AISLAN COSTA
Plant / Project Manager
Abu Dhabi,UAE
Summary
Thirty years of experience in the steel-producing industry, working closely with R&D centers (USA and France), engineering, and, mainly, at various rolling mills and Roll shops in Brazil, the USA, and Europe. In addition,I am a project manager – head of Thin Slab Caster and Rolling at Emirates Steel (UAE).
I was part of the team in charge of the Arcelor Mittal Tubarão (formerly CST) Hot Strip Mill start-up in 2002. This mill is Brazil's first Arcelor Mittal Flat products hot strip mill.
Overview
31
31
years of professional experience
Work history
Head
Emirates Steel, Hot, Coils
Abu Dhabi, UAE
09.2021 - Current
- Thin slab caster and rolling (TSCR) - Project manager
- Starting a new project to enhance Emirates Steel's product portfolio by selecting OEM and running the TSCR project while building up a team
- Current Team: 5 senior experts report (automation, finishing, quality, caster, and liquid steel)
- Established a process relocation of sheet pile / heavy section rectification yard to a more productive process line, replacing forklift handling materials for EoT cranes.
- A plant topographic survey was conducted using drone flight and photogrammetric methodology, underground mapping, and soil investigation of the entire plant. It was concluded on time and under budget.
- It was performed an entire project selection, commercial and technical, of specialized partners to develop a long-term BOO (build, own, and operate) basis contract to generate at least 20 MWp electricity capacity by installing PV cells at the rooftop of the buildings and carports. This will enable savings of up to 3 million US dollars when the contract ends.
Hot Strip Mill Plant manager
Arcelor Mittal Tubarão
Vitoria, Brazil
07.2019 - 08.2021
- Operations and maintenance, responsible for safety, production, quality, environment, cost, and people´s development of 298 employees working 24 x 7 crews, 14 reliability engineers, and three managers
- Follow up on mainline stoppages and productivity.
- Increase Hot Strip Mill production annual capacity to reach 4.5 Mt by the end of 2023 (currently 4.3 Mt/year)
- Monthly overtime rate reduction by changing practices and reviewing meeting concepts
- Motivate people by running a team integration plan
- Get a developing project to train the team and make them able to assume new positions
- Challenge the maintenance team to a 15% cost reduction (approx.100 MR$ annual budget)
Finishing Products Plant manager
Arcelor Mittal Tubarao
Vitoria, Brazil
09.2018 - 06.2019
- Operations and maintenance, responsible for safety, production, quality, environment, cost, and people´s development of 378 employees working 24 x 7 crews, five reliability engineers, and two managers.
- Increase 10% of the overall wrench time productivity by the end of the year.
- Finishing lines dashboard to follow up on mainline stoppages and productivity.
- Increase Finishing line production annual capacity to reach 850Kt by the end of 2019 (used to be 810Kt/year).
- Monthly overtime rate reduction plan by changing practices and reviewing meeting concepts.
- Motivate job rotation among shift managers.
- Get a developing plan to train the team and make them able to assume new positions.
- Challenge the maintenance team to a 10% cost reduction (approx
- 25 MR$ annual budget) by applying reliability tools, minimizing risk equipment, and increasing team productivity.
- Increase 10% of the overall wrench time productivity by the end of
Operating Technology Team manager
Arcelor Mittal Tubarao
Vitoria, Brazil
09.2015 - 08.2018
- Monitored team development, setting performance objectives and providing constructive feedback for continued growth. Fourteen process engineers are responsible for process stability and improvements.
- HSM stabilization plan to ensure higher productivity and mill stability
- Bottleneck analysis to reach 4.3 Mt HSM production by the end of 2018
- Promote initiatives to improve mill stability (unexpected roll changes and cobbles reduction), Quality, and cost reduction.
Finishing & Shipping manager
Arcelor Mittal Tubarao
Vitoria, Brazil
04.2015 - 08.2015
- Responsible for safety, production, quality, cost, and HR of 112 employees working 24 x 7 on four crews,
- Finishing lines Optimization plan to reach the nominal capacity by the end of 2015 through operational practice changes, training, and implementation of short-term projects
- Monthly overtime rate reduction plan from 4.5 % to 0.12% by changing practices and reviewing meeting concepts
- Motivate operators by engaging them in a training plan to enable them to assume new operations positions.
