WQD2011 - KAIZEN - EMAL - Cast Iron Recycling Group Hopper Level Detection
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Ultrasonic sensors were installed to improve level detection in three hoppers at an aluminum company. Previously, infrared sensors were unreliable due to dust, vibration, and malfunctions. The ultrasonic sensors provide more accurate and reliable level detection without issues from environmental factors. This prevents production issues and downtime caused by incorrect level readings from the old sensors. The company now uses ultrasonic sensors for all applications in dusty conditions.
![Quality Month: Kaizen No. Page No.:
KAIZEN REPORT
Company logo Company Name EMIRATES ALUMINIUM Department Carbon, Lab & Port Section/Process INSTRUMENT MAINTENANCE
Improvement Title: CAST IRON RECYCLING GROUP HOPPER LEVEL DETECTION
Category: [ ] Quality improvement [ ] Health & Safety [ ] Environment [ ] Productivity [x ] Office processes [ ] Product design improvement [ X ] Service improvement
Before Situation Root Cause Analysis Improvement Measures After Situation
1. INFRARED PHOTOCELLS WERE • ULTRASONIC SENSOR-ANTI FOG, TO AVOIDE FREQUENT BREAKDOWNS AND INCREASE RELIABLE LEVEL
IN CAST IRON RECYCLING GROUP, DIRTY CAST IRON, CLEAN CAST IRON AND USED FOR THESE THREE IMMUNE TO DUST, VIBRATION AND DETECTION ULTRASONIC SENSORS WERE INSTALLED INSTEAD FOR ALL THREE
CARBON HOPPER, EXISTING TYPE HIGH LEVEL SENSORS (PHOTOCELL) GIVING APPLICATIONS. NOISE. TEACHABLE FOR REQUIRED APPLICATIONS .
FREQUENT TRIPPING DUE TO MALFUNCTION OF THE SENSOR. 2. INFRARED SENSORS TRANSMISSION IS DISTANCES (LEVEL)-TRIAL WAS
AFFECTED BY LIGHT, WEATHER CHANGES, SUCCESSFUL, HENCE TAKEN IN LINE.
DIRECT SUNLIGHT, RAIN,FOG, DUST &
POLLUTION.
3. THIS KIND OF SENSORS’ RELIABILITY
DEPENDS ON ALIGNMENT OF SENSOR WITH
ITS REFLECTOR.
4. IN THESE APPLICATIONS WHERE DUST
AND VIBRATION ARE PRESENT THIS WAS
GIVING BREAKDOWNS DUE TO
MALFUNCTION.
5. IT REQUIRES FRIQUENT CLEANING OF
DUST DEPOSITION. New Sensors
6. IN THE CASE OF 6420-LSH-205 THE
6420-LSH-205/ 206 & 207 DOWN TIME MONTH WISE LOCATION OF THE SENSOR IS ABOVE THREE
300.00
METERS HEIGHT WITH NO PROPER ACCESS.
250.00
6420-LSH-205
DOWNTIME
200.00 (In MIN)
6420-LSH-206
150.00
(In MIN)
100.00 6420-LSH-207
(In MIN)
50.00
0.00
Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11
MONTH
Benefits: Participation
1. NO BREAKDOWNS REPORTED AFTER THAT DUE TO MALFUNCTION OR FALSE LEVEL
2. ON MANY OCCASSIONS AFTER THE ABOVE DATE THESE SENSORS DETECTED ACTUAL BUILD UP OF
LEVEL DUE TO CARBON BLOCKS. THIS PREVENTED ESCALATION OF JAMMING AND SUBSEQUENT
HARDSHIP OF CLEARING IT.
