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Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal

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'Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal' at the Ideas.Arabia 7th International Conference 2012

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Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal

  1. 1. Loading/unloading jig for anodes and butts Suggestors: J. Iqbal M. Wazir Bashir Mohiuddin
  2. 2. Agenda• Process Flow chart/Background• Problems• Suggestion• Benefits
  3. 3. Process Flow Chart Butts From Pot Dispatch to pot room room Butts Cleaning Rodded anodes Baked Anodes Butts Removal Mantling (Kilns)Carbon to G/M Thimble Casting removal
  4. 4. Reasons of Loading/Unloading• 5 to 10 butts with badly bent rod/day.• Average of 10 rejected anodes/day.• Shutdown/breakdown: • 7300 anodes re-rodded in 2011. • 900 butts handled during butt blast shutdown.
  5. 5. Risk Factors • Stepping on the moving Forks of Fork lift • Standing on the unstable suspended load. • Stretching the body to latch or unlatch the hanger. • Lack of communication. • 2 incidents (finger injuries)
  6. 6. SuggestionDesign & fabricate a jig attachment• Safe and stable for operator.• Suitable for handling anodes/butts with any condition (bend rods etc.)
  7. 7. Benefits• Operators’ Safety and security• System improvement for anodes/butts handling• Plant operation security.
  8. 8. Thank You

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