Head
Arcelor Mittal Galati
Galati, Romania
07.2013 - 03.2015
- Progress, Process, Quality, and Customer Service Team for the Galati Hot Strip Mill responsible for:
- Establish and review standard procedures to run pickled & oiled coils, keeping the non-conform product level below 3,5% per month.
- Improve the Hot Strip Mill yield losses by reducing the cobble rate and the % of non-conform products.
- Finish up technical studies and contract out qualified companies to upgrade the finishing mill level 1 and 2 systems.
- Implement #1 coiler automation project (Phase 1) and prepare it for mechanical changes (Phase 2), standardizing all three coilers mandrel types
- Follow up and Promote actions to enhance workplace safety focusing on near misses, shop floor safety audits, communication meetings, and other corporate safety tools.
- Coordinate and implement quality control objectives, activities, or procedures to resolve production problems, maximize product reliability, and minimize costs.
- Manage a team of engineers to run projects to improve quality, and customer satisfaction and reduce costs by improving yield and reducing non-conform products.
Senior Hot Strip Mill engineer
Arcelor Mittal Burns Harbor
Burns Harbor, USA
10.2008 - 06.2013
- Reduce the # of unplanned F7 roll changes by ripped tail end occurrences reduction.
- The main achievements were: rejected rate reduction for bruises, pinchers, and gauge diversions, and the Iron roll stock losses reduction (around US 2.2millions in savings/in 2010)
- Reduce the HSM roll consumption by roll shop and HSM practices (around US$ 2.95 Million in savings/in 2010)
- Improve the HSM productivity by reducing the delay rate and increasing the delay-free productivity (US$ 4.94 million in savings/in 2011)
- Follow up of hot strip cobbles and hot coil defects: causes, consequences, and actions to minimize occurrences.
- Operators/supervisors/ mill engineers training to improve mill stability.
Senior Hot Strip Mill engineer
Arcelor Mittal Tubarão
Vitoria, Brazil
07.2000 - 09.2008
- Six Sigma project conclusions in Tubarão HSM - US$ 800,000 savings using the DMAIC approach 2
- Tubarão HSM cobble rate reduction being a technical advisor and using a methodological approach (cobble rate reduction from 0.30% to 0.14%) - around US$ 1.5 million in savings.
- Process development for light gauges (thickness below 1,8mm) - Increase the % of lighter gauges up to 25% of the Production Mix.
- Implementation of HSS rolls in the Finishing mill and also CPC rolls - Increase the performance (t/mm) by using HSS rolls without re-griding
- Follow up on hot rolling process parameters (dimensional and quality performance)
- Operators/supervisors/ mill engineers training to improve mill stability
- Follow up on the Coil Box technical assistance by SMS-Demag.
Roll Shop Assistant Manager
Companhia Siderurgica Nacional(CSN)
Volta Redonda, Brazil
04.1993 - 06.2000
- Supervise, technically and administratively, two roll shops (HSM and Cold mill), managing around 100 operators working 24 x 7
- Re-build / revamp older roll grinding machines to meet tighter roll requirements to improve Hot strip mill and cold mill coil quality
- Developing roll inspection procedures (NDT - internal roll process evaluation (surface and internal roll quality) -100% of the ispectors trained.
- Development of roll improvement - HSM - HSS rolls and BUR with 5%Cr. Increasing roll campaigns and strip surface quality - estimate cost savings of US$ 250,000.00 per year.
- Follow up the roll shop technical assistance by Thyssen Group
- Carried out day-to-day duties accurately and efficiently.
- Conducted testing to diagnose system faults.
