Live Case Study
This session presents a Lean Six Sigma improvement project in an aluminum smelter with the objective of saving 10% of the spare cost associated with tapping yoke failures. To reach this target, DMAIC methodology was followed using some of the 7 quality tools, SIPOC, hypothesis testing, and lean tools such as Gemba to identify and eliminate lean wastes and run pilot test based on hypotheses testing. In the Emirates Global Aluminum Smelter, tapping yokes are used to tap the molten metal from reduction pots into the crucible, which is then transported to the cast house for casting activity. From historic data, the rate of tapping yoke failure has been on the rise and has reached 30%, which caused increased cost of repair/consumables and many other lean wastes. With the implementation of improvements, the organization has gained various benefits including financial savings, reduced rates of tapping yoke failure, and improved employee and customer satisfaction.