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.

Using APS fundamentals recommend a visual management system for Potroom Crucible repairs

Crucible repairs is from the time the Crucible leaves the Potroom for Maintenance until the Potroom pick up the Crucible for use in Production

HeavyEngineering

Pot Rooms

Ingot Mill BLD 107 BLD 108

S + B

Curing Refractory

BLD 107

4 Days

2 Days

1 Day

to cool

7 Days2 Days

PotroomsPotrooms•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

S & BS & B

•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 engineeringHeavy engineering•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

BricklayersBricklayers

•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

Use a Visual Management SystemMANUALlocated in Bld 107 (and possibly in each other work area)

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

ELECTRONICe-mail on computer network

James David Clutterbuck:

James David Clutterbuck:

Heavy Engineering,RefractoryS&B Sandblasting

*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)

*E-mail from Bld 107 sent when crucible is out of service to “start the clock” to:

Bill Van BerkelS &BHeavy Engineering includingWayne 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)

Possibility to reduce the number of crucibles in maintenance system

Designated pick-up and drop-off crucibles locations

Suitable machinery to demolish crucibles

Potential for Heavy Engineering Workshop to pick up crucible from S & B

Alter red cure tags to green - in line with basic principals of APS

Extend e-mail systems to include all relevant parties

Determine whether there is a requirement for second hot top