Nintex > Case Studies > Enhancing Safety and Efficiency at Tomago Aluminium with K2 Software

Enhancing Safety and Efficiency at Tomago Aluminium with K2 Software

Technology Category

Cybersecurity & Privacy - Identity & Authentication Management
Cybersecurity & Privacy - Security Compliance

Applicable Industries

Metals
Paper & Pulp

Applicable Functions

Quality Assurance

Use Cases

Onsite Human Safety Management
Time Sensitive Networking

About The Customer

Tomago Aluminium is the largest aluminum smelter in Australasia, operating 24 hours a day since 1983. The company contributes $1.5 billion annually to the Australian economy, of which $800 million is spent locally. The smelter produces 585,000 tons of aluminum every year, which accounts for 25% of Australia’s primary aluminum. 90% of the product is exported to the Asia-Pacific region. The company has 840 pots that are extremely important to the business, as any instability could cost the company millions of dollars. Therefore, it is crucial for the company to find and resolve problems quickly.

The Challenge

Tomago Aluminium, Australasia’s largest aluminum smelter, was grappling with a disconnected IT infrastructure and an over-reliance on paper forms and email-based processes. This led to a lack of transparency and visibility into potential safety issues, making it difficult to ensure that tasks were being carried out safely and that safety issues were addressed promptly. The company was using surveys within SharePoint and paper forms to conduct life-saving controls, which created safety risks and made reporting difficult. Additionally, the company had to audit its 840 pots daily, a process that was tedious and time-consuming. The data collected from the pots had to be written down manually and then entered into a shared spreadsheet, a process that was prone to errors and inefficiencies.

The Solution

Tomago Aluminium implemented several solutions with K2 Software to automate its key processes. The software allowed the company to utilize an SQL database and integrate solutions with SAP, providing the flexibility to develop additional business solutions to improve efficiency and cut costs. The life-saving control process was automated, enabling employees to log issues automatically and check the status of safety tasks easily. The company also automated the pot auditing process. Auditors now enter data on-site using their mobile phones and a stylus, and the data is consolidated by the time they return to their desks. A Power BI report is automatically generated with the appropriate data and graphs, and copies are emailed to all necessary parties. The company also automated over a dozen other processes, including statutory compliance and contractor onboarding.

Operational Impact

The implementation of K2 Software has brought about significant operational improvements at Tomago Aluminium. The automation of the life-saving control process has improved safety by enabling employees to log issues automatically and check the status of safety tasks easily. The automation of the pot auditing process has not only saved time but also improved the accuracy of the data collected. The data is now more reliable, eliminating the risk of misinterpretation due to illegible handwriting. The automation of other processes, such as statutory compliance and contractor onboarding, has also led to significant time savings and increased efficiency. The company has been able to move from being reactive to proactive, responding to data faster and making information more readily available for analysis and reporting.

Quantitative Benefit