Innovation 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. Innovation Storyboard
[EMIRATES ALUMINIUMCOMPANY LTD ]
[Anode jacking system :Provision of jubliee clips ]
[08 -2010- 01 2011 ]
[Reduction R1]

2. 1. About the Organization
• Emal is one of the world’s largest green field
smelter
• Emal aims at high quality delivery of its
products to customers, safety, every thing can
be improved
• Aluminium ingots, sow, slabs
• Taweelah

3. 2. The Idea
FIXING OF JUBLIEE CLIPS TO
ANODE JACKING SYSTEM
UNIVERSAL SHAFT

4. PROBLEM
• Frequent detachment of the universal shaft in
Super structure during Anode movement
• Unbalance on the beams/anodes resulting in
pot instability and anode effects.

5. 3. People Involvement
• Anode jacking system on super structure
• REDUCTION
• SID: Red/RM/ 002
• Suggestors :Leyson, Jayaprakash, Madison,
• Melchor, Sebado, Ullas,
• Ravindra, Gereliv, Satish.
• Supervisor : Luis Dominguez

6. 4. Process
The main aim is to avoid the universal
coupling from getting detached from
the driven j actuator shafts even the chance
when the grub screws loosens.

7. 4. Process (contd.)
The inclined shafts of the anode jacking
system is getting detached during the
operation and beam raising.

8. Anode Jacking System On The Pot Superstructure
The grub screws loosens during The universal coupling Until it detaches from the shaft.
the operation. starts to move away from
the set location.
MAINTAINED GAP INCREASED GAP CONTACT BEFORE IT DETACHED
GRUB SCREW

9. Anode Jacking System On The Pot Superstructure
Installed a double hose clamp onto the bus bar
riser side as it is taking more load.

10. Anode Jacking System On The Pot Superstructure

11. BENEFITS
• Minimum of 2 AED Jubilee clip and @ 3 jubilee clips
/ super structure.
• Detachments Before implementation : 5 times
• Detachments after implementation Zero .
• Reduction in damaged instances after
implementation
• Safety of the equipment and men working in area
enhanced.
• Anode effect of the pot : reduced to Zero because
of this reason.

12. 6. Learning
• Installed in all the 756 pots successfully
• No repetition of the problem till date
• Awarded the best suggestion of Emal
• Simple solutions have tremendous effect on
the system

13. 7. Way Forward
• All the team members were awarded .
• Selected as the best suggestion for Emal
• Applied in the design of future pots for further
expansion of Emal .
• Motivated in providing many more innovative
suggestions

14. Q&A

15. Thank You