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Safety Improvements, Environmental Protection Enhancements, Customer Focus, Cost Control Initiatives See Alcoa's Massena Facilities Through Tough 2002 Challenges
MASSENA, NEW YORK, February 5, 2003–2002 was a year of celebration and a year of challenge for the men and women of Alcoa’s Massena Operations. In July, the West Plant opened the doors to the community for tours, environmental, technical and historic displays, entertainment and a chicken barbeque provided by the Massena Volunteer Fire Department to celebrate a century of aluminum production in Massena. Those who visited the plant were presented with a lilac tree to nurture as a symbol of the growth and prosperity that Alcoa and the North Country communities have shared through the past century and hope to continue into the future.
The 100th year of operation for Alcoa’s plants in Massena was very demanding. Depressed economic conditions have negatively impacted the local engineered products operations’ bottom line for nearly two years, and primary metals operations at Massena were adversely affected by globally declining metal prices during the last half of 2002. These conditions continue to pose challenges into 2003 both locally, and across the corporation.
During 2002, Alcoa Engineered Products Massena worked through a restructuring process realigning the organization as a more customer focused facility that can be more responsive to fluctuating market conditions. “Efforts to reduce costs, improve customer focus and enhance productivity in the recent past has better positioned Massena’s Alcoa Engineered Products (AEP) facility to meet the challenges we will face in the coming year,” AEP Operations Manager Erick Lewis explained. “The corporate restructuring announced with the 2002 year-end financial statement is a continuation of the Alcoa Business System philosophy of providing the customer with the product they want, in the quantity they need, when they require it, while eliminating waste in the process and providing a safe work environment for employees and the community, in order to be a successful long-term business. All locations, including Massena are required to utilize the Alcoa Business System to meet or exceed corporate goals. The changes made in 2002 provide a solid foundation to improve our competitive position into the future.”
Massena’s Smelting Operations made great strides in improving efficiency and productivity since the Alcoa/Reynolds merger in May of 2000. However, global competition, low metal prices and higher operating costs required the Massena Smelters, particularly the East Plant, to revisit cost reduction options in order to remain competitive. As 2003 begins, both smelters will be operating with streamlined organizations after workforce reductions in December 2002 and into January.
“We are grateful for the support of our local, county and state government representatives, economic development, and New York Power Authority incentives that will assist us in controlling costs as we work to become more competitive at the Massena East Plant,” Massena Smelting Operations Manager Nelson Dubé stated. “Alcoa is facing the challenges of doing business under the current economic conditions by refocusing on the things that can be controlled - cost containment, safety, environmental
control and process efficiency improvements to better meet customer needs. We at Massena have been working jointly to incorporate these same corporate initiatives and better position our plant for the future. Unfortunately, this has required workforce reductions.”
Throughout these changes, the number of accidents and severity of injuries were reduced at both facilities through employee efforts to identify hazards, improve housekeeping and implement ergonomic initiatives. No one at the West Smelter or in Massena’s Engineered Products departments suffered a lost time injury and serious injuries at the East Plant were reduced by 28%. The focus for 2003 will be to accelerate ergonomic improvements and standardize safe work practices as Massena Alcoans strive for an injury-free workplace.
With the majority of the environmental remediation work completed at both local Alcoa facilities, environmental enhancement activities were initiated last year as work was started on creating about 100 acres of new wetlands on the East Plant site. “During the Remediation Project at the West Plant some of the existing wetlands had to be converted into upland areas and required replacement under the agreements with New York State Department of Environmental Conservation,” Remediation Project Manager Rick Esterline explained. “We are enhancing the basic wetlands being created with bluebird houses, wood duck boxes, houses for wrens, chickadees, nuthatches and other small birds, mallard nests, bat boxes and an osprey nesting platform. A public observation area will be completed in 2003 on the north side of the site and we are working with the St. Regis Mohawk Tribe to plant black ash trees in the area, a tree beneficial to the basket making industry that has become less populous since industrialization. The purpose of this project is not just to replace wetlands, but to create a habitat that will enhance the environment and restore diminished area resources.”
Massena Operations maintained international ISO 9002 and QS-9000 quality certification at both facilities last year. In 2002, employees began efforts to earn ISO 14001 certification, the environmental control quality system standard, by the first quarter of 2003.
Alcoa continued its tradition of commitment to the community in 2002. Through Alcoa Foundation grants and local donations, nearly $350,00 was given last year to support a wide array of projects, educational programs and community needs. Alcoa provided funding, mentors and case studies for the Massena Tech Prep Program and Brasher Falls Central School Planetarium Partnership. $100,000 was given for Massena’s Bicentennial Celebration. Funding was also given to local colleges and universities for scholarships, the Norfolk Rescue Squad building fund, Cerebral Palsy Association, Rose Hill, Norwood Village Green, Community Performance Series, Ogdensburg Command Performances, Gibson Gallery ArtPartnership, AEIOU, Renewal House, Orchestra of Northern New York, American Red Cross, and Franklin County Northern Adirondack Envirothon.
Last year, Massena Alcoans contributed over $80,000 to the United Ways of Northern New York and Franklin County and 43,538 items to the Annual Employee Food Drive. Groups of employees earned Alcoa Foundation grant funding by volunteering to assist with projects to enhance the Veterans Memorial Park, Massena Minor Hockey and the Massena Library.
“The efforts of employees at all levels of the organization to successfully implement tough changes has established a strong foundation for meeting the demands of the marketplace and the needs of our customers,” Lewis stated. “We continue to have a tremendous challenge ahead of us. Both businesses at Massena must relentlessly improve their efficiency in an extremely competitive global economy.”
“We must sustain and build on the progress made in 2002,” Dubé added. “Our first priority is the safety of employees and environmental protection. Costs reduction and process efficiencies through the further deployment of our ABS system remains critical for our success. And, we will continue to work with the New York Power Authority toward a long-term contract that will enable us to plan for the future.”
Alcoa’s Massena Operations is the oldest continuously operating aluminum facility in the world. Serving customers in the automotive, transportation, aerospace and industrial distribution markets, it is one of Alcoa’s approximately 360 locations in 38 countries. Currently employing 1492 people, Massena Operations is the largest private employer north of Syracuse, contributing $250 million dollars annually to the local economy in payroll, local purchases and tax payments. Alcoa employs 127,000 worldwide.
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