VolumeVolume 22 // 20202019

PRIME MINISTER’S VISIT IS GOOD NEWS FOR TOMAGO ALUMINIUM COST AND WASTE 2020 HAS BEEN A REDUCTION IN VERY STRANGE YEAR CASTHOUSE TOMAGOWAR ON WASTE GIVES BACKBRINGS THROUGH IT’S HUNTER RIVER HIGH OUT-OF-PAYBIG REWARDS DONATION FOR TOMAGO SCHEME SCHOOL PROGRAM CONTENTS

CEO Message 3

FEATURE STORY PRIME MINISTER’S VISIT IS GOOD NEWS FOR TOMAGO ALUMINIUM 4

2020 has been a very strange year 6 Fresh ways to develop Tomago’s leaders 7 Keeping out the elements 8 Achieving balance in production 9 ‘Project Productivity’ is reviewing Tomago’s efficiency 10 Tomago attracts the best and brightest 11 Tomago receives recognition at 12 the Workplace Giving & Excellence Awards War on waste brings big rewards to Tomago 14 Everyone has a story to tell 16 New online systems make life easier 17 Equipment upgrades a part of Tomago’s 18 new year resolution Predatory peregrines’ new Tomago home 19 Apprentices adapt to COVID constraints 20 Tomago is making good Kinnections 21 Making complexity look simple 22 Celebrating years of service Inside back cover Key Performance Indicators Back cover

Do you have an interesting story to tell? If you have a suggestion for TAC News please contact Katie Burns at [email protected] CEO MESSAGE

Matt Howell Chief Executive Officer

COLLEAGUES, WELCOME TO THIS EDITION OF TAC NEWS.

What a year! Meal and break rosters have been staggered On the plus side, we are already holding a to avoid crowding in crib rooms and other number of impressive entries for next year’s If anyone had told us 12 months ago about small spaces, and we have placed strict Excellence Awards and we plan to celebrate what lay ahead we would probably have limits on the number of onsite visitors. those individual and team efforts as soon as laughed at them, but what we have been the restrictions ease. through was incredible. Those practices are continuing and we will adapt to ongoing changes but it was As I write this we are seeing positive signs A sweltering summer, catastrophic bushfires an excellent effort by everyone and a that a COVID-19 vaccine might not be too far and a global pandemic that touched our wonderful result. off. When that will be is hard to say but until lives in ways we didn’t think possible. it gets here I encourage everyone to maintain While we are onsite we are safe but that There is no argument that 2020 has been a those basic health measures we have all changes when we go outside, so I urge major disruptor for Australian business but been practicing since March. everyone to stay vigilant and be careful about here at Tomago we have worked together possible COVID-19 contact away from work. Let me say that, after the experience of throughout the COVID-19 pandemic to keep 2020, I could not be more proud of the our business going and our jobs secure. Through our combined efforts I am Tomago Aluminium workforce. We have done extremely pleased and proud to say we I am extremely proud and very impressed exceptionally well so far and I want all of us haven’t had one single COVID-19 case or with the way everyone rose to the challenge to get through this together. one forced job loss because of the disease of dealing with the pandemic. and that is a credit to everyone. It’s always good to end on a bright note and Over the last several months we have seen what can be brighter than gold? Despite the social and medical upheavals countless news stories about gyms, pubs, caused by the worst pandemic since the I would like to congratulate every member clubs and restaurants, schools and even Spanish Flu more than a century ago, we of the new-look Tomago Workplace Giving hospitals affected by COVID being forced made 2020 one of our best, most consistent Fund and those who have managed its to close for deep cleaning. years for product delivery. recent revamp. Whenever I see those reports I realise It was for us a time of quality in the great Less than six months after it re-launched, it how well everyone here responded to the uncertainty of a national medical emergency, has been recognised in the highly-respected threat and how lucky we are because, quite a period in which we saw an enormous Workplace Giving Excellence Awards, winning honestly, I have no idea how in hell you improvement in process stability and Gold in the Best Launch or Refresh category would deep clean an aluminium smelter cost control. and Bronze for Best Overall Program. and I don’t want to see it happen! Rodded stock inventory rose to impressive Tomago Aluminium has a strong culture of Right from the start we have said that levels, anode quality and electrolysis giving back to the local community because anyone showing any signs of the virus performance was exceptional and the we know we can make a difference. should, for the sake of themselves, their Casting team improved ingot chain reliability families and their workmates, get tested I would like to take this opportunity to wish to keep pace with metal flow. Our support as quickly as possible. There is nothing to be you and your families all the best for the departments also continued to deliver. gained by coming to work and soldiering-on. Christmas and New Year holiday period Sadly, the COVID-19 restrictions meant we and extend my thanks to those who will be Those who were able to work from home were unable to go ahead with our annual working during that time to keep everything did so and some are still doing that. Those Innovation and Excellence Awards and operating smoothly. who had to stay onsite are working to strict Supplier Awards this year, which is very protocols, maintaining social distancing, Let’s hope that 2021 brings a welcome disappointing because, here at Tomago, practicing correct hygiene and thoroughly return to normality! we enjoy rewarding those who go that cleaning work areas and tools. extra mile. Best regards, Matt

Volume 2 / 2020 Page 3 PRIME MINISTER’S VISIT IS GOOD NEWS FOR TOMAGO ALUMINIUM

L-R: Prime Minister Scott Morrison with Brett Timney (Maintenance Superintendent), Andy Robbins (Manager) and Hon Dr David Gillespie MP

TOMAGO ALUMINIUM Mr Morrison was in the Hunter region to Mr Morrison said the electricity sector HAS HAD SOME VERY talk about energy security, delivering his needs to deliver 1,000 megawatts of SPECIAL VISITORS National Energy address at a meeting new, dispatchable energy to replace hosted by the Hunter Business Chamber Liddell, adding the Federal government SINCE OPENING IN 1983 at WesTrac’s head will back the new gas power plant if BUT IN SEPTEMBER IT office at Tomago. the energy sector fails to replace Liddell’s capacity. WELCOMED ITS MOST In that address the Prime Minister SIGNIFICANT VISITOR SO outlined the Federal government’s post- The government’s Liddell taskforce had FAR – PRIME MINISTER COVID-19 energy recovery plan, part found closing the plant without adequate SCOTT MORRISON. of which includes building a gas-fired replacement capacity could mean power station in the Hunter Valley, should an increased risk of power outages Australia’s energy sector fail to replace as well as a 30 per cent increase in the generating capacity that will be lost energy prices over two years once the when AGL’s Liddell power station closes plant closes, something Mr Morrison in 2023. describes as unacceptable. By committing to increase generating The PM’s visit was all good news for capacity in time for the summer of Tomago Aluminium, where reliable 2023/24, the government has set April power generation is critical to the 2021 as the deadline, putting pressure business’s viability. on national energy providers to show Tomago Chief Executive Officer Matt they can replace generating capacity Howell, who attended the National lost through power station closures. Energy Address, said he is frequently The Prime Minister also confirmed asked what will happen when the Liddell during his visit to the Hunter that Snowy power station closes so the Prime Hydro Limited is currently developing Minister’s speech came as great news plans to build the gas-fired generator at for Tomago Aluminium in particular and Kurri Kurri if the electricity sector fails energy intensive manufacturing industry to fill the capacity gap left by Liddell’s in general. scheduled closure.

