Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal
Loading/unloading jig for anodes and butts Suggestors: J. Iqbal M. Wazir Bashir Mohiuddin
Agenda• Process Flow chart/Background• Problems• Suggestion• Benefits
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
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.
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)
SuggestionDesign & fabricate a jig attachment• Safe and stable for operator.• Suitable for handling anodes/butts with any condition (bend rods etc.)
Benefits• Operators’ Safety and security• System improvement for anodes/butts handling• Plant operation security.