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: August 2011 Kaizen No. Page No.:
Suggestion ID:10776
KAIZEN REPORT
Company logo Company Name Department Section/Process
EMIRATES ALUMINIUM Carbon, Lab & Port Maintenance
Improvement Title: To eliminate the chances of breaking of PC charging sockets
Category: [] Quality improvement [■ ] Health & Safety [ ] Environment [ ] Productivity [ ] Office processes [■] Product design improvement [ ] Service improvement
Before Situation Root Cause Analysis Improvement Measures After Situation
There was frequent damage of the Battery charging socket Fish bone diagram is attached as an An engineering solution to the This solution has been implemented in all the Personal
of battery operated Personal Carriers used for transporting annexure. Root cause was found to problem was proposed after carefully Carriers parked and charged in carbon maintenance
employees within the plant. be due to the system deficiency analysing the problem and root cause workshop. After the implementation for the last two
which was allowing vehicle movement analysis. The solution was very simple, months, there is no cases of charging sockets getting
This breakage was also a safety hazard due to the chances of even if its plug is still connected to but the idea was quite innovative and damaged.
having electric shock at the exposed parts of the socket. the charging socket. very much effective.
A very inexpensive relay was
(Please view attachments)
This issue was identified by many people during the process introduced in the charging circuit,
of hazard notifications, tool box talks were deployed several which would ensure that the socket is
times, but still the socket damage continued to happen. There physically disconnected to drive the
was no system that would ensure that this does not happen. vehicle.
(Please view attachments)
Benefits: Participation
1. No more socket breakage and so it improves the availability of charging point. For implementing this project there was participation from both maintenance and operation in CLP
2. Electrical shock hazard is eliminated in the socket as there is no more damage. and also from the mobile vehicle maintenance section.
Standardization Horizontal Deployment Opportunities (Replication):
Following the successful implementation in the maintenance workshop, the drawing has been This has been implemented in 7 PCs and has been suggested for implementation in all the PCs in
forwarded to the mobile vehicle workshop for updating the drawing and implementation in all PCs the EMAL complex.
across EMAL.
Single Point Lesson: Remark / Management Comments:
Sometimes the solution can be very simple for a complex problem. It takes someone’s imagination
to think through the problem to arrive at it.
Sign
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
19.07.2011 31.08.2011
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: ____/____/________