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 ]
[Torque measuring device ]
[SID 055]
[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
TORQUE MEASURING DEVICE
• The production of aluminium is by
the process of electrolysis
• The anode is clamped to the bus bar
by the anode clamps .

4. POT CELL
VIEW OF THE SUPERSTRUCTURE WITH ANODES
Anode clamp

5. The Problem
ANODE CLAMPS DAMAGES WHILE ANODE SETTING BY ABRE/PTM
NO INSTRUMENT TO COMPARE THE VALUES AND SETTING ON
ABRE
DAMAGES TO THE ANODE STEM AND THE BUS BAR

6. • Damaged anode clamp shaft
Damaged anode clamps view
Damaged clamps (July- Dec-2010)=321
Damaged clamps (Jan- Apr 2011) =180
Damaged anode clamp shaft

7. The Proposal / Solution
TORQUE MEASURING DEVICE FOR ABRE & PTM CALIBRATION
INTRODUCTION OF A TORQUE TRANSDCER ON A
FABRICATED JIG TO:
PERIODICALLY COMPARE AND SET THE TORQUE OUT PUT
OF THE PNEUMATIC / HYDRAULIC WRENCHES

8. Implementation
The transducer was assembled and mounted on the jig
fabricated ,custom made for this purpose .
The jig is placed in position with the anode clamping and
the clamp calibrated to the set torque of 340 N m
The readings recorded for each of the 36 anode clamp on
the ABRE
This value is compared with the torque in the PTM
available in the touch screen while changing the anode.
The nearest value is around + / - 2 %

9. IMPLEMENTATION
ANODE CLAMP DUMMY BOLT
WELDED ON A SOCKET
TORQUE TRANSDUCER
RUBBER CUSHIONING
FABRICATED DEVISE
MOUNTING JIG

10. TORQUE METERING DEVISE FOR ABRE & PTM WRENCH CALIBRATION
IMPLEMENTATION:
ACTUAL CALIBRATION DONE IN ABRE-2
TORQUE METERING DEVISE FORKLIFT FORK

11. 3. People Involvement
• Suggestors: Leyson, Ullas Gereliv

12. Implementation
The transducer was assembled and mounted on the jig
fabricated ,custom made for this purpose .
The jig is placed in position with the anode clamping and
the clamp calibrated to the set torque of 340 N m
The readings recorded for each of the 36 anode clamp on
the ABRE
This value is compared with the torque in the PTM
available in the touch screen while changing the anode.
The nearest value is around + / - 2 %

13. BENEFITS
By applying a set torque of 340 N M and calibrating the
ABRE to the set torque (pneumatic) and comparing it
with PTM applied torque (while anode changing ) the
result of :
1) Drastic reduction of breakages of the anode clamps is
established which was due to over / under torquing is
achieved
2) Substantial amount of saving is achieved

14. 7. Way Forward
• All the team members were awarded .
• Selected as the best suggestion for Emal
• Applied in the calibration of further anode
clamps .
• Motivated in providing many more innovative
suggestions

15. Q&A

16. Thank You