Education
MBA - Strategy And Economics
Getúlio Vargas Foundation (FGV)
Rio de Janeiro 01/2019 - 01/2021
MBA - Production Engineering
Dom Cabral Foundation
Vitoria 01/2006 - 01/2007
Master of Science - Production Engineering
UFRJ - Rio de Janeiro Federal University
Rio de Janeiro 01/1997 - 06/2000
Bachelor of Science - Metallurgical engineering
Military Institute of Engineering
Rio de Janeiro 01/1988 - 11/1992
Skills
- January/2023 Austria/Italy – Thin slab Casting and Rolling Layout - Visit – 80 hours
- July/2022 Austria/Italy – Pickling Line - Visit – 80 hours
- July/2022 Italy – Arvedi Thin Slab Casting and Rolling - Visit – 48 hours
- June/2018 Brazil – AHSS Metallurgy - Hot Rolling (R&D - Vitoria) – 24 hours
- June/2013 USA - Metallurgy for Professionals : Hot Rolling (R&D - East Chicago) – 24 hours
- Nov/2011 Luxemburg - Talent Pipeline Training (Leadership training) – 40 hours
- Aug/2011 USA–Burns Harbor- Project Management (ESI-George Washington University)–24 hours
- Dec/2010 USA – Burns Harbor - Metallurgy for Professionals – Defectology – 24 hours
- Apr/2005 USA - Pittsburgh- International Rolling Mill Academy (ALSTOM) - 36 hours
- Oct Nov/2004 Brazil - GREEN BELTS – SIX SIGMA Methodology-80 hours
Accomplishments
- PRIZES AWARDED! 2011 International Iron & Steel Conference - Indianapolis - USA
- AISTech - The Iron & Steel Technology Conference and Exposition
- Roll Consumption reduction at Arcelor Mittal 80” Burns Harbor Hot Strip Mill through roll shop grinding practices and mill stability Improvements (presented and published in the
- February issue of 2012 Iron & Steel magazine-selected for the 2012 Rolls Technology Award for best paper
- 2018 49th Rolling Seminar - Process, Rolled and Coated Products - Sao Paulo - Brazil
- ABM - (Materials and Metallurgy Brazilian Association
- Slab width forecast optimization in continuous casting production to reduce losses by width change
- 2013 International Iron & Steel Conference - Pittsburgh - USA
- AISTech - The Iron & Steel Technology Conference and Exposition
- Shape Performance improvements at Arcelor Mittal 80” Burns Harbor Hot Strip mill
- 2010 International Iron & Steel Conference - Pittsburgh - USA
- AISTech - The Iron & Steel Technology Conference and Exposition
- Adding value to the Hot Rolled Coil Business at Burns Harbor by Reducing the number of Unplanned Roll Changes while Sharing Technical Experiences on the Arcelor Mittal
- 2007 International Iron & Steel Conference - Indianapolis - USA
- AISTech - The Iron & Steel Technology Conference and Exposition
- Tail-end Crashing Reduction Using Six Sigma Methodology 2004 41st Rolling Seminar - Process, Rolled, and Coated Products - Vitoria - Brazil
- ABM - (Materials and Metallurgy Brazilian Association)
- Process Developments of light gauges in CST HSM 2000 37th Rolling Seminar - Process, Rolled, and Coated Products - Curitiba-Brazil
- ABM - (Materials and Metallurgy Brazilian Association)
- Evolution and recent developments in work rolls to the finish stands from HSM (presented)
Languages
English
Fluent
Portuguese
Native
Spanish
Advanced
Romanian
Intermediate
Timeline
Head
Emirates Steel, Hot, Coils
09.2021 - Current
Hot Strip Mill Plant manager
Arcelor Mittal Tubarão
07.2019 - 08.2021
Finishing Products Plant manager
Arcelor Mittal Tubarao
09.2018 - 06.2019
Operating Technology Team manager
Arcelor Mittal Tubarao
09.2015 - 08.2018
Finishing & Shipping manager
Arcelor Mittal Tubarao
04.2015 - 08.2015
Head
Arcelor Mittal Galati
07.2013 - 03.2015
Senior Hot Strip Mill engineer
Arcelor Mittal Burns Harbor
10.2008 - 06.2013
Senior Hot Strip Mill engineer
Arcelor Mittal Tubarão
07.2000 - 09.2008
Roll Shop Assistant Manager
Companhia Siderurgica Nacional(CSN)
04.1993 - 06.2000
MBA - Strategy And Economics
Getúlio Vargas Foundation (FGV)
01/2019 - 01/2021
MBA - Production Engineering
Dom Cabral Foundation
01/2006 - 01/2007
Master of Science - Production Engineering
UFRJ - Rio de Janeiro Federal University
01/1997 - 06/2000
Bachelor of Science - Metallurgical engineering
Military Institute of Engineering
01/1988 - 11/1992
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