Page 4 Volume 2 / 2020 Getting out into the plant the PM got an appreciation for the size and scale of our smelter.

L-R: Senator Hollie Hughes, Prime Minister Scott Morrison, Hon Dr David Gillespie MP with Nathan Skyrm (HV Electrician) and Chuck Luck (HV Electrician) in the Substation control room

“This will ensure there is more than “He was also able to answer our The PM’s announcement was enough reliable supply and allows us questions,” Matt said. a very positive outcome to pursue the opportunity for a firmed Tomago Aluminium has the largest renewable energy portfolio, knowing that because improvements to interruptible electricity load in the Liddell will no longer be available. the electricity network mean country with just one of the potlines “This announcement reflects all the having an electricity consumption increased reliability for us. hard work we and others have been equivalent to about 250,000 homes. doing to get some balance into the “It means everything lost by the closure In times of extreme demand or stress energy debate.” of Liddell will be replaced by a number on the grid caused by natural hazards of sources, but most importantly, we After making his address at WesTrac the like bushfires, Tomago can quite literally, won’t have to rely on the weather to Prime Minister visited Tomago Aluminium keep the lights on in New South Wales keep the lights on.” where he, Minister for Energy and by switching-off one or more potlines Emissions Reduction Angus Taylor, for limited periods of time, freeing-up NSW Senator Hollie Hughes and electricity for broader consumption. Dr David Gillespie MHR spent an hour That scenario does not come without touring the smelter. risk though. Shutting down a potline, The group visited the Substation control Matt says, is easy; starting it up again room and also witnessed a Potline is quite complex and there is always a anode change. risk it will not happen and that, he says, would be catastrophic. “Getting out into the plant the PM got an appreciation for the size and scale “Cheaper, cleaner and more reliable of our smelter. He was certainly paying energy is absolutely critical,” attention. He was well briefed and he he said. “The less likelihood we asked us some probing questions. have of interruptions (to our power supply) the less likelihood we have of a potline ‘freeze’.

Volume 2 / 2020 Page 5 2020 HAS BEEN A

L-R: Lauren Kelly and Dean Crosswaite conduct a deep clean on one of VERY STRANGE YEAR our metal haulers Caption TBA

THE WORLD HAS CHANGED SINCE COVID-19 FORCED ITS WAY INTO OUR LIVES. BUT DOES ITS PRESENCE MEAN WE ARE CHANGING TO A ‘NEW NORMAL’?

When Prime Minister Scott Morrison “At a board level we stopped face- Technology has also played a big part. declared the virus a global pandemic in to-face meetings because of border Developed to the point where outbreak late February things changed rapidly. closures, we went to Zoom online or hotspot demographic information conferencing and increased the can be identified, it can also send States closed down and shut their frequency of meetings. SMS notifications to employees via borders, schools stopped operating, their smartphones. major sporting events were cancelled With around 1200 employees and or delayed and industry started doing contractors split over various shifts “Through it all we have said to people: things differently. on a large site, social distancing was ‘if you’re not well, stay home,’” Simon challenging, but not as difficult as other said, “and it’s a strategy that’s been Tomago Aluminium was not exempt workplaces due to the size of the site. working well. from any of this and the early Within some teams it was more difficult uncertainty gave rise to concern and “So far we have had zero cases onsite where tasks required more than one even now, several months on, some and we are very thankful to everyone person. In these instances we had things are still noticeable. for that.” to implement better controls such as Tomago’s People, Safety and mandatory respiratory protection and Anthony Cook, Tomago’s Occupational Environment Manager, Simon Mitchell, higher levels of cleaning. Health and Hygiene Officer, says the recently underscored the changes smelter will continue to follow all New “Our employees understand they that were made in our workplace and South Wales Health directives and have a role to play though, a mutual have been affecting our lives since late is encouraging everyone to continue commitment to look after each other February. practicing social distancing and good and it’s a strategy that is working well. hand hygiene. While it is true Tomago Aluminium had In some circumstances we’ve had a broad Pandemic Policy in place as people working from home.” Programs have also been put in place part of its operating plan long before to manage interstate contractors and “We have reinforced the support COVID-19 arrived, Simon says that restrict plant visitors and, following available for people with mental health even with the best-written plan, it was government guidelines, equipment issues. For many people social isolation impossible to see how the pandemic cleaning and social distancing are now can be really difficult along with the was going to play out as time went on. firm requirements in the gymnasium, uncertainty of the world around them. as are limits on attendance numbers. “So we had to re-write the Pandemic To that end I certainly think a lot has Policy,” he said. changed as a community.” With a word of hope Simon suggests that, there is signs that the Australian “The biggest challenge of COVID-19 Surprisingly, and despite the social community is keeping control of the for us here at Tomago has been in and workplace upheavals, the ‘new spread of the virus at this time but we adapting to the new way we work, right normal’ has not seen any material all need to be vigilant and maintain the across the plant, along with supporting impacts on performance or production. commitment to personal hygiene and employees through this difficult and In fact some performance records have social distancing including outside of uncertain period. actually been broken. work as well. “Hand sanitiser and social distancing On the other side of the coin there quickly became a way of life and people have been challenges with the arrival of have avoided getting together in large some equipment such as forklifts and groups by staggering their meal breaks other capital equipment. and start times.”

Page 6 Volume 2 / 2020 FRESH WAYS TO DEVELOP TOMAGO’S LEADERS

The TAC Mentoring Program was launched earlier this year COMING INTO A LEADERSHIP ROLE IS NEVER EASY AND LEARNING HOW THE MANAGEMENT PUZZLE FITS TOGETHER ON EVERY LEVEL CAN BE A DAUNTING PROSPECT.

A new mentoring program pairing One of the main reasons behind the As the mentoring program is being management team members with mentoring program was to reduce trialled a new two-year Leadership superintendents new to role looks set formality and promote a ‘big brother/big Development program is in the final to become part of Tomago Aluminium’s sister’ support network, developing into stages of preparation before being training arsenal after spending the last a relationship without any real structure rolled-out next year, taking training from few months in development. and “able to continue for years”. being done as needed to being carried out using a more structured format. The program framework, developed “It isn’t a formalised course and we by HR advisor Keiran Turner, effectively haven’t had anything like this in place “There is no formalised ‘road map’ crosses departmental lines with its before. We’ve had formal coaching but for new supervisors about how to partner pairings, linking mentors nothing like a mentoring program,” lead teams other than their own and mentees from different parts Simon added. experience; they have to work it out of the business. as they go along. Going into the future Ben Cook, HR Superintendent said we want every supervisor to have a Explaining the need for the new those in the new program will always plan,” Ben said. program, Tomago’s People, Safety have their direct team leaders for formal and Environment Manager, Simon instructions and workplace coaching The Leadership Development program Mitchell, says getting advice from a but the mentoring program is purely calls for new supervisors to have six leader outside your normal reporting advice-based. months of structured training with arrangement can be really helpful for face-to-face and peer-to-peer learning The mentoring program is completely someone new to their role. led by experts in a variety of fields, driven by the mentee, meaning advice including HR and Safety. “This new mentoring program brings is sought rather than given. people together from different areas Experienced supervisors will also The Tomago’s management team and lets them talk candidly about any have attention paid to their career including the CEO Matt Howell, challenges or issues they might be development programs with internally- signed up to be mentors. having professionally and get ideas led trainers teaching core leadership from a different perspective, rather than Currently the program is running as a skills across seven key areas. from someone who they report directly pilot until the end of this year, when it Up to 70 people will go through the to,” Simon said. will be reviewed and Simon suggests training, which will be structured that, if it is formally adopted, it has the “That’s why Keiran Turner, with help across four modules and two annual potential to cascade downward for use from Chief Financial Officer Stacey workshops over a two-year period. at all levels. Sleeman, devised it, aiming it at people who have been recently promoted and He also suggests there is every are new to their roles.” likelihood that people going through the program will travel full circle to one day become mentors themselves.

