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Innovation Storyboard[EMIRATES ALUMINIUMCOMPANY LTD ]     [Torque measuring device ]              [SID 055]           [Red...
1. About the Organization• Emal is one of the world’s largest green field  smelter• Emal aims at high quality delivery of ...
2. The Idea        TORQUE MEASURING DEVICE•   The production of aluminium is by    the process of electrolysis•   The anod...
POT CELLVIEW OF THE SUPERSTRUCTURE WITH ANODES                                         Anode clamp
The ProblemANODE CLAMPS DAMAGES WHILE ANODE SETTING BY ABRE/PTMNO INSTRUMENT TO COMPARE THE VALUES AND SETTING ONABREDAMAG...
•   Damaged anode clamp shaft                     Damaged anode clamps view                     Damaged clamps (July- Dec-...
The Proposal / SolutionTORQUE MEASURING DEVICE FOR ABRE & PTM CALIBRATIONINTRODUCTION OF A TORQUE TRANSDCER ON AFABRICATED...
ImplementationThe transducer was assembled and mounted on the jigfabricated ,custom made for this purpose .The jig is plac...
IMPLEMENTATIONANODE CLAMP DUMMY BOLT  WELDED ON A SOCKETTORQUE TRANSDUCERRUBBER CUSHIONINGFABRICATED DEVISE  MOUNTING JIG
TORQUE METERING DEVISE FOR ABRE & PTM WRENCH CALIBRATIONIMPLEMENTATION:                       ACTUAL CALIBRATION DONE IN A...
3. People Involvement• Suggestors: Leyson, Ullas Gereliv
ImplementationThe transducer was assembled and mounted on the jigfabricated ,custom made for this purpose .The jig is plac...
BENEFITSBy applying a set torque of 340 N M and calibrating the  ABRE to the set torque (pneumatic) and comparing it  with...
7. Way Forward• All the team members were awarded .• Selected as the best suggestion for Emal• Applied in the calibration ...
Q&A
Thank You
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WQD2011 - INNOVATION - EMAL - Torque measuring device

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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 Quality Day 2011.

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Transcript of "WQD2011 - INNOVATION - EMAL - Torque measuring device"

  1. 1. Innovation Storyboard[EMIRATES ALUMINIUMCOMPANY LTD ] [Torque measuring device ] [SID 055] [Reduction R1]
  2. 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. 3. 2. The Idea TORQUE MEASURING DEVICE• The production of aluminium is by the process of electrolysis• The anode is clamped to the bus bar by the anode clamps .
  4. 4. POT CELLVIEW OF THE SUPERSTRUCTURE WITH ANODES Anode clamp
  5. 5. The ProblemANODE CLAMPS DAMAGES WHILE ANODE SETTING BY ABRE/PTMNO INSTRUMENT TO COMPARE THE VALUES AND SETTING ONABREDAMAGES TO THE ANODE STEM AND THE BUS BAR
  6. 6. • Damaged anode clamp shaft Damaged anode clamps view Damaged clamps (July- Dec-2010)=321 Damaged clamps (Jan- Apr 2011) =180 Damaged anode clamp shaft
  7. 7. The Proposal / SolutionTORQUE MEASURING DEVICE FOR ABRE & PTM CALIBRATIONINTRODUCTION OF A TORQUE TRANSDCER ON AFABRICATED JIG TO:PERIODICALLY COMPARE AND SET THE TORQUE OUT PUTOF THE PNEUMATIC / HYDRAULIC WRENCHES
  8. 8. ImplementationThe transducer was assembled and mounted on the jigfabricated ,custom made for this purpose .The jig is placed in position with the anode clamping andthe clamp calibrated to the set torque of 340 N mThe readings recorded for each of the 36 anode clamp onthe ABREThis value is compared with the torque in the PTMavailable in the touch screen while changing the anode.The nearest value is around + / - 2 %
  9. 9. IMPLEMENTATIONANODE CLAMP DUMMY BOLT WELDED ON A SOCKETTORQUE TRANSDUCERRUBBER CUSHIONINGFABRICATED DEVISE MOUNTING JIG
  10. 10. TORQUE METERING DEVISE FOR ABRE & PTM WRENCH CALIBRATIONIMPLEMENTATION: ACTUAL CALIBRATION DONE IN ABRE-2 TORQUE METERING DEVISE FORKLIFT FORK
  11. 11. 3. People Involvement• Suggestors: Leyson, Ullas Gereliv
  12. 12. ImplementationThe transducer was assembled and mounted on the jigfabricated ,custom made for this purpose .The jig is placed in position with the anode clamping andthe clamp calibrated to the set torque of 340 N mThe readings recorded for each of the 36 anode clamp onthe ABREThis value is compared with the torque in the PTMavailable in the touch screen while changing the anode.The nearest value is around + / - 2 %
  13. 13. BENEFITSBy applying a set torque of 340 N M and calibrating the ABRE to the set torque (pneumatic) and comparing it with PTM applied torque (while anode changing ) the result of :1) Drastic reduction of breakages of the anode clamps is established which was due to over / under torquing is achieved2) Substantial amount of saving is achieved
  14. 14. 7. Way Forward• All the team members were awarded .• Selected as the best suggestion for Emal• Applied in the calibration of further anode clamps .• Motivated in providing many more innovative suggestions
  15. 15. Q&A
  16. 16. Thank You
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