Bratsk aluminum plant: history, modernization, management system

The Bratsk Aluminum Smelter is the largest enterprise in terms of world and domestic standards, where 30% of all domestic aluminum and 4% of world metal production are produced.

History

The fraternal aluminum plant was launched in 1966, and until 1973 additional capacities were launched. The power supply to the enterprise is provided by the Bratsk Hydroelectric Power Station. In 1980, the enterprise received worldwide recognition, having received the "Golden Mercury" award, given for merits in the field of international cooperation and production development.

The change in ownership took place in 1993: the company became an open joint-stock company of JSC "Bratsk Aluminum Plant". The total number of shares issued from that moment has not changed and is 5,505,305 units.

Before the beginning of the 21st century, the company changed owners several times. Since 2000 and until now the enterprise is managed by RUSAL. The Bratsk Aluminum Smelter is one of the largest assets of Russian Aluminum. In 2001, BrAZ celebrated the anniversary smelting of aluminum, since the plant was founded, 25 million tons of aluminum were produced. Thirty million tons of metal was melted in 2006.

Production

At the time of launch, the enterprises were designed to produce 915 thousand tons of metal per year. Since 2007, the plant has begun a large-scale modernization, the process is still going on. During this time, the Bratsk Aluminum Plant was able to produce one million tons of products per year, for the first time new capacities were demonstrated in 2008.

Primary aluminum in the plant is produced in electrolysers using Soderberg technology. The company's assets include 25 buildings, comprising three electrolysis shops, anode mass plants, fluorosols and production areas for the production of crystalline silicon. Within the framework of modernization and with the aim of producing competitive products, in 2008 the foundry complex for the production of flat ingots was put into operation, its capacity is 100 thousand tons of products per year.

RUSAL Bratsk Aluminum Plant receives energy from the Bratsk Hydroelectric Power Station and consumes up to 75% of the plant's total capacity. Raw materials for production are supplied from Kazakhstan, as well as from partners from Guinea, Italy and other countries.

Main types of products:

• Aluminum in pigs of high purity weighing 15 kilograms (grade A995-A95).
• Metal of technical purity in bars of T-shaped.
• Aluminum ingots, alloys of aluminum marking AMg2, AMg3. Metal for rolling mills.

All products are certified according to world standards and ISO and OHSAS protocols.

Modernization of production and social policy

The main task at the enterprise is to increase the output of quality products in accordance with the demands of the world consumption market. In 2012, the Bratsk Aluminum Plant started producing more than ten new types of ingots and metal alloys. In the same year, new equipment was launched to achieve the best results of work and the quality of evaluation of the products received. The foundry complex Wagstaff received modern mixers, and an estimation of the purity of aluminum during the smelting process was evaluated by the Limca plant.

In order to improve the environmental situation and reduce the impact on the environment, the Bratsk Aluminum Smelter implements the program "Ecological Soderbergh", in 2012 the newest gas purification unit in the building No. 25 was installed.

The social policy of the enterprise is realized in observance of all norms of the Labor Code of the Russian Federation and the construction of housing for employees. It is expected that about 14.5 thousand people will take part in the housing program. Housing is acquired by employees of the company for preferential mortgage lending, part of the funds (about 50%) is repaid by RUSAL. In the summer, the employees of the plant have the opportunity to send children to the camp located in the Krasnodar Territory free of charge.

Production management system

The leader in many endeavors was the Bratsk Aluminum Plant. The production system introduced at the enterprise is the fruit of an in-depth study of world-class management standards, its own rich experience and the capabilities of the Russian market. The main postulate of the program is the statement that the interests of the staff are top priorities. So there was a need to create a middle class in the enterprise, for which the average wage level was determined - no less than 2 thousand dollars a month, a high level of responsibility in its place, a quality education with the ability and the desire to raise its level.

"Break the stereotype!" - the production system of the Bratsk aluminum plant. The book with the description of the system was issued by the managing director of BrAZ in co-authorship with several experienced managers of the company. The essence of the system consists in a step-by-step solution of problems when moving towards the goal, in total 18 steps are described. According to the authors, each subsequent step can be realized only after comprehending and obtaining a complete picture of the results of the previous ones. On the basis of a multifaceted analysis, the next step crystallizes, leading to the ultimate goal.

Effectiveness of the system

After the introduction of a new type of management at the enterprise, the profit significantly increased, the quality of products improved, for the better, the attitude of the staff to their work and, in general, to the company changed.

Main achievements:

• The production of metal increased to 1 million tons per year (there were 920,000 tons).
• The increase in labor productivity up to 2.9 times, the optimization of the number of personnel has occurred through the reduction of staff from 11 to 4 thousand people.
• Overhaul period of equipment has decreased to 15%, which indicates its reliability.
• The number of stocks of raw materials in warehouses has decreased by 10-30%.
• The quality of the products does not depend on the raw materials, remaining unchanged at altitude.
• Reduced the number of accidents at work.
• Due to the introduction of new environmental protection systems, the amount of emissions to the atmosphere has been reduced.
• The cost price of the products produced by the Bratsk Aluminum Smelter is one of the lowest in the world.
• The company's production capacity is fully loaded, despite the crisis.
• Investments in the company were practically not carried out, efficiency was achieved due to operating activities.

Address

The fraternal aluminum plant is a city-forming enterprise. The main facilities are located in the Irkutsk region, the city of Bratsk.