Volume 2 / 2020 Page 7 KEEPING OUT THE ELEMENTS

THE PHRASE ‘KEEPING A ROOF OVER OUR HEADS’ IS A FAMILIAR ONE THAT HAS TAKEN-ON GREAT IMPORTANCE AT TOMAGO, WHERE ROOF REPAIR AND REPLACEMENT WORK HAS BEEN GOING ON SINCE AUGUST.

Locations earmarked for repair their location a 250-tonne crane with standby in case there is a fall, removing included the Rod Shop, Regain a 29 metre arm has been used to the person from the restrictive harness Shed 5 and the Casthouse. hoist them 75 metres into position. as quickly as possible. Some 89 linear metres of vents A large section of roof measuring Using specially-coated, chemical- have been replaced. some 60 metres wide and 140 metres resistant aluminium and steel sheets long was replaced at the Rod Shop’s Overseen by Worley, the total and clear industrial grade, wire- F1 building and a number of new job involves the replacement of reinforced Alsynite panels for light purlins installed. approximately 7,000 square metres of transmission, the projects have a roof –almost two-and-a-half soccer $2.5 million total combined cost. At the same time a major section of pitches –by roof teams comprising some Regain Shed 5’s roof was replaced, “It’s not a cheap exercise,” Marius 20 specialist operators as well as crane new purlins installed where needed de Beer, Tomago’s Senior Mechanical operators, scaffolders and riggers. and parts of the fascia and guttering Engineer, said. “Basically we’re replaced or repaired. The work is being carried-out by catching-up with the roof repairs. RIG, Programmed, Instant Scaffold It’s been many years since the roofs Other roof repairs aimed at stopping and Wheeler. were last replaced but from now on it roof leaks are being carried out at will be an ongoing project.” LMO and CPO. Those working on the roofs move about carefully, treating the old surfaces In fact, Tomago will have its own Ventilators have also been replaced on like very brittle egg shells. Because of Painting and Roofing Supervisor who the Casthouse and Rod Shop roofs with the roof pitch and slipperiness when will be responsible for carrying-out bigger, more efficient units replacing the there is even a modest amount of regular maintenance checks, according much smaller vents originally installed, moisture, they do not work when to Worley’s Senior Project Manager, giving better airflow. the weather is inclement. Keith Wilson. The new vents being installed on the Working at heights also means every As well, TAC will also have a replacement Casthouse roof are 4.8 metres long and team member wears a full safety roofing allocation built into the Capital weigh 600 kilograms each. Because of harness. A rescue crew is also on Works budget for future years.

Page 8 Volume 2 / 2020 ACHIEVING BALANCE IN PRODUCTION

SOMETIMES THINGS ARE UP, SOMETIMES THINGS ARE DOWN BUT WHEN THE UPS AND DOWNS ARE WHERE THEY SHOULD BE IN THE ROD SHOP AND THE POTLINES, THAT CAN ONLY BE A GOOD THING.

It goes without saying that, at any strict quality control measures. A metal “We didn’t have enough anodes in aluminium smelter, the main source of sample from each of the 840 pots is stock to even cover a 12-hour period. interest is aluminium production. taken for technical analysis every 36 We could have run out of anodes,” he hours and determines if corrections said, underscoring the risk of a potline LMO Process Superintendent need to be made. shut-down should that have happened. Tom Connell and LMO Operations Superintendent Josh Gorton have a side To achieve consistently low iron “We started building-up our stock levels interest though – purity and quality. To be content in the aluminium, operation from that point and in October this year more exact, iron content in the potlines and process stability is necessary to we had 1220 rods in stock, a record for and keeping the amount under control. ensure the anodes are properly covered us, and we have averaged stock above and bath heights kept to their target to 1000 for seven consecutive months.” The iron content is introduced by raw prevent anode pin damage. materials and liquid cryolite contacting Jerry says the Rod Shop is in a the anode pins during operation. The Anode quality is also important and constant process of inspecting, amount of iron is measured in parts per anode iron impurities have been cleaning, repairing and preparing million (ppm) with 900ppm considered reduced throughout the year. used stems and adding new ones the upper level before metal quality as necessary. Rod Shop teams also ‘Consistency’ is a word used in the Rod starts tapering off. maintain Tomago’s fleet of stems, Shop this year and is usually applied maximising their lifespans rather than The target, according to Tom, is to get to the rodded stock levels, which are replacing them each year, a common the number under 900 and that’s where currently at a record high and have (and costly) practice in other smelters. it was in September and October, been since March. running smoothly at 860ppm. Pointing-out that 310 anodes are “In the three months previous to then it needed in the potlines every 12 hours, had been sitting above the 900 target, Acting Production Superintendent, at around 930,” he said. Jerry Tawalo said that in December 2019 Achieving the right average rodded stock numbers stood Tom said iron content is kept low by numbers can be a difficult at just 245. controlling the work processes using task but the Potline and Rod Shop teams are showing that not only can the numbers be reached, they can also be managed.

Volume 2 / 2020 Page 9 ‘PROJECT PRODUCTIVITY’ IS REVIEWING TOMAGO’S EFFICIENCY L-R: Andre Rangel, Katrina Whiteley, Brendon O’Donnell and Craig Wells

Despite the issues that have rocked Rangel, who has worked with the THERE IS NO DOUBT the country our business has made TAC Continuous Improvement team noticeable improvements in process since 2018. THAT 2020 HAS BEEN stability, with performance gains in The project team is working through A TOUGH YEAR rodded stock inventory, improved a systematic review process and FOR BUSINESSES anode quality and exceptional current engaging directly with each department efficiency results in electrolysis. AROUND THE as it works to design and implement COUNTRY AND, LIKE In the Casthouse, Ingot Chain reliability sustainable improvements. SO MANY, TOMAGO has improved metal flow stability and all Every aspect of the business including support departments have constantly ALUMINIUM HAS NOT staff, operations, trades, contractors delivered to help us run smoothly. BEEN EXEMPT FROM and external services will be reviewed, COVID-19’S EFFECTS. Like every business though, Tomago as will other areas such as maintenance Aluminium needs to be competitive strategy completion, contractor efficiency and to do that it has to continually find and agreed technical indicators. ways of cutting costs and improving “We are reviewing the way Tomago overall efficiencies. Aluminium does business,” Project To ensure we remain competitive we Productivity Team Leader Craig Wells have launched Project Productivity, an said, adding: “We need to make sure internally-run review of all aspects of we apply a very robust validation the business. process that is critical in ensuring we maintain process stability while making Project Productivity is being managed improved business decisions.” in-house, the decision to use our own people rather than external consultants Craig believes this is a great opportunity giving us a huge advantage: they work for Tomago to stay ahead of the global in the business and understand the AP18 smelters on the cost stack and plant’s day-to-day workings. demonstrate what can be achieved with a “can do” attitude within the workforce. Project Productivity is being led by Cast Products Superintendent Craig Wells “We know we are already a benchmark with team members Katrina Whiteley in some areas of the business so there (Projects Superintendent – Electrolysis), is absolutely no reason why we can’t be Brendon O’Donnell (Maintenance a benchmark in all aspects,” he said. Supervisor – Cast Products) and Aquila Project Productivity is expected to take Business Improvement Analyst Andre between 12 and 18 months to complete.