Standardization: It has been decided to use only ultrasonic sensors for all future applications in dusty Horizontal Deployment Opportunities (Replication): Applicable wherever infrared sensors have
conditions been used in similar conditions
Single Point Lesson: Selecting measuring devices according to local environmental conditions will Remark / Management Comments:
help improve reliability
Sign
Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG)
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: ____/____/________](https://image.slidesharecdn.com/wqd2011kaizenemal-castironrecyclinggrouphopperleveldetection-111127053756-phpapp01/85/WQD2011-KAIZEN-EMAL-Cast-Iron-Recycling-Group-Hopper-Level-Detection-1-320.jpg)
WQD2011 - KAIZEN - EMAL - Cast Iron Recycling Group Hopper Level Detection
- 1. Quality Month: Kaizen No. Page No.: KAIZEN REPORT Company logo Company Name EMIRATES ALUMINIUM Department Carbon, Lab & Port Section/Process INSTRUMENT MAINTENANCE Improvement Title: CAST IRON RECYCLING GROUP HOPPER LEVEL DETECTION Category: [ ] Quality improvement [ ] Health & Safety [ ] Environment [ ] Productivity [x ] Office processes [ ] Product design improvement [ X ] Service improvement Before Situation Root Cause Analysis Improvement Measures After Situation 1. INFRARED PHOTOCELLS WERE • ULTRASONIC SENSOR-ANTI FOG, TO AVOIDE FREQUENT BREAKDOWNS AND INCREASE RELIABLE LEVEL IN CAST IRON RECYCLING GROUP, DIRTY CAST IRON, CLEAN CAST IRON AND USED FOR THESE THREE IMMUNE TO DUST, VIBRATION AND DETECTION ULTRASONIC SENSORS WERE INSTALLED INSTEAD FOR ALL THREE CARBON HOPPER, EXISTING TYPE HIGH LEVEL SENSORS (PHOTOCELL) GIVING APPLICATIONS. NOISE. TEACHABLE FOR REQUIRED APPLICATIONS . FREQUENT TRIPPING DUE TO MALFUNCTION OF THE SENSOR. 2. INFRARED SENSORS TRANSMISSION IS DISTANCES (LEVEL)-TRIAL WAS AFFECTED BY LIGHT, WEATHER CHANGES, SUCCESSFUL, HENCE TAKEN IN LINE. DIRECT SUNLIGHT, RAIN,FOG, DUST & POLLUTION. 3. THIS KIND OF SENSORS’ RELIABILITY DEPENDS ON ALIGNMENT OF SENSOR WITH ITS REFLECTOR. 4. IN THESE APPLICATIONS WHERE DUST AND VIBRATION ARE PRESENT THIS WAS GIVING BREAKDOWNS DUE TO MALFUNCTION. 5. IT REQUIRES FRIQUENT CLEANING OF DUST DEPOSITION. New Sensors 6. IN THE CASE OF 6420-LSH-205 THE 6420-LSH-205/ 206 & 207 DOWN TIME MONTH WISE LOCATION OF THE SENSOR IS ABOVE THREE 300.00 METERS HEIGHT WITH NO PROPER ACCESS. 250.00 6420-LSH-205 DOWNTIME 200.00 (In MIN) 6420-LSH-206 150.00 (In MIN) 100.00 6420-LSH-207 (In MIN) 50.00 0.00 Nov-10 Dec-10 Jan-11 Feb-11 Mar-11 Apr-11 May-11 MONTH Benefits: Participation 1. NO BREAKDOWNS REPORTED AFTER THAT DUE TO MALFUNCTION OR FALSE LEVEL 2. ON MANY OCCASSIONS AFTER THE ABOVE DATE THESE SENSORS DETECTED ACTUAL BUILD UP OF LEVEL DUE TO CARBON BLOCKS. THIS PREVENTED ESCALATION OF JAMMING AND SUBSEQUENT HARDSHIP OF CLEARING IT. Standardization: It has been decided to use only ultrasonic sensors for all future applications in dusty Horizontal Deployment Opportunities (Replication): Applicable wherever infrared sensors have conditions been used in similar conditions Single Point Lesson: Selecting measuring devices according to local environmental conditions will Remark / Management Comments: help improve reliability Sign Copy Distribution: Date of Starting: Date of Completion: Control No. (by DQG) 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: ____/____/________