The document details a safety modification for the core cutting machine used in Emirates Aluminium's technical lab, highlighting improvements made to enhance health and safety measures. Key changes included the installation of safety interlocks, a new guard, and revised operating procedures to mitigate risks associated with the machine's unsafe design. This initiative not only improved safety conditions but also motivated the team towards continuous improvement practices within the organization.

1. Quality Month: Kaizen No. Page No.:
KAIZEN REPORT
Company Name Department Section/Process
EMIRATES ALUMINIUM CARBON LAB & PORT INSTRUMENT MAINTENANCE
Improvement Title: CORE CUTTING MACHINE (TECH. LAB.) SAFETY MODIFICATION’
Category: [ ] Quality improvement [X] Health & Safety [] Environment [ ] Productivity [ ] Office processes [ X ] Product design improvement [ X] Service improvement
Before Situation Root Cause Analysis Improvement Measures After Situation
• As per EMAL EHS • Provided permanent
• In CLP technical laboratory, Lab Technicians are using policies this clamping Handle
Anode Core Cutting Machine to cut different size of sample. operation is arrangement.
The machine design is very unsafe to use (as shown in completely non- • Provided a handle to
picture 1). standard, so we think push the sample
• During Operation operator is at high risk to get injured to modify the • Provided a guard.
because of the lack of safety measures (as shown in picture machine and to • Provided a safety
2) incorporate all interlock so that
possible safety machine stops if the Clamps
measures guard is lifted
• Operator has to hold • Provided a start +
the carbon sample emergency stop GUARD WITH SAFETY
INTERLOCK
with his hands switch functionality
• operator needs to for easier and safer
push the sample by operation.
hand for cutting.
• Exposure to carbon
dust
• Possibility of
operator using
shortcut and going
Complete manual operation
back to original
operation method.
Benefits: Participation
Elimination of man-machine direct interface. Operation is safer than before
Standardization Horizontal Deployment Opportunities (Replication):
The operating procedure of the machine has been revised and now the people are working with
new standard operating procedure. The same idea is being implemented in all other machine in the lab with similar
application. The idea can be implemented in other plants.
Single Point Lesson: Remark / Management Comments:
The in-house modification has generated higher motivation among all the teams and now they
are more energetic to give more ideas. The simple solution has improved the safe working
conditions while working on the machine. Sign
Copy Distribution: Date of Date of Completion: Control No. (by DQG)
Starting:01.09.2011 30.09.2011

2. 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: ____/____/________