WQD2011 - INNOVATION - EMAL - Anode jacking system Provision of jubliee clips
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WQD2011 - INNOVATION - EMAL - Anode jacking system Provision of jubliee clips

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Innovation case study submitted by Emirates Aluminium during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World ...

Innovation case study submitted by Emirates Aluminium during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011.

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WQD2011 - INNOVATION - EMAL - Anode jacking system Provision of jubliee clips Presentation Transcript

  • 1. Innovation Storyboard [EMIRATES ALUMINIUMCOMPANY LTD ][Anode jacking system :Provision of jubliee clips ] [08 -2010- 01 2011 ] [Reduction R1]
  • 2. 1. About the Organization• Emal is one of the world’s largest green field smelter• Emal aims at high quality delivery of its products to customers, safety, every thing can be improved• Aluminium ingots, sow, slabs• Taweelah
  • 3. 2. The IdeaFIXING OF JUBLIEE CLIPS TOANODE JACKING SYSTEMUNIVERSAL SHAFT
  • 4. PROBLEM• Frequent detachment of the universal shaft in Super structure during Anode movement• Unbalance on the beams/anodes resulting in pot instability and anode effects.
  • 5. 3. People Involvement• Anode jacking system on super structure• REDUCTION• SID: Red/RM/ 002• Suggestors :Leyson, Jayaprakash, Madison,• Melchor, Sebado, Ullas,• Ravindra, Gereliv, Satish.• Supervisor : Luis Dominguez
  • 6. 4. ProcessThe main aim is to avoid the universal coupling from getting detached from the driven j actuator shafts even the chance when the grub screws loosens.
  • 7. 4. Process (contd.)The inclined shafts of the anode jacking system is getting detached during the operation and beam raising.
  • 8. Anode Jacking System On The Pot SuperstructureThe grub screws loosens during The universal coupling Until it detaches from the shaft. the operation. starts to move away from the set location. MAINTAINED GAP INCREASED GAP CONTACT BEFORE IT DETACHED GRUB SCREW
  • 9. Anode Jacking System On The Pot Superstructure Installed a double hose clamp onto the bus bar riser side as it is taking more load.
  • 10. Anode Jacking System On The Pot Superstructure
  • 11. BENEFITS• Minimum of 2 AED Jubilee clip and @ 3 jubilee clips / super structure.• Detachments Before implementation : 5 times• Detachments after implementation Zero .• Reduction in damaged instances after implementation• Safety of the equipment and men working in area enhanced.• Anode effect of the pot : reduced to Zero because of this reason.
  • 12. 6. Learning• Installed in all the 756 pots successfully• No repetition of the problem till date• Awarded the best suggestion of Emal• Simple solutions have tremendous effect on the system
  • 13. 7. Way Forward• All the team members were awarded .• Selected as the best suggestion for Emal• Applied in the design of future pots for further expansion of Emal .• Motivated in providing many more innovative suggestions
  • 14. Q&A
  • 15. Thank You