Page 10 Volume 2 / 2020 This year we collaborated with the University of Newcastle to target local students as well as using Seek, a national jobseeker tool

TOMAGO ATTRACTS THE BEST AND BRIGHTEST

TOMAGO ALUMINIUM TAKES A GREAT DEAL OF PRIDE IN ATTRACTING THE BEST PEOPLE POSSIBLE TO OUR WORKFORCE.

In the broader community the quality Early next year four graduates will start “The positions here offer great of our apprentices is well-known their careers with Tomago Aluminium, development opportunities and Tomago and the number of applicants for the one each in chemical engineering, Aluminium rewards the successful Company’s yearly intake is almost mechanical engineering, electrical candidates. At the same time, the new unprecedented. engineering and IT/ automation arrivals also bring a fresh set of eyes engineering. to the business and that helps our After recently completing next year’s organisations ability to diversify and apprentice intake, for example, a total Not surprisingly, the number of be more innovative,” she added. of 436 applications were received for applicants for each position was high the four electrical and three mechanical with more than 340 local, interstate and As it is with the apprentices, the apprenticeships on offer. international people showing interest selection progress is rigorous. One in the four openings, according to HR position received 123 applications But there is another, less-known Advisor, Kate Wagner. and just two were interviewed with Tomago Aluminium intake, one in one going forward. Another had which the successful applicants are “This year we collaborated with the 117 applicants, of which four were recent university alumni, coming to us University of Newcastle to target local interviewed. to fill two-year graduate engineering students as well as using Seek, a positions. national jobseeker tool,” Kate said.

Volume 2 / 2020 Page 11 Westpac presented Wayne Pringle and Katie Burns with a special framed Headspace came onsite in July to receive their cheque for $10,500 collection of photos as a thank you for Tomago Aluminium’s contribution

TOMAGO RECEIVES RECOGNITION AT THE WORKPLACE GIVING & EXCELLENCE AWARDS

FOR MANY YEARS TOMAGO ALUMINIUM EMPLOYEES HAVE BEEN GENEROUSLY DONATING TO LOCAL CHARITIES AND SUPPORTING THE WESTPAC RESCUE HELICOPTER THROUGH TWO INDIVIDUAL OUT-OF-PAY PROGRAMS AND IT HAS NOT GONE UNAPPRECIATED.

Over the years Tomago Aluminium and custodians are actively seeking more In another small change under the its employees have donated around members and encouraging everyone new arrangements, every new Tomago 1.7 million dollars across 40 charities to donate a minimum of $3 each week. employee is automatically signed-up to and the Westpac Helicopter Service. the Fund for the minimum $3 per week “The company also traditionally but can choose to increase the amount On July 1 this year some changes were donates additional funding, matching or, alternately, opt-out and all donations made to the donation program, with employee contributions which is a huge are tax deductible. the two out-of-pay schemes merging boost for our nominated charities,” into one and becoming the Tomago Katie Burns said. The changes also mean current Workplace Giving Fund. employees can use T-Net to join the In the last 12 months we have program or change their donation Supporting the changeover campaign, donated just under $200,00 ($97,800 amount. They simply visit T-Net and select every employee received a personal from employees and the rest from ‘Workplace Giving Fund’ in the upper letter and flyer announcing the launch, management) which was split navigation bar and follow the prompts. which was promoted by site-wide between multiple charities. emails, our weekly newsletter, TAC News Since its relaunch just under six months As a way of encouraging new fund magazine, posters and social media. ago the new-look Tomago Workplace members, the Tomago Workplace There were even large signs promoting Giving Fund is showing positive results, Giving Fund did some special the Fund placed along Tomago’s experiencing a thirteen per cent giving of its own with two lucky entrance and on our road sweepers. membership increase for a 68 per cent members winning a luxury night total participant rate across the site. The campaign was supported away for two people. Monthly donations have also increased by TAC management and led by “We want to see Tomago’s charity by 16 per cent. Communications Advisor Katie Burns contribution amounts continue to and AWU Site Delegate Wayne Pringle. “In a year of unprecedented challenges grow in 2021 and beyond. Continual we are very proud of our employees’ In line with the change and knowing growth is our goal,” Wayne Pringle contributions through workplace that every dollar matters to under- noted, “and we thought a special giving along with the generosity of resourced charities, the fund’s getaway might help that.” the business,” Katie Burns said of the increase in member numbers.

Page 12 Volume 2 / 2020 CHARITY DONATIONS

HELP EVERYONE

EVERY year Tomago employees select a number of recipients for our annual charity donations by popular vote and our contributions are presented at a special morning tea. Got Your Back Sista also received a cheque for $10,500, along with Carrie’s Place and Soul Caf é This year our four charities were Headspace, Carrie’s Place, Soul Café and Got Your Back Sista, each one In late November, Tomago Aluminium’s receiving $10,500 to help with their Workplace Giving Fund was recognised in the ongoing operations and programs. highly-respected Workplace Giving Excellence Starting in 2021 there will be some changes to the way the new Tomago Awards, scoring Gold in the Best Launch or Workplace Giving Fund chooses its Refresh category charities. Many of the restrictions regarding charity nominations have been lifted (although they will still need to have a local connection) and, rather than selection by broad-based vote, only fund members will be able to nominate charities and cast votes. Tomago Workplace Giving Fund “We would like to thank all of our Workplace Giving Australia, a custodians Wayne Pringle and Katie Workplace Giving Fund members for non-profit organisation, helps Burns said an extensive site-wide their contributions – their support is businesses develop workplace- campaign with posters, signs, emails appreciated and allows us to continue based best practice giving and magazine stories had been used to making a difference in our local programs as an effective way promote the revamped charity program community,” she added. of supporting charity. since June. That superb effort following the As in the past, our one-off charity “We want to get the message out that relaunch has not gone unnoticed. drives like this year’s bushfire this is something that is worth being a donation to local RFS brigades In late November, Tomago Aluminium’s part of,” Katie said. and the Buy a Bale campaign for Workplace Giving Fund was recognised drought stricken farmers in 2018, The money raised is used across in the highly-respected Workplace are not part of the revised program a broad spectrum of worthwhile, Giving Excellence Awards, scoring Gold and all employees are welcome to hardworking groups and over the years in the Best Launch or Refresh category donate to these campaigns when we have supported a diverse range of ahead of the Australian Investment they arise. charities, big and small. Council and Bain and Company, backing it with a Bronze for Best “Tomago Aluminium and its Our recipient list includes – but Overall, finishing just behind winner employees have a strong culture of is not confined to – the Hunter JB Hi Fi and EnergyAustralia. giving back to the local community Medical Research Institute, Hunter and with these changes we have a Breast Cancer Foundation, John The awards were presented online real opportunity to provide a truly Hunter Children’s Hospital, Variety this year due to COVID-19 restrictions substantial amount of money to The Children’s Charity, the Starlight and Workplace Giving Australia Chief some very worthwhile causes,” Children’s Foundation, Cystic Fibrosis Executive, Jenny Geddes, commended Katie said. Foundation, the Mark Hughes all the organisations that took part. Foundation, Ronald McDonald House, “No matter how great it all seems, “These organisations have prioritised Newcastle City Mission, Dementia we can always do better. We know this form of giving and are seeing the Research, Camp Quality, Oz Harvest, it’s worth it,” Wayne added. benefits to their organisations and, of Soldier On, Canteen and Lifeline. course, to the charities they support,” You know it’s worth it. Ms Geddes said.

