0975ALUCHEMIE BACK TO BENCHMARK

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1、ALUCHEMIEBACKTOBENCHMARKPatrickClaudel,ErwinSmits,OlivierRibal,HenkPauwAluchemie,OudeMaasweg80,3197KJBotlek,TheNetherlandsKeywords:anodequality,variation,processcontrol.AbstractAnodeprobleminvestigationAluchemiewasconsideredtobethebenchmarkinAnodesintheIn2005and2006,Aluchemie'sanodeq

2、ualityhadasevereimpact90’sbutmadethewrongstrategicchoicesearly2000andsufferedontheefficiencyofourcustomers.Theexistingqualitysystemseveralcustomercomplaints.Anewandrigorousapproachwasunabletosignalthequalitydeviationbeforetheproblemwaslaunchedin2007broughtusbackasthesupplierofchoice.

3、Ourseenatthecustomer’sfacility.Acloseranalysisofproductpurposeistosharewithourpeersthesuccessfactorsandfindingsvariationconfirmedawellknownscenario:alimitedpercentageofthisfirststepofourjourneyforamoreefficientanode.ofpoorqualityanodeaffectedthepotlineprocessstabilityandstartedawider

4、potlineproblem.TheteamfirstdrewAluchemie'svariationfingerprint.ThistoolclearlyidentifiesprioritiesanddevelopsloweffortsolutionsveryProducttraceabilitywashoweverweak.Theonlyacceptablequickly.Encouragedbycustomerfeedbackandchallengedbythetracerfoundfortheperiod2005-2006wasthegreenprodu

5、ctionresultsofthevariationanalysis,theoperationalteamscreatedamonthmarkedoneveryanode.Theleadtimebetweengreensetofbasicsrulesinordertoeliminatetheworstpractices.anodeproductionandanodeusedinpotlinewasassumedtobeFinally,Aluchemieestablishedanearlywarningsystemtosustaintwomonths.Soanod

6、echaracteristicssortedbygreenproductionandfurtherimprovethelevelofquality.monthwerecomparedwithcustomerfeedbacktwomonthslater.These3elementswillbereviewedindetail,illustratedbyAtthisstage,average,standarddeviation,percentilesandpracticalapplicationsanddocumentedfindings.percentageofh

7、ighandlowoutlierswerecalculatedforallkeyproductcharacteristics.StatisticalanalysisshowedthatpercentilesIntroductionandoutlierswerefarmoresensitiveinpredictinganodeproblems.Amongallcharacteristics,highairreactivitydustoutliersmatchedEveryanodeproducerisfacingthechallengetodeliverbestw

8、ithspikesand