Kaizen 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.

1. Quality Month: September 2011 Kaizen No. Page No.:
KAIZEN REPORT
Company Name Department Section/Process
EMIRATES ALUMINIUM CARBON, LAB & PORT BAKING FURNACES
Improvement Title: New design for Ring Main Cover lifting trolley.
Category: [ ] Quality improvement [X ] Health & Safety [ ] Environment [ ] Productivity [ ] Office processes [ ] Product design improvement [ ] Service improvement
Before Situation Root Cause Analysis Improvement Measures After Situation
Manual Ring main cover lifting 1- We received feed back
trolley was being used in that operators are facing
Baking Furnaces, and it was back pain problem due to
very difficult to lift the ring manual trolley.
main hole cover due to heavy 2- The manual trolley was
weight. ABF operators were having huge potential of
facing back pain problem due incident
to manual trolley and sick leave 3- Design of the trolley was
was increased significantly. It reviewed and feed back
was experienced that in given to SLWP.
different smelters operators 4- New hydraulic trolley was
were facing back pains due to made as per EMAL
usage of fully manual requirement.
equipment.
(Photographs / data graph and description)
(Photographs / data graph and description)
Benefits: Participation
1- ABID MASOOD
1- Easy handling of ring main trolley and less stress on operators back. 2- Pandarinathan Sankar
2- Due to hydraulic mechanism sick leave reporting reduced. 3- Khursheed Ahmed
3- Manual trolley was supplied by the SLWP, we reviewed and provided our feed
back for improvement and it was redesigned as per our requirement to hydraulic
operation without involving any cost.
Standardization Horizontal Deployment Opportunities (Replication):
The hydraulic operated trolley has been deployed in all required areas and operators This method can be used in other smelters in Baking Furnace operation.
have been trained on the usage.
Single Point Lesson: Remark / Management Comments:
Due to simple and innovative idea, significant comfort to the operators were provided
and now they do not feel any stress while carrying out the task.
Sign
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
5/01/2011 5/3/2011
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
community at large to promote Continual Improvement and good practices. We confirm that the improvement has been initiated and completed during the Kaizen Blitz week
Signed by Authorised signatory: _______________________Name:________________________________Designation:_____________________________________ Date: ____/____/________