WQD2011 - KAIZEN - EMAL - Vibro compactor Height Gauge Junction box Relocation
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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.
![Quality Month: Kaizen No. Page No.:
KAIZEN REPORT
Company Logo Company Name Department Section/Process
Emirates Aluminium CARBON LAB & PORT INSTRUMENTATION MAINTENANCE
Improvement Title:
Vibro compactor Height Gauge Junction box Relocation
Category: [ ] Quality improvement [ ] Health & Safety [ ] Environment [ ] Productivity [ x ] Office processes [ ] Product design improvement [ ] Service improvement
Before Situation Root Cause Analysis Improvement Measures After Situation
Junction box for height Relocation of junction box to
Anode height gauge in vibro compactor( paste plant) gauge wire termination eliminate vibration effect and
Giving frequent malfunction causing the plant to shut down. is mounted on the to make it easily accessible for
vibrating table maintenance.
During operation
vibration causes loose
connections and
breaking of signal
wires.
Termination screws
getting damage
Access of junction box
is difficult hence
tightening or
reconnection of wires
take long time.
Work place is oily and
always there’s
possibility of accidents
Benefits: Participation
SIGNIFICANT REDUCTION IN BREAKDOWN AND PASTE REJECTION IN PASTE PLANT Kamlesh, Sourabh
Standardization Horizontal Deployment Opportunities (Replication):
The operating procedure of the machine has been revised and now the peoples are working with Same will be implemented for all 4 vibro compactors
new standard operating procedure.
Single Point Lesson: Remark / Management Comments:
The simple and innovative idea has improved the safe working conditions for the operators and
now they feel comfortable while working in the area.
Sign
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
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: ____/____/________](https://image.slidesharecdn.com/wqd2011kaizenemal-vibrocompactorheightgaugejunctionboxrelocation-111127060258-phpapp01/85/WQD2011-KAIZEN-EMAL-Vibro-compactor-Height-Gauge-Junction-box-Relocation-1-320.jpg)
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WQD2011 - KAIZEN - EMAL - Vibro compactor Height Gauge Junction box Relocation
- 1. Quality Month: Kaizen No. Page No.: KAIZEN REPORT Company Logo Company Name Department Section/Process Emirates Aluminium CARBON LAB & PORT INSTRUMENTATION MAINTENANCE Improvement Title: Vibro compactor Height Gauge Junction box Relocation Category: [ ] Quality improvement [ ] Health & Safety [ ] Environment [ ] Productivity [ x ] Office processes [ ] Product design improvement [ ] Service improvement Before Situation Root Cause Analysis Improvement Measures After Situation Junction box for height Relocation of junction box to Anode height gauge in vibro compactor( paste plant) gauge wire termination eliminate vibration effect and Giving frequent malfunction causing the plant to shut down. is mounted on the to make it easily accessible for vibrating table maintenance. During operation vibration causes loose connections and breaking of signal wires. Termination screws getting damage Access of junction box is difficult hence tightening or reconnection of wires take long time. Work place is oily and always there’s possibility of accidents Benefits: Participation SIGNIFICANT REDUCTION IN BREAKDOWN AND PASTE REJECTION IN PASTE PLANT Kamlesh, Sourabh Standardization Horizontal Deployment Opportunities (Replication): The operating procedure of the machine has been revised and now the peoples are working with Same will be implemented for all 4 vibro compactors new standard operating procedure. Single Point Lesson: Remark / Management Comments: The simple and innovative idea has improved the safe working conditions for the operators and now they feel comfortable while working in the area. Sign Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG) 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: ____/____/________