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Alcoa in Profile: Russia
2005 Alcoa completed the acquisition of the Samara Metallurgical and Belaya Kalitva Metallurgical Manufacturing Association (in July 2007 it was reorganized by joining JSC Alcoa Metallurg Rus) from Russky Aluminy for $257 million.
2005 - 2007 Total investments (including the acquisition) reach nearly $290 million and target aligning the Russian production facilities with Alcoa’s best global standards.
2008 Completion of the investment program
In order to improve product quality and raise production efficiency to global standards according to the requirements of large customer companies in Russia and around the globe Alcoa upgrades production and implements new technologies at SMZ and Alcoa Metallurg Rus.
Other than equipment purchase and upgrade, major funds are invested in implementation of Environment, Health and Safety System, improvement of Alcoa Business System, employee training and development of workforce potential.
With regard to development forecasts of the Russian and global aluminum markets Alcoa invests in casthouse, mill products and forgings productions that provide material for the most rapidly developing sectors of the Russian economy.
The investment projects at Samara Metallurgical plant are worth over $140 million, investments in production facilities of AMR (Alcoa Metallurg Rus) exceed $100 million.
PRODUCTION FACILITES OF ALCOA RUSSIA
JSC Samara Metallurgical plant (SMZ) is Russia’s largest producer of fabricated aluminum
The share of SMZ in the mill products market is nearly 40%.
Samara Metallurgical plant is:
- 388 acres of land
- 7,3 million square meters under roof
- 4 725 employees
JSC SMZ has 4 business units
- Casthouse
- Extrusions
The largest extrusion press in Russia - Mill products
- Forgings
The largest forging press in Russia
JSC Alcoa Metallurg Rus (AMR, the legal successor of Belaya Kalitva Metallurgical Manufacturing Association) is Russia’s largest producer of fabricated aluminum.
The share of JSC AMR in the mill products market is nearly 10% .
Alcoa Metallurg Rus is:
- 190 acres of land
- 3,5 million square meters under roof
- 3 277 employees
JSC AMR has 4 business units
- Casthouse
- Extrusions
- Mill products
- Forgings
MANUFACTURED PRODUCTS
SMZ manufactures a wide variety of flat-rolled, extruded and forged products:
- coils, including can stock (body, end and tab), tin stock, lacquered strip
- sheet, profiles, panels, tubes, forgings, incl. large-scale ones
JSC AMR manufactures a wide variety of flat-rolled, extruded and forged products:
- coils, plate for aerospace
- profiles, panels, tubes, forgings.
Customers in packaging, aerospace, automobile, building and construction, oil&gas widely use the products of both locations and their capacity to design and develop new solutions.
INVESTMENT PROGRAM
The investment program at JSC SMZ includes:
- Casthouse: development of high-quality ingot production for can stock and fabricated aluminum in aerospace sector
- Extrusions: development of fabricated aluminum production for oil&gas, building and construction
- Forgings: development of large-scale forgings production for aerospace
- Mill Products: development of can stock production, tin stock and lacquered stock
The investment program at JSC AMP includes:
- Casthouse : development of high-quality ingot production for defense industry
- Forgings : development of forgings production for export wheels
- Rolled products: development of plate production for aerospace with features that comply with world standards and directive technologies of the global aerospace customers
Alcoa signed a cooperation agreement with United Aircraft Corporation (UAC) to provide UAC with advanced metallic materials, modern structural concepts and manufacturing technologies for UAC future generation civil aircraft. Technological cooperation will cover a wide variety of items including proprietary alloys, heat-treated sheet and plate, hard-alloy extrusions, and forgings
QUALITY CERTIFICATES
The Samara plant's production and quality control systems have been ISO 9001/9002 certified.
The plant’s environmental management system has been ISO 14001:1996 certified.
Awarded certificates are:
- Aviation standard certificate, valid until June 2009, certificate # FM 502650
- Automotive standard certificate, valid until April 2009, certificate # FM 502651
- Standard of Russian Maritime registry of shipping (requirements to supplier of shipbuilding sector), valid until February 2008, certificate # FM 04.00001.141
- Standard of Air Registration Boards of the Interstate Aviation Committee (to produce aerospace materials), valid until July 2010, certificate # СПМ-8/2
- Nadcap SAE Aerospace Standard AS7003, valid until May 2008, certificate #118632
- European guideline for press-forming equipment PED 97/23/EC- Appendix I, 4.3, AD2000-W0/TRD100, valid until June 2010, certificate #7145CZ-041-001
The Belaya Kalitva plant's production and quality control is ISO 9001 and AS 9001 certified
- Registration certificate BSi № FM 500617 in conformity with quality management system requirements AS/EN9100, REV B, BS EN ISO 9001:2000 and AS 9104 as a supplier of aerospace materials
- Approval #1624684 to produce plate according to requirements of ABS (American Bureau of Shipping)
- Certificate # РОСС RU.ИС11.Р00520 to produce metal products, aluminum products and aluminum alloys according to requirements of all-union standard Р ИСО 9001-2001
- certificate СПМ-14/1 of Aviation register for production of aviation materials
- NADCAP certificate in ultrasound control
- The facility is undergoing the procedure for environmental management system certification.
CORPORATE SOCIAL RESPONSIBILITY ACTIVITY
Since 2005, Alcoa Russia and Alcoa Foundation have invested in the communities about USD 1800000. Alcoa Russia focuses on programs in education and sustainability which are implemented in all regions where Alcoa has presence. These programs include Alcoa Foundation Technical Education Support in three leading technical universities and educational programs in conservation and sustainability for middle schools.
OAO SMZ and OAO AMR also implement community programs to address the local needs. As part of Alcoa program Ten Million Trees, Alcoa employees planted about 4000 trees.
The combined community investments in the Samara region in 2005-2007 amount to more than USD 750 000. Initiatives :
- Alcoa Foundation Technical Education Support Program in Samara State Aerospace University (SGAU): 50 scholarships to best students at engineering faculties, 5 development stipend for young faculty members, technical upgrades of lecture rooms and laboratories.
- Conservation and sustainability program “We are un charge of the future” for middle schools of the Kirovsky district in Samara.
- Children’s cardiology program “Heart to Heart”.
- Assistance to educational organizations in Samara, e.g. Center of Special Education for Children with Disabilities, to youth organizations, veterans, Alcoa volunteers’ events to clean up, refurbish and landscape the Metallurg district.
The combined community investments in Belaya Kalitva and the Rostov region in 2005-2007 amount to more than USD 700 000. Initiatives :
- Alcoa Foundation Technical Education Support Program in Donskoy State Technical University (DGTU): 50 scholarships to best students at engineering faculties, 5 development stipend for young faculty members, technical upgrades of lecture rooms.
- Conservation and sustainability programs “We are un charge of the future” and “Friends of Islands of Nature” for middle schools in Belaya Kalitva and its region.
- Assistance to educational organizations in Samara, e.g. the Cossacks’ Cadet Boarding School, to youth organizations, veterans, Alcoa volunteers’ events to clean up, refurbish and landscape the city.
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