Productivity Improvements at Direct Chill Casting unit in Aluminium Bahrain (ALBA)

Abstract

ALBA has been producing Rolling Ingots utilizing two DC casting units viz., DC1 & DC6. Out of total annual production of 140,000 MT of Rolling Ingot, DC6 production was 100,000 MT (1xxx, 3xxx & 8xxx series alloys) while DC1 production was 40,000 MT of 5xxx series alloy. Due to higher cost of production & low productivity at DC1, ALBA management decided to close down DC1 as a part of restructuring exercise and maximizing production at DC6 to meet customers demand. An extensive study was carried out towards improving productivity. Four levers of improvement which has the maximum impact were identified e.g., furnace preparation practices, preparatory activities between casts, increasing casting speed etc. Various action plans were drawn up & were implemented. These actions were closely monitored by DC operators themselves by using trend charts. As a result a 30% improvement in productivity was achieved at DC6 on a consistent basis.