Volume 2 / 2020 Page 13 The scrap steel recovery was turned around in five weeks, and it came as a big cash injection at a critical time.

Sam Lloyd and Jeremy Ireland surveying some scrap on the Tomago shipping pad WAR ON WASTE BRINGS BIG REWARDS TO TOMAGO

A few months ago a project was A portion of the steel scrap is being re- LIFTING THE LID ON launched to look at the way Tomago cast by Molycop and returned back to WASTE AND THE WAY managed their scrap steel and to Tomago in the form of anode pins. The optimize the scrap value, that’s rest? Most likely already being used for WE PROCESS IT. either sold on the scrap market a thousand other purposes. or re-processed onsite. There was an even bigger reward There was a two-fold purpose to the to come though. Whilst Jeremy was plan, the clean-up delivering a financial doing a process audit, 3,500 tonnes of return while at the same time ridding the scrap steel was identified offsite which site of unwanted and unsightly mess. returned a massive $1.3 million to the company’s coffers. With the launch of the project, Casthouse Maintenance Supervisor On completion of the offsite scrap Brendon O’Donnell and his recovery, a recycling process was set Maintenance team had identified in stone to ensure a constant flow of approximately 40 tonnes of cast-iron, reusable scrap which returns in excess in the form of used ingot moulds. of $50k a month to the business. Business Improvement team member The scrap steel recovery was turned Jeremy Ireland was able to negotiate around in five weeks, and it came as a a premium tonnage rate with Molycop’s big cash injection at a critical time. Waratah foundry which saw an 82% For Jeremy though, collecting and increase in the initial submitted price. recycling the unwanted metal is simply This was a $11,480 cash return to a smart move that adds value to the the business. way Tomago is using its resources, a sentiment echoed by Sam Lloyd who

Page 14 Volume 2 / 2020 SOWS BEFORE SOWS AFTER

A pile of scrap pins ready to be re-processed.

says scrap aluminium is also getting a The change to in-house recycling did They were also able to separate high second chance at Tomago courtesy of require some procedural changes but value scrap for a return of more than a bit of ‘out of the box’ thinking by the the process alterations were greenlit by $5,000. The team now has separate scrap metal recovery team. management and accepted by everyone. bins for high value brass and copper and expects to recoup around $12,000 “We were storing our scrap aluminium For Jeremy the success of the waste a year from the separation process. onsite, mostly recovered from stopped metal recovery efforts revolves around pots. When we had enough to fill a a strong team, from management all Sam says the waste recovery efforts skip bin we were sending it to Weston the way through to Corey Lundy and his are ongoing rather than simply being a Aluminium at Kurri Kurri and they team who, quite literally, did the heavy one-off exercise. were giving us 40 per cent of the LME lifting on the iron. “We keep exploring; we make room (London Metal Exchange) value for it,” “It’s been a big team effort. It’s for change. The business is constantly Sam said. everyone’s responsibility to look at waste evolving so we’ve got to change with it; Three bins of metal handled by Weston from a different angle. The impact we’re we’ve got to do things differently.” Aluminium typically returned between having now is impressive. It’s green, So if you see any opportunities for $45,000 and $55,000 each month we’re recycling and we’re making things high value scrap in your area – brass, (depending on the LME valuations) but more sustainable,” Jeremy said. copper, stainless steel or cast Iron a way was found to keep the metal Leigh Osmond and the PTA (otherwise known as the ‘Big Four’) get in-house for full reclamation, a 100 per Maintenance crew, along with the LMO in touch with Jeremy. cent return on 30 tonnes of aluminium day workers and Brooke McBride from each week by running it through a Odds are it will be worth a bit more procurement, saw a number of scrap single furnace dedicated to handling than a car boot load of bottles and cans value opportunities in unusual places. the recovered waste. cashed-in at the recycling depot. The first was to collect stainless steel All-up, the implementation of this chisel tips and send them back to their internal process will deliver an annual manufacturer, earning $1,700 a tonne or benefit of more than one million dollars. close to 10 times the usual scrap value.

Volume 2 / 2020 Page 15 L-R: Keiran Turner, Heath Buman, Mark Westbury, Phil Carpenter and Tim Smith. TOMAGO Aluminium employees and their families have access to free confidential, independent, short-term counselling and crisis counselling through our Employee Assistance EVERYONE HAS A Program (EAP) operated by Converge international. Call 1300 687 327.

STORY TO TELL Our Peer2Peer Network is made up of employees who have been trained to listen to the problems of others IN OCTOBER, AS PART OF MENTAL HEALTH MONTH, and give reassurance while offering WE INVITED EVERYONE TO TALK ABOUT THEIR OWN information and advice. MENTAL HEALTH JOURNEY. Lifeline telephone counselling is available by calling 13 11 14.

As part of the Hunter Manufacturers By listening to their stories we are These films, along with films from other Mental Health Initiative, Tomago letting our friends and workmates know businesses, helped to make up the Aluminium partnered with other they are not alone and that we can help. Hunter Manufacturing Network video, businesses in the Hunter manufacturing that was circulated across the wider During Mental Health Month, seven network during October’s Mental Health community. Check it out at: employees agreed to tell their stories; Month, which this year focused on the https://youtu.be/aatZgxDBNlo Tim Smith, Andrew Thurlow, Phil ‘Everyone Has A Story’ project and the Carpenter, Brad Hickey, Keiran Turner, Tomago’s People, Safety and experiences that have impacted our lives. Daniel Bolch and Heath Buman all Environment Manager, Simon Mitchell, Those experiences have left their mark participated. said that in line with the company’s and given us stories to tell. By sharing mental health strategies a group is Each one spoke of the particular situation them and talking about our experiences currently undergoing anti-bullying that had affected their lives, how they we can start breaking down the barriers training with the Workplace Health worked through it and gave advice for surrounding mental illness. and Safety Committee. anyone experiencing similar issues. Many of us choose to keep our stories “It’s practical training for mental health Each week throughout October, we hidden because we feel uncomfortable in general as well as offering self-help released a new video of one of our telling them. Because of that, none of us strategies. employees opening up about their own really knows what others have going- mental health journey. These videos “It helps people change their own on in their lives or what they have been were made accessible to all employees thinking, the way they see the story through on their individual journeys. and shown across the site with in their minds,” Simon said. Every year around 20 per cent of supervisors and their teams watching Since the onset of COVID-19 the rate Australians experience some kind of it during toolbox talks. of mental illness across Australia has mental illness. Sadly, 70 per cent of “We were really appreciative of how climbed steadily, driven by anxiety, those – roughly 3.5 million people – honest everyone was. Everyone who took uncertainty and depression so taking do not get professional help. part just wanted to have the opportunity the time to really listen to someone By asking our employees to share their to help someone who might be watching. could be one of the most helpful stories we hoped to be able to give It was really heart-warming,” said things any of us can do. people the courage and confidence to Tomago’s Communications Advisor discuss those things that have affected Katie Burns, who recorded each them in their lives and is a positive way conversation for the video. of normalising peoples’ situations.

