The principle objective of this paper is to demonstrate the capability of QC Team Niyantran from BALCO to strengthen the electronic communication between supervisory computer and pot controller system installed in pot line where aluminium production takes place using Halt-Heroult Process of electrolysis inside the pot. This communication plays a crucial role in the metal production process.
The modification described in this paper will boost communication process which will in return improve system productivity and quality. The O & M departments will widely use this modified system and also acquire benefits from it.
Restoring communication failure (i.e. Fault 21) has always been a difficult task for maintenance department of potline which adversely affects the production & quality of metal and also the operational control over electrolysis process. The team members’ analyzed data using various quality tools and identified supply failure of CAN Repeator Box (which plays the predominant role in the above mentioned communication) as the root cause of the problem. Accordingly, with the help of brainstorming process it is decided to implement “alternate supply arrangement for CAN repeator box using electrical automation.”
Implementation of modified system has given many tangible and intangible benefits which include the reduction of MTTR per occurrence from 60 minutes to aprrox 10 minutes and thus improving the current efficiency of potline to 95.4 %. Along with this, the system working conditions has been made more reliable, efficient and safe for use.