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

1. Loading/unloading jig for
anodes and butts
Suggestors:
J. Iqbal
M. Wazir
Bashir Mohiuddin

2. Agenda
• Process Flow chart/Background
• Problems
• Suggestion
• Benefits

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. 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. 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. Suggestion
Design & fabricate a jig attachment
• Safe and stable for operator.
• Suitable for handling anodes/butts with
any condition (bend rods etc.)

7. Benefits
• Operators’ Safety and security
• System improvement for anodes/butts
handling
• Plant operation security.

8. Thank You