Secrets of the Aluminati: Bottleneck Assessment within an Aluminum Rolling Mill

Abstract

This work demonstrates how heuristic-based capacity estimation techniques were used to determine the utilization of the preheat process of Commonwealth Rolled Products (CRP), an aluminum rolling mill. CRP wished to evaluate its processes to determine whether its present capacity was compatible with its long-term strategic plan. The preheat process in particular presented a challenge because of its parallel work cells, interdependent finish times, and variable runtimes. This analysis was used to determine whether the present preheat plant could support the future state volume and product mix. We will summarize the CRP process and the business circumstances before moving to the modeling approach that was used to solve this problem without relying on a high-fidelity simulation. Given the outputs of that model, we will conclude with next steps for CRP, including the operational levers used to ease the capacity situation following the capital decision. Note that in order to protect company confidential information, sensitive values and information are masked in this document.