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WQD2011 - INNOVATION - EMAL - Modification of ALF3 Funnels
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WQD2011 - INNOVATION - EMAL - Modification of ALF3 Funnels

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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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  • 1. Innovation Storyboard[EMIRATES ALUMINIUM COMPANY LTD ] [MODIFICATION OF ALF3 FUNNELS ] [APRIL 2011- ON GOING ] [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 IdeaModification of alumina funnel
  • 4. PROBLEM• Frequent damages of Alf3 & alumina funnels• Pot starving• Un balance in the material dump weight
  • 5. 3. People Involvement• SUGGESTOR :• LEYSON, ULLAS• Supervisor : Luis Dominguez
  • 6. 4. Process• Modification of Aluminium and AlF3 funnels• Re design of the aluminum and AlF3 funnel in house• In house fabrication of funnels
  • 7. Modification of Alumina and ALF3 Funnels HUGE ELEPHANT LEG FORMATIONS ON THE BREAKER TIPS, FUNNEL NOZZLE IS TOTALLY BLOCKED RESTRICKTING THE FLOW OF MATERIAL.ELEPHANT LEG FORMATIONS ONTHE BREAKER TIPS, FUNNELNOZZLE IS TOTALLY BLOCKEDAND COATED BY THE SPLASHESOF METAL.
  • 8. Modification of Alumina and ALF3 FunnelsFUNNEL NOZZLE TIPS ARE GETTING DAMAGED AND WHOLE NOZZLE AREGETTING BENT. BEND NOZZLE DAMAGED TIP NEW FUNNEL Material choking due to damaged nozzle tipIN NUMBERS OF OCCASIONS, FUNNELS ARE DETACHED AND/OR FOUNDMISSING AFTER IT FALLS INTO THE BATH AND MELTED. THE PURITY OFTHE METAL IS HAMPERED.
  • 9. Modification of Alumina and ALF3 Funnels SOLUTION TO THE PROBLEM
  • 10. Modification of Alumina and ALF3 FunnelsThe funnel nozzle end is The funnel nozzle angle of reduced 2 inches inclination is reduced from shorter. 55 deg. to 45 deg.MODIFIED FUNNEL ORIGINAL FUNNEL ORIGINAL FUNNEL MODIFIED FUNNEL ( WITH DAMAGED TIP)
  • 11. Modification of Alumina and ALF3 FunnelsORIGINAL NOZZLE DISTANCE HAS BEEN CHANGED TO FACILITATE THE ELEPHANTLEG FORMATION ON THE BREAKER TIPS AND TO AVOID THE SPLASHES OF BATH AND METAL FROM BEING DEPOSITED ON THE NOZZLE TIPS. ORIGINAL DISTANCE INCREASED DISTANCE
  • 12. BENEFITS• Minimizing the no of funnel replacement• Minimizing the frequent no of exposure to heat & fluoride gas for the maint. Techs.• Decreased environmental impact• Health of the employee improvement• Heat stress reduced during summer
  • 13. Benefits• Exact amount of feeding of alumina to pots• No elephant formation resulting in blockage of funnel• Damage to funnel reduction• Cost of funnel and inventory affected
  • 14. Benefits• Financial• No of calls till today for funnels : 9557• Min cost for repair of funnel: 225 AED• Total cost for 9557 = 2,150,325AED• New funnels installed =238• Failure of new funnels till date =ZERO• Cost saved : 1,465,300AED
  • 15. 6. Learning• Installed up to 2421 funnels successfully• No repetition of the problem till date• Awarded the best suggestion of Emal• Simple solutions have tremendous effect on the system• In house development saves millions
  • 16. 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 .• Approved by the DX technology provider.• Design being patented by Emal• Motivated in providing many more innovative suggestions
  • 17. Q&A
  • 18. Thank You

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