Innovation Storyboard

[EMIRATES ALUMINIUMCOMPANY LTD ]

[Anode jacking system :Provision of jubliee clips ]

[08 -2010- 01 2011 ]

[Reduction R1]

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

2. The Idea

FIXING OF JUBLIEE CLIPS TO

ANODE JACKING SYSTEM

UNIVERSAL SHAFT

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.

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

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.

4. Process (contd.)

The inclined shafts of the anode jacking system is getting detached during the operation and beam raising.

Anode Jacking System On The Pot Superstructure

MAINTAINED GAP INCREASED GAP CONTACT BEFORE IT DETACHED

The grub screws loosens during

the operation. The universal coupling

starts to move away from

the set location.

Until it detaches from the shaft.

GRUB SCREW

Anode Jacking System On The Pot Superstructure

Installed a double hose clamp onto the bus bar

riser side as it is taking more load.

Anode Jacking System On The Pot Superstructure

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.

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

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

Q & A

Thank You