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State of the Plant Meeting Review Of January – February 21, 2012

State of the Plant Meeting Review Of January – February 21, 2012. Introduction – Mark Shelley Safety –Ed Chojnicki Plant Financial Performance – Simon Michael Manufacturing – Fred Espinoza / Raul Reyes Plant OTD Performance – Stephen Law Quality – Mark Shelley

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State of the Plant Meeting Review Of January – February 21, 2012

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  1. State of the Plant Meeting Review Of January – February 21, 2012

  2. Introduction – Mark Shelley • Safety –Ed Chojnicki • Plant Financial Performance – Simon Michael • Manufacturing – Fred Espinoza / Raul Reyes • Plant OTD Performance – Stephen Law • Quality – Mark Shelley • Kaiser LA Vision/Direction (Update) – Mark Shelley • Kaiser®Select– Tom Gannon – VP of Sales/Marketing

  3. PLANT FOCUS • Operational Efficiency • Maximize Metal Profits • Mix Rationalization • KaiserSelect® • EHS Culture/Sustain

  4. 2012 Key Metrics, Targets, & Initiatives

  5. Key Points: • Cast house , 4000 TP & 2400 TP manufacturing efficiencies are key drivers for the positive EBITDA • Good spending control – R&M spending, OT, and Deval October Financial Results January- 2012 Financial Results $265K (EBITDA) = Total Revenues Total Costs = Break Even Revenues Costs Improved Customer Service Increases Revenues Improved Efficiency Lowers Cost

  6. Controllable Mfg. Cost – Earned vs. ActualAnd Press Efficiency Trends 6

  7. 2011 Kaiser Values – Valued Corporate Citizen LCIR 2012 Key Plant Focus Initiative 7 7

  8. 2011 Key Initiatives – October Status • EHS Performance • No recordable injuries in January • Hard hat policy in December • Implementation of adding disposable plastic bottles to the banned from the plant list. • 2012 key focus on using the FMEA for focus to the safety initiatives. • Continued emphasis on separation of pedestrians from mobile equipment.

  9. Kaiser Los Angeles2011 On-Time Delivery Performance 10 10

  10. ON TIME DELIVERY DETAIL 2011 Feb-March: Schedule issues LA/KMZ, system. Mill driven. DT balance of majority of monthly issues 11

  11. External Vital Few – Los Angeles 12

  12. External Quality Justified Claim Free Performance % Of Line Items Justified Claims Average Average #claims per month

  13. Internal Vital Few

  14. Lean Sigma (CI) • Key Initiatives (SDx) • Safety • BIC Customer Service • Quality Performance • Controllable Cost • Capacity/Other • Summary

  15. 2011 Key Initiatives – Press Efficiency Overall Press Efficiency Recovery Impact= -11% Efficiency ’08 vs. ‘09 New equipment was installed at the end of 2008.

  16. 4000 Press Efficiency 4000 TP Efficiency 17

  17. 2010 Key Initiatives – Manufacturing Efficiency 18 18

  18. 2400 Press Efficiency 2400 Press Efficiency 19

  19. 2011 Key Initiatives – Manufacturing Efficiency 20 20

  20. 1650 Press Efficiency 1650 Press Efficiency 21

  21. 1650 Press Efficiency

  22. 2012 Cast House Pounds/Cast Hour Operating Melter Furnace 1 1 2 2 2 2 1 1 1 1 1 2 1 1 1 1 1 1 23

  23. Cast House Efficiency Cast pounds/labor hr August 2011 3,032 lbs/lbr.hr in 21 casting days January 2012 3,296 lbs/lbr.hr in 19 casting days

  24. METAL PROFITS MAXIMIZATION BOOK 25

  25. Cast House Efficiency Metal Profit

  26. 2012 PLANT FOCUS • Resolution of NOx Compliance • Meeting Cast House burner NOx compliance • ISO14001 Compliance • EHS Risk Reduction • Ergonomics • Press Downtime Reduction • Controllable Manufacturing Variance • Enhancement of Engineering/Maintenance • Systems, Practices, Capabilities, Management, Spending • Achieving 98% Service Levels for “A” and “B” Items • Maintain Competitive Lead Times

  27. Mix Rationalization Strategy • Established a “Mix Rationalization Strategy” for the Plant • Mix Rationalization Team – Marketing, Sales, and Manufacturing • Established Team Strategy • Implementation of Strategy underway • Heat Sink exit strategy underway • Excessive lengths exit strategy underway • Fabrication strategy implementation • “Specific” financial, processing, “noise” analysis & exit strategy • Example: KenFabrica • Leaded Alloy Exit Plan – February 2012 28

  28. 2011 KaiserSelect® Product Introductions • KaiserSelect® Rod Implementation – Q1 - 2011 • Rod Diameter: 0.75” - 3.00” (COMPLETE) • KaiserSelect® Manifold Bar – Q2 • 2.00” – 8.00” (COMPLETE - ONGOING) • KaiserSelect® Large Rod – Q3 • Rod Diameter: 3.00” – 8.5” (COMPLETE – Q1 – 2012) • KaiserSelect® Log/Billet – Q4

  29. KaiserSelect®

  30. KaiserSelect®

  31. KaiserSelect®

  32. KaiserSelect®

  33. Questions?

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