Case Study: Novelis achieves optimized throughput and reduced work in process with iGrafx Process for Six Sigma

iGrafx helps predict production weaknesses and strengths, simulating real complexity and interactions

Novelis, the world leader in aluminum rolling, needed a way to model the real complexity of its cold mill area (1 cold mill, 2 slitters, 5 annealing ovens) where up to 500 coils with different process paths, phase times, resource usage and queue effects interact. The company engaged iGrafx and deployed iGrafx® Process™ for Six Sigma to build a process model capable of representing true asset availability and production variability and to predict potential production issues in advance.

iGrafx delivered a simulation-based solution that loads coil-by-coil data, allows injection of new demand during runs, and produces macro-driven reports to highlight weaknesses and strengths several days ahead, enabling concrete action plans. The iGrafx implementation reduced work in process and lead time, improved cash flow, optimized asset workload and production costs, and gave planners the ability to predict throughput, queues, WIP, machine utilization and optimal maintenance timing—delivering measurable economic benefits and a permanent mindset change.

Novelis

Emanuele Strada

Continuous Improvement Coordinator