Objectives of Quality Education 1. To give students an understanding of Quality principles. 2. To give students an opportunity to apply Quality principles. 3. To give Students a better understanding of the nature of work and how business operates.
Problem Statement Using APS fundamentals recommend a visual management system for Potroom Crucible repairs Boundary Crucible repairs is from the time the Crucible leaves the Potroom for Maintenance until the Potroom pick up the Crucible for use in Production
Crucible Flow Path Pot Rooms Ingot Mill BLD 107 BLD 108 2 Days to cool BLD 107 S + B 1 Day Heavy Engineering Curing Refractory 4 Days 2 Days 7 Days
Limiting Factors Potrooms S & B • Must have 11 crucibles • Must have 9 lids • Life of Crucible is unpredictable • No communication with all groups that are involved with repairs • Don’t know when a crucible is completed • Have to wait for the crucible • Don’t know when a crucible is coming • Don’t know the priority • Crucible must be cold • Can only work on one at a time • Must wait for room in the shed Heavy engineering Bricklayers • Have other work • Don’t want management interfering • Can only do one at a time • Need to hire contractors when there is extra work • Complete rebuild takes around 3 weeks • Average repairs take 7 weeks • Can only brick one at a time • Can only cure one at a time • No warning when a crucible is arriving • Refractory work is 2 days • Curing is normally 4 days
James David Clutterbuck: Recommendations Develop a “pull” system for maintenance of crucibles Implement counter measures for incidents where more than one crucible enters the maintenance system at one time, or when processes such as HE workshop take longer than the average time eg.3 weeks Use a Visual Management System MANUAL located in Bld 107 (and possibly in each other work area) Heavy Engineering, Refractory S&B Sandblasting ELECTRONIC e-mail on computer network
Communication Currently Future • E-mail from Bld 107 sent when crucible is out of service to “start the clock” to: • Bill Van Berkel • S &B • Heavy Engineering • including • Wayne Durbidge • Danny Hooper • Heavy Engineering to notify S&B of estimated completed date • Establish a central board in Bld 107 that show the status of each crucible in the various repair stages (supported electronically) • E-mail from Bld 107 to • Bill Van Berkel • S and B • Heavy Engineering • Bill Van Berkel raises a work ticket to S&B and Heavy Engineering • Danny Hooper raises a work ticket for refractory • Bld 107 do not know if a crucible is completed • Danny Hooper does not know when a crucible is arriving • (cannot plan his workers and shifts)
Potential for Heavy Engineering Workshop to pick up crucible from S & B Suitable machinery to demolish crucibles Designated pick-up and drop-off crucibles locations Determine whether there is a requirement for second hot top Alter red cure tags to green - in line with basic principals of APS Extend e-mail systems to include all relevant parties Recommendations Possibility to reduce the number of crucibles in maintenance system