Page 16 Volume 2 / 2020 NEW ONLINE SYSTEMS MAKE LIFE EASIER

L-R: Recognition App Team – Donna Stephen, Matt Wright and Amanda Gill

A DISCUSSION IN HR EARLY THIS YEAR FOCUSED ON IMPROVING WAYS FOR TEAM LEADERS TO BETTER RECORD IMPORTANT CONVERSATIONS WITH THEIR MEMBERS.

The HR team wanted a better way to Those early discussions led to a Supervisors still sit down with individual record noteworthy conversations with a development phase that blossomed team members for a formal meeting but particular focus on recognising positive into an impressive new smartphone rather than making notes on a form, performances by team members. app for diary notes, which went live everything is done online. across the site in June. Such conversations, known as diary The important aspect of the Online notes, are meant to be made when Called the Record of Discussion app, Performance Review was to make a leader recognises the good work it is available through the K2 Workspace it function properly without giving done by a team member or when for mobile phones or through T-Net. supervisors any more work to do. verbal coaching is given for a Using the app, verbal recognition and “We were drowning in paperwork performance opportunity. coaching notes are easily entered and it wasn’t adding value nor did it The problem is, of course, that team directly into SAP in exactly the same make things any safer. With this new leaders are busy, they don’t always time it takes to tap out a text message method we are trying to use the system carry a diary or notebook with them and now the system is capturing even more rather than use up supervisors’ and if something comes up before they more information, ensuring employees time,” Ben Cook said. get to make the diary note then the are given the recognition they deserve. “Supervisors are able to access discussion (and the notation) might In one two-week period alone 17 people and amend the form at any time well be forgotten. were recognised for their efforts using and also access training schedules. Tomago Aluminium is a technology the app. Three were recognised for their Everything becomes part of the leader and we do have an enviable IT teamwork, one for work quality, 11 for overall development plan.” department, so HR Advisors Donna their productivity and work quantity The change has rolled two projects Stephen and Amanda Gill sat down and two for WHSE. into one with the bonus of less with IT’s Matt Wright to talk about A second project that went live across reassessing for everyday tasks. what could be done. the site in late October is the new Online Performance Review, which replaces the old paper review form.

Volume 2 / 2020 Page 17 One of our new Metal Haulers One of TAC’s new Casthouse Furnace Tending vehicles

EQUIPMENT UPGRADES A PART OF TOMAGO’S NEW YEAR RESOLUTION

EVERY BUSINESS NEEDS TO BE PROPERLY MAINTAINED AND THAT MEANS INVESTMENT. SO JUST WHAT ARE WE LOOKING AT FOR THE COMING YEAR IN TERMS OF UPGRADES, COST AND WASTE REDUCTION AND NEW SPECIALIST VEHICLES?

Upgrading and maintaining is a activities to ensure our power supply To ensure the demands of transporting necessary and important part of remains robust and we continue to almost 600,000 tonnes of metal each staying competitive for any business operate safely and reliably for many year is met with minimal downtime and and here at Tomago we are no different more years to come. delay, the fleet needs to be reliable. To to anyone else. ensure that reliability, the company has “Our intent is to scale back the overall replaced four metal haulers, specialist One of the major areas of focus right capital spend (on the substation) trucks which will be used to tow ladles now and set to come in for even over about a five-year period, while of molten metal around the site. more attention in 2021 is the Tomago maximising its lifecycle,” Dane said. main high voltage Substation. The Another three units will be delivered soon The job is a complex and challenging TAC HV Substation consists of some to bring the total up to seven brand new one requiring specialist work teams of Australia’s largest fleet of power metal haulers. In addition, the Hot Metal made up of Tomago Aluminium transformers, switchgear and high Transport Trailer fleet are also being employees, engineering alliances and power rectification assets. This is renewed with great feedback from external contractors. Tomago’s main path for smelting our drivers on how smooth the new and auxiliary power supply. There is also an element of risk suspension system is operating. involved replacing and repairing many For Senior Electrical Engineer, Dane Some things though can change of the larger components and, not Fernandez, it is a case of not just without any change being noticed. surprisingly, most of the work does not maintaining functionality of the assets, Two 20-year-old Volvo A25 articulated mean simply using off-the-shelf parts. but ensuring long term power supply six-wheel dump trucks are being rebuilt security for the whole business Future planning means taking a broad at a cost of $200,000 each rather than through an accelerated risk reduction overview of the whole site, assigning being replaced, simply because they investment strategy worth around capital expenditure as needed to either are “the best for the job”. $10M per year for the next few years. upgrade or replace equipment as it It is all a matter of spending money becomes necessary and setting-up a “Generating value for TAC is a balancing wisely, identifying problem areas, buffer against ongoing costs. act between performance, cost and managing them correctly and making risk. Maintaining and overhauling what New forklifts with lift capacities ranging the right decisions. we’ve got to maximise our equipment’s between five and 16 tonnes are also Is there an end point? With new life-cycle, targeted replacement of on the horizon, as well as a Casthouse equipment needs, people coming up critical infrastructure and components Furnace Tending vehicle to replace the with new ideas and new processes based on risk, and digitising our control very old and obsolete current fleet. being developed the answer is: and protection where possible are key “probably not”.

Page 18 Volume 2 / 2020 L-R: Trish Rapley, Robyn Parker and Darren Clarke PREDATORY PEREGRINES’ NEW TOMAGO HOME

WHEN A PAIR OF PEREGRINE FALCONS STARTED SWOOPING TOMAGO CREWS WORKING AT HEIGHTS, THE PROBLEM CALLED FOR SOME CLEVER LATERAL THINKING. The nest box built by Darren Clarke being put into place

