the world's most advanced and comprehensive pot process control system used in reduction, was completed at Sohar Aluminium at the end of 2019 bringing new functionality to the Smelter’s Operations. Parallelly, MESAL (Manufacturing Execution System for Aluminium), an essential component in the process of managing Smelter operations and production, was also successfully upgraded to the latest versions.
Going beyond
Seeking to generate feasible ideas to expand its supply chain from both ends through the development of potential local small and medium-size downstream and upstream businesses in the region, the company held its first “Ideathon”, a 2-days event for local business owners, entrepreneurs, and university students. “Sohar Aluminium endeavours to develop the aluminium sector in Oman that will serve as stepping-stones in further growth of the region and increase In-Country Value while providing entrepreneurial opportunities for young Omanis. Several ideas were deliberated and discussed, and the winning ideas are being established as a new business.
Boosting & Utilizing R&D
The Company has long realized the importance of utilizing Research and Development in its efforts to advance itself in the industry. To that end, several MoUs have been signed recently between Sohar Aluminium and local top universities and colleges to boost this filed. Through these agreements, the company provides opportunities for researchers to use its facilities and processes to explore and test potential theories and new technologies in the field of aluminium production. It, on the other hand, benefits from these research as well as the state-of-art facilities of the colleges. In 2019 the company conducted detailed studies on specific actions related to renewable energy, scrap recycling and new product development paving the way for future innovations. The company also initiated in the same year the first project in reverse engineering approach with Sohar University.
Value Creation
In August 2019, the company rolled out its revamped Value Creation (VC) programme aiming to add value in every objective of the company’s strategic plans. Ever since, several VC initiatives have been initiated and implemented across the plant. All initiatives are generated, captured, selected, committed, and executed in all departments. Part of the programmes is recognizing individuals and teams on a monthly basis for delivering exceptional projects to the organization.
Sohar Aluminium’s journey ahead seems well envisioned and road is paved. Aspiring to become a benchmark for the industry, the company is heading towards reaching the new horizons and a bright future through transitioning from ensuring stable operations towards growth and sustainability.