![CathodeTails CathodeTails](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Untitled-570x480.png)
Cathode tail manufacture
Project Objectives
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Develop and implement a sustainable and cost effective manufacturing process for the manufacture of 9B type reduction cell collector bar tails for Bell Bay Aluminium
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Identify possible methods for converting old tails to new design tails
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Also develop a cost effective recycling process for used 9B collector bar tails
Project Team
![tom](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Tom.jpg)
Tom Frain
Kempe Engineering
![roger](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Roger-1.jpg)
Roger Aalbregt
Kempe Engineering
![brendan](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Brendan.jpg)
Brendan Sherriff
Bell Bay Aluminium
![wilkins](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Wilkins.jpg)
Peter Wilkins
Tasmanian Alkaloids
![trent Trent](https://businessactionlearningtas.com.au/wp-content/uploads/2016/10/Trent.jpg)
Trent Swain
TasRail
Facilitators
![bill-woodworth-colour](https://businessactionlearningtas.com.au/wp-content/uploads/2016/07/bill-woodworth-colour.jpg)
Bill Woodworth
Bell Bay Aluminium
![roxanne-chugg-colour Roxanne](https://businessactionlearningtas.com.au/wp-content/uploads/2016/07/roxanne-chugg-colour.jpg)
Roxanne Chugg
Excellent Outcomes
Key measurables
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Product cost competitive with overseas supplier
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A product that is equal or superior in performance than imported equivalent
Companies involved
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Kempe Engineering (co-host)
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Bell Bay Aluminium (co-host)
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TasRail
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Tasmanian Alkaloids
Approach taken
- Produced a detailed costing model to establish if new design was viable
- Highlighted areas for improvement in costing model
- Visited BBA to hear voice of customer
- Developed a functional and efficient manufacturing cell design
- Created future state value stream map
- Developed controls for managing new process
- Used computer modeling to prove effectiveness of tail design
- Designed implementation plan
- Value stream mapping
- Tools used:
- WORMPIT (waste walk)
- Time in Motion Study
- