Quality Month: Kaizen No. Page No.

KAIZEN REPORT

Company Name Department Section/Process

EMIRATES ALUMINIUM CARBON LAB & PORT INSTRUMENT MAINTENANCE

Improvement Title: CORE CUTTING MACHINE (TECH. LAB.) SAFETY MODIFICATION

Category: [ ] Quality improvement [X] Health & Safety [] Environment [ ] Productivity [ ] Office processes [ X ] Product design improvement [ X] Service improvement
Before Situation Root Cause Analysis Improvement Measures After Situation
As per EMAL EHS Provided permanent
In CLP technical laboratory, Lab Technicians are using policies this clamping Handle

Anode Core Cutting Machine to cut different size of sample. operation is arrangement.
The machine design is very unsafe to use (as shown in completely non- Provided a handle to
picture 1). standard, so we think push the sample
During Operation operator is at high risk to get injured to modify the Provided a guard.
because of the lack of safety measures (as shown in picture machine and to Provided a safety
2) incorporate all interlock so that
possible safety machine stops if the Clamps
measures guard is lifted
Operator has to hold Provided a start +
the carbon sample emergency stop GUARD WITH SAFETY
INTERLOCK
with his hands switch functionality
operator needs to for easier and safer
push the sample by operation.
hand for cutting.
Exposure to carbon
dust
Possibility of
operator using
shortcut and going
Complete manual operation
back to original
operation method.

Benefits: Participation

Elimination of man-machine direct interface. Operation is safer than before

Standardization Horizontal Deployment Opportunities (Replication):

The operating procedure of the machine has been revised and now the people are working with
new standard operating procedure. The same idea is being implemented in all other machine in the lab with similar
application. The idea can be implemented in other plants.
Single Point Lesson: Remark / Management Comments:
The in-house modification has generated higher motivation among all the teams and now they
are more energetic to give more ideas. The simple solution has improved the safe working
conditions while working on the machine. Sign
Copy Distribution: Date of Date of Completion: Control No. (by DQG)
Starting:01.09.2011 30.09.2011
Declaration: We are submitting this Kaizen case voluntarily to DQG for participation in Kaizen Blitz competition. We are glad to authorize DQG to share this information with the Business
community at large to promote Continual Improvement and good practices. We confirm that the improvement has been initiated and completed during the Kaizen Blitz week.

Signed by Authorised signatory: _______________________Name:________________________________Designation:_____________________________________ Date: ____/____/________