Environment Superintendent Robyn the birds. With the alternative plan an After six weeks of random visits Darren Parker and WHS Advisor Trish Rapley application for the falcons’ disposal, stopped seeing the birds. The last time he met with the affected Environment, Darren contacted a Western Australian saw them they were mating so he knew Sunshine Workshop and Emissions expert who had successfully relocated the female would soon be laying eggs. work groups to better understand birds using ‘aversion therapy’. A few days later Robyn Parker saw the what was happening. With Tomago fully behind the project a female sitting in Darren’s nesting box. The teams had been working on fume new and suitable location was found for The male was still close by protecting treatment centres and other areas the Peregrines. A date was set for the the area but that has since stopped. above the falcon nest sites and had West Australian expert to visit and start The great news? They have successfully tried to deter the birds. Suggestions the aversion therapy before breeding bred chicks and are busy feeding them. were made and measures taken to season. Darren designed and built a Darren is “99.9 per cent certain” they minimise worker injury risk, but a more nesting box and a crane was organised have found a nesting site that does not permanent solution was needed. to lift it into place. need the amount of protection of their old Peregrine falcons are a protected species But then COVID-19 hit. Borders were site. Hopefully, teams will be able to work and that placed constraints on how closed, flights were cancelled and, without fear of being swooped by one of and when any action could be taken, unlike our Peregrines, the man from the world’s fastest predatory birds and especially during breeding season. the West was unable to fly. that is definitely a win-win for everyone. Advice was sought from Taronga Zoo With breeding season approaching Darren has explained that, in the wild, Sydney, the University of Canberra and a ‘Plan B’ was needed. Darren the only danger to Peregrine nests the National Parks and Wildlife Service volunteered to attempt the daunting comes from above. with the aim of finding a solution that aversion therapy himself with guidance “When looked at from a falcons’ would provide safety for the falcons from the WA expert. point of view it explains the level of and Tomago employees. The old nesting site was made aggression shown to our work mates,” Help came from an unexpected quarter inaccessible for the birds and Darren Trish said. when Bake Ovens Operator Darren started coming in before dawn most “The birds were simply protecting the Clarke saw a painting of a Peregrine mornings and climbing up onto the area from people who had to access it, hanging in Trish’s office. It piqued his stacks before first light, his presence often working above their nest.” interest and started a conversation. making the falcons uncomfortable and shocking them into defence mode. Peregrine mortality rates are very high Trish explained how the birds were and only a minority survive to breeding affecting our workmates and Darren This action resulted in a series of swoops age. To see them nesting equates to the let it be known that, from the age of on him lasting up to 10 minutes as perseverance of a world class athlete. 11 he had been training, breeding and he tried to make it uncomfortable for rehabilitating birds of prey and that them to prepare their nest in peace, The plan now is to install cameras prior to emigrating to Australia 14 years but Darren persevered, ensuring the inside the nesting box to learn more ago, his passion had been falconry. birds remained uneasy and uncertain, about this dynamic species and, for when they woke up, the man standing years to come, let people the world He understood the potential risks to our brazenly in the middle of their nesting site over watch these magnificent apex employees and offered to help relocate would be there to disturb their morning. predators raise their young.

Volume 2 / 2020 Page 19 It’s all getting back to some degree of normal although we are still doing things like splitting lunch breaks and morning tea breaks to make sure we get our social distancing right. Our 1st year apprentices in the TAC Workshop APPRENTICES ADAPT TO COVID CONSTRAINTS

TO SAY 2020 HAS BEEN AN ODD YEAR FOR THE WORLD WOULD BE FAIR, BUT TO SAY IT WAS A STRANGE INTRODUCTION TO THE WORKING WORLD FOR OUR FIRST-YEAR APPRENTICES WOULD BE NOTHING SHORT OF AN UNDERSTATEMENT.

As far as Apprentice Training Supervisor TAFE day for the apprentices but moved apprentices generally coped well with Greg Wall can remember, the last few in-house. Theory classes were still in the it,” Greg said. years in Tomago’s apprentice training morning but were done online and the “It’s all getting back to some degree area have all had a certain sameness afternoon practical classes were held in of normal although we are still doing to them. the apprentice training area. things like splitting lunch breaks and The seven first-year apprentices arrived Second, third and final-year apprentices morning tea breaks to make sure we mid-January, spent the first few months were also involved, joining the new get our social distancing right.” training with Greg and Electrical Trainer chums online as all 28 apprentices took With 2020 sliding towards its Tim Bolam, settled into the routine of part in Zoom sessions for their TAFE conclusion Greg has already started attending TAFE one day each week, theory lessons. making plans for the new year. worked through the various mechanical For 10 weeks Greg became a surrogate or electrical modules of their training TAC received a whopping 436 TAFE teacher, overseeing the practical plan and then started filtering out into applications for its annual seven-person exercises, assessing skills and taking various areas of the plant to learn their apprentice intake – well above the usual photographs as work progressed, respective trades. number – and sorting through them has providing TAFE with the necessary been time consuming. Except this year, it didn’t quite work to documentation to show each exercise the script. had been completed correctly. Employment offers have gone out and the orientation process is underway “This year was a bit more of a When face-to-face TAFE classes ahead of the mid-January start for the challenge,” Greg recalled. “The first restarted in term four it was a great ‘class of 2021’. three months were okay but then relief to everyone, especially when it COVID arrived and it all changed was decided that practical work would And the ever-present problem of overnight and got very interesting.” take priority over theory. COVID-19? TAFE training came to an abrupt halt in “No argument, it has been a strange “We’ve pretty much got our plan early April when face-to-face classes year for us but TAC was able to worked out now.” were cancelled. Wednesday was still back-up on the TAFE training and the

Page 20 Volume 2 / 2020 The Karuah Kinnection team are extremely grateful for the support of local organisations like Tomago Aluminium TOMAGO IS MAKING GOOD KINNECTIONS

THE YOUNG MEN AT KARUAH MISSION ARE PART OF A VULNERABLE COMMUNITY BUT A SHARED LOVE OF BASKETBALL HAS TURNED THEM INTO FEARSOME PLAYERS.

Like many Aboriginal people they have Enthusiasm picked-up a notch when of just one week it rolled into its second struggled with unemployment and the Mission’s young men started competition and has been playing – and education has been lacking. Isolation is encouraging each other to play and winning – since mid-October. a problem and mental health issues an was given a huge boost when former The great thing, Michelle said, is that unfortunate reality. National Basketball League star everyone wants to play. Butch Hays turned up as its coach. At Karuah Mission those negatives were “We had one young fella, he was about turned into a major positive with the Once associated with the Adelaide 12, and we had to take him out of emergence of the Karuah Kinnection 36ers, the , the the team because he was too young. basketball team, a collection of 16 Newcastle Falcons, the North He said: ‘I’m not frightened of ‘em!’ to 25-year-olds who, with the help of Melbourne Giants and the Canberra but they (league administrators) were some enthusiastic volunteers, proved Cannons in the NBL and the Maitland worried about him.” to be tough competitors. Mustangs in the NSW Waratah League, the 232-game NBL veteran had a few The team sport initiative has been Tomago Aluminium is proud to be tricks and trade secrets to pass-on to incredibly empowering for everyone onboard as a Karuah Kinnection team his young charges. involved, Michelle noticing that, after supporter, helping-out by supplying 18 a few weeks of training and playing, pairs of basketball shoes and Hunter Butch is CEO at SNAP Programs, confidence levels were at an all-time high Primary Care are supplying their a not-for-profit group assisting other and mental health issues had tapered-off. training shorts and shirts. organisations and families in supporting both young people and disabled people Surprisingly, she said, the advent of The team was formed soon after through a variety of programs. COVID-19 was actually a bonus for volunteers responded to a desperate some of the players. plea for help from a Mission elder “We are so blessed to have Butch deeply concerned about the self-harm helping us,” Michelle Perry, Acting “We had a couple of the boys with and attempted suicide rates among the Chair of the Karuah Land Council, said. anxiety issues who didn’t want to community’s younger members. play at the stadium in front of people Since he started coaching the team but COVID meant there was no-one Suicide is the leading cause of death Karuah Mission has not reported a there to watch because people had to for indigenous children aged 5-17 single suicide attempt and the general stay away. That helped them get their years. Statistically, Aboriginal and mental health of the young players confidence,” she said. Torres Straight Islanders aged 15-24 has improved. are almost four times more likely to Who knows? We might be helping a The team recently completed its first commit suicide than similarly-aged whole team of potential Butch Hays’s competitive season, finishing third of the non-indigenous people. break into the NBL. seven teams in the league. With a break

Volume 2 / 2020 Page 21 L-R: SAP Migration Team – Stephen Pfennigwerth, Ed Bohatko, Matt Wright, Nathan Allen, Ian Mcdonald, L-R: Charmain Underwood and Deborah Chen Sue Dunstan and Dennis Moncrieff were also part of the SAP Migration Team MAKING COMPLEXITY LOOK SIMPLE

DENNIS MONCRIEFF IS NOT ONE TO LET GRASS GROW UNDER HIS FEET AND SOON AFTER TAKING-UP THE ROLE OF INFORMATION SYSTEMS SUPERINTENDENT HE JUMPED STRAIGHT INTO A MAJOR PROJECT.

By his own admission, Dennis enjoys a onsite, then we have access to it The only noticeable difference? technical challenge and has been doing all the time. We can’t afford to lose “It’s now faster,” said Dennis. so ever since he moved into Information access with our production systems For an encore performance Dennis Systems in 2009, after starting as an that run the plant, so teaming-up SAP and his team are also redesigning Automation team contractor in 2002. with the existing infrastructure here T-Net, modernising it to make it a makes it possible to get Cloud levels He moved into the role of IT more responsive application and of uptime ourselves.” Superintendent in August and one of his renaming it as well. first jobs was to migrate the company’s Dennis suggests there are also some “The main problem we have with it is Systems Applications Product – that obvious security problems to consider. that it doesn’t work on mobile phones which we all refer to as ‘SAP’ – from Cyber security is an ongoing hot because it doesn’t ‘scale’ to fit the the Cloud, bringing it back inhouse and button issue and if the Cloud can be screen. Yet everyone has a smartphone under the control of the IT Department. compromised it would be vulnerable. so could use it on the move. The reason, Dennis explains, is a With technology company IBM keen “We want people to be able to do simple one with the potential for to partner with Tomago Aluminium to things faster and more easily through wide-reaching benefits. run the SAP suite for the next decade, that little device in their pockets.” Dennis describes the change as a “We’re a single site, one entity in one cost-neutral proposition Once completed, expected to be location so it makes sense to have it sometime in the first quarter of the new onsite. There is basically one cable The SAP migration was done painlessly year, T-Net will be known as The Foil. that connects us to two data storage over a weekend in late August. The locations in Sydney. system was shut down at 5pm on the For Dennis and the IT team, the fun Friday evening and it was back online part of it all is turning complexity into “If someone puts a backhoe through by the Sunday afternoon, some 12 simplicity. that cable we lose our connection to hours ahead of schedule. the Cloud and all our data. If it’s here,

Page 22 Volume 2 / 2020 CELEBRATING YEARS OF SERVICE

35 YEARS Liquid Metals Cast Products Daniel O’Hare Richard Dean Cast Products John Miller Lou Prete Ian Winters Michael Carmody Darren Morris Neil Harrington Sally-Anne Hungerford 30 YEARS Scott Archibald Laboratory Cast Products Shane Filip Ian Brogan Gary Wood Shannon Ridley Liquid Metals Liquid Metals Plant Management Aaron Notley Peter Greentree Nicola Harvey Joel Leigh Glen Sceresini Human Resources Con Filactos Carbon Plant David Miller Craig Rogers David Prior Christopher Harris SECS 20 YEARS John Holloway Anthony Jensen 25 YEARS Nil JULIE Carbon Plant Maintenance Guy Hodgkinson 10 YEARS Stephen Pfennigwerth Ian Huhta RAE Carbon Plant Plant Management Cast Products Darren Gray Michelle Whyte Doug Searl Scott Reece Robert Graham What is your current role? Payroll Officer

ALUMINIUM FACT If you had $100 to spend on Aluminium can be recycled forever: It can be melted down and yourself what would you do reformed without losing any quality, and the process can be with it? repeated over and over again. Definitely book a massage!

Biggest regret? Worrying about the SUPPORTING LOCAL CHARITIES small stuff. AND COMMUNITY EVENTS... Favourite food? Every year Tomago Aluminium supports a number of local charities, Italian or Thai. community events and local schools through sponsorship and donations. In 2020 we (and our employees) have supported the following: What were your first

• Breast Cancer Awareness • Rathmines School Breakfast Club thoughts on TAC? • Carrie’s Place • Royal Fire Service – Raymond Terrace How nice the team was. • City United Cricket Club • Royal Fire Service – Medowie What’s the best piece of (Leukemia fundraiser) • Royal Fire Service – Salt Ash-Williamtown advice you’ve been given? • Got Your Back Sister • Royal Fire Service – Thornton Be kind, be grateful and stay • Headspace • Soul Café humble. • HRMI – Concussion clinic • Survivor’s R Us • Hunter Manufacturing Awards • The John Hunter Children’s • Hunter Primary Care/Karuah Hospital – NICU Kinnection Basketball Team • The Rotary Club • Immune Deficiency Foundation Trust • Tomago Bowling Club • Leukaemia Foundation • Variety • Make-A-Wish Australia • Westpac Rescue Helicopter • Port Stephens International • Youth Express Women’s Day Breakfast KEY PERFORMANCE INDICATORS

EFFECTIVE METAL PRODUCTION (Tonnes/Mth) Yearly Actual Monthly Actual DC ENERGY CONSUMPTION (kWh/t AI)) Yearly Actual Monthly Actual

52,000 14,000

50,000 13,800 50,715 50,366 50,341 50,342 49,435 49,626 49,345 49,181 49,088 49,609 49,274 13,711 13,700 49,179 48,873 48,000 49,082 13,600 13,662 48,678 48,376 13,514 47,002 13,535 13,544 46,000 13,400 13,522 13,452 13,403 13,405 13,371 45,979 13,394 45,664 45,483 13,359 13,345 Tonnes per month Tonnes per month Tonnes

44,000 13,200 13,316 13,311 13,269 13,266 13,356 13,248

42,000 13,000

40,000 12,800

2012 2013 2014 2015 2016 2017 2018 2019 Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec 2020 2012 2013 2014 2015 2016 2017 2018 2019 Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 YTD 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 YTD

The Effective Metal Production is the total amount of hot metal tapped from the pots. Energy Consumption measures how much power we use to make one tonne of aluminium. It includes both hot metal tonnes delivered to Cast Products plus any reclaimed cold metal The lower this number the better!

IRON IN METAL (Fe ppm)) Yearly Actual Monthly Actual HAZARD EVENT RATIO Yearly Actual Monthly Actual

1,250 50 1,271

1,200 45 46 1,209 44 1,150 40 1,167

1,100 37 35 1,108 1,107 1,084 1,050 33 33 33 1,066 30 32 32

1,000 30 29 1,033 1,030 27 999 1,008 25 950 24 952 Tonnes per month Tonnes per month Tonnes 957 23 937 940 933 22 927 927 20 21 900 19 18 874

850 861 15

800 10

750 5

0 2012 2013 2014 2015 2016 2017 2018 2019 Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec 2020 2015 2016 2017 2018 2019 Jan Feb Mar Apr May Jun Jul Aug Sept Oct Nov Dec 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 YTD 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 2020 YTD

Iron in metal is our main measure of quality and purity. The Hazard Event Ratio measures the number of injuries in proportion The lower the iron content is, the better. to the number of safety related events.