The effect of material productivity on scrap reduction on aluminum reduction pot process

TALENTA - Conference on Engineering, Science and Technology 2017

工业技术;自然科学

Huda, L.N.^1

Industrial Engineering Department, Faculty of Engineering, Universitas Sumatera Utara, Medan

20155, Indonesia^1

关键词: Aluminum reduction;    Aluminum smelting;    Continuous process;    Control procedures;    Process capabilities;    Process Improvement;    Production failure;    Production process;   

Others  :  https://iopscience.iop.org/article/10.1088/1757-899X/309/1/012117/pdf
DOI  :  10.1088/1757-899X/309/1/012117

来源: IOP

【 摘 要 】

Scrap in the production process is defined as part of production that can not be accepted as the final product due to production failure. The amount of scarp occurring in the reduction pot production process of one of the aluminum smelting furnaces exceeds the acceptance standard of 5 to 10%. This affects the amount of production produced. The purpose of this study is to reduce the amount of scrap produced to increase the productivity of the materials used. The solution is carried-out by making improvements using Lean Six Sigma method. In the initial calculation, material productivity ranged from 0.88. Based on the study, the factors that cause the high amount of scrap produced is the use of Na2O which is inserted into the alumina is different in size and the influence of noise that occurs in pots that are difficult to control. The analysis base on Lean Six Sigma obtained process cycle efficiency (PCE) equal to 86,92% for actual condition. Process improvement is carried-out through define, measure, analyze, improve and control procedure on Na2O feeding process and PCE value decrease 6,05%. This indicates that increased process capability will reduce scrap. A decrease in scrap amount of about 6% will be able to increase material productivity by 0.05%. This indicates that continuous process control is needed to decrease the number of scraps and increase productivity.