Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal

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'Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal' at the Ideas.Arabia 7th International Conference 2012

Educación Empresariales Tecnología

Loading/unloading jig for
anodes and butts

Suggestors:

J. Iqbal
M. Wazir
Bashir Mohiuddin

Agenda

• Process Flow chart/Background
• Problems
• Suggestion
• Benefits

Process Flow Chart

Butts From Pot Dispatch to pot
room room

Butts Cleaning Rodded anodes

Baked
Anodes
Butts Removal Mantling
(Kilns)

Carbon to
G/M

Thimble
Casting
removal

Reasons of Loading/Unloading

• 5 to 10 butts with badly bent rod/day.

• Average of 10 rejected anodes/day.
• Shutdown/breakdown:
• 7300 anodes re-rodded in 2011.
• 900 butts handled during butt blast shutdown.

Risk Factors
• Stepping on the moving Forks of Fork lift
• Standing on the unstable suspended load.
• Stretching the body to latch or unlatch the hanger.
• Lack of communication.
• 2 incidents (finger injuries)

Suggestion

Design & fabricate a jig attachment

• Safe and stable for operator.

• Suitable for handling anodes/butts with
any condition (bend rods etc.)

Benefits

• Operators’ Safety and security

• System improvement for anodes/butts
handling

• Plant operation security.

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Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal

1. Loading/unloading jig for anodes and butts Suggestors: J. Iqbal M. Wazir Bashir Mohiuddin

2. Agenda • Process Flow chart/Background • Problems • Suggestion • Benefits

3. Process Flow Chart Butts From Pot Dispatch to pot room room Butts Cleaning Rodded anodes Baked Anodes Butts Removal Mantling (Kilns) Carbon to G/M Thimble Casting removal

4. Reasons of Loading/Unloading • 5 to 10 butts with badly bent rod/day. • Average of 10 rejected anodes/day. • Shutdown/breakdown: • 7300 anodes re-rodded in 2011. • 900 butts handled during butt blast shutdown.

5. Risk Factors • Stepping on the moving Forks of Fork lift • Standing on the unstable suspended load. • Stretching the body to latch or unlatch the hanger. • Lack of communication. • 2 incidents (finger injuries)

6. Suggestion Design & fabricate a jig attachment • Safe and stable for operator. • Suitable for handling anodes/butts with any condition (bend rods etc.)

7. Benefits • Operators’ Safety and security • System improvement for anodes/butts handling • Plant operation security.

8. Thank You

Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal

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Idea of the Year Competition 2012 - Health & Safety Category Winner - Dubal