Kaizen case study – Silver Prize winning submission by Dubal during 3rd Continual Improvement & Innovation Symposium organized by Dubai Quality Group's Continual Improvement Subgroup to celebrate World Quality Day 2011.

1. Quality Month: November 2011 Kaizen No. Page No.:
KAIZEN REPORT
Dubai Aluminium Company Limited (DUBAL) Department: Cell Relining & Pre Heat Section/Process : Tool Crib Area
Improvement Title: Improve Materials Management in Tool Crib
Category: [√] Quality improvement [√] Health & Safety [√] Environment [√ ] Productivity [ ] Office processes [ ] Product design improvement [ √ ] Service improvement
Before Situation Root Cause Analysis Improvement Measures After Situation
Potential Causes: 5S Implementation: Adopted DUBAL’s
5S Procedure which included activities for
 Lack of differentiation in critical spares
example (reference: DB/GEN.25.01):
vs. common items; fast moving vs. slow
 Awareness sessions to all levels
moving items
including contractors
 Under-utilized space due to slow
 Prepared roadmap for 3S
moving items and idle items/ tools/
Implementation by involving team (After 5S Implementation)
consumables etc.
 Sorted critical spares, common items,
 Unclear inventory levels ( Overall as well emergency tools and eliminated
as item-wise) unwanted items
 Difficulty in accessing tools/ items
 Lack of ownership by employees for  Defined inventory levels for all the
 High searching time in finding materials/ items/ material issue materials/ items tools etc.
tools etc.  Undefined Emergency handling tools and  Fabricated specialised racks and
equipment purchased plastic bins
 Delays in services due to stock-outs of materials
when needed  No status description is up-dated (work-  Defined colour codes to the area and
in-progress; OK/ Not Ok etc.) standardized labelling
 No ownership by employees to maintain the area Conclusion:  Re-layout and defined place for all
Why-Why Analysis confirmed the root materials and identified both locations
 Difficulty in managing emergency situations  Innovative storages (Refer
cause as: and items
Annexure-1)
Absence of Workplace Management  Assigned 5S to maintain the area  Effective space utilization
System in the area More……………………..
Benefits: Participation
 Projected savings of AED 500k due to reduced inventory levels of consumables, hand tools and 1. Ibrahim Baggash Senior Manager, Smelter Services
maintenance spares 2. Abdulla A. Manager, Cell Relining & Pre Heat
 ZERO stock-outs for critical and strategic materials 3. Aziz A. Superintendent, Cell Relining
 Improved workplace safety, productivity, customer services and reduced environmental wastes 4. Imran Area Assistant Planner
 No time delays in accessing materials, tools, consumables and equipments 5. Hussain Sr. Technician
 3S and 5S Certification – Complying with DUBAL’s Certification Requirements 6. Supported by Area Operators / Contractors (108 Employees)
Standardization Horizontal Deployment Opportunities (Replication):
 5S discussions in Tools Box Talks (reference: MOM of Shift Safety Meetings)
 Cell Relining Refractory Storage Area
 Standardized spares labelling and inventory (Min / Max) levels
 Cathode Storage Area
 Assign colour coding to different area (reference: DB/GEN.25.01.A02)
 Tool Crib 1 & 2 (Operational Area Potrooms)
 Material issues and receipt are controlled through Logbook and Excel- DATABASE
Single Point Lesson: Remark / Management Comments:
5S is an excellent system, it boosts employee moral by promoting a sense of pride in their respective
Waste reduces when things can be seen clearly areas while giving them greater ownership of their responsibilities in the workplace.
Sign: Abdulla A. (Manager, Cell Relining & Pre Heat)
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
01.06.2010 07.07.2011
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in “Improvement Case Study-KAIZEN” competition. We are glad to authorize DQG to share this information with the
Business community at large to promote Continual Improvement and good practices.
Signed by Authorised signatory: _______________________ Name: Ibrahim Baggash Designation: Senior Manager, Smelter Services Date: 15/ 10/ 2011

2. ANNEXURE – 1

3. Before After

4. Before After

5. Before After

6. Before After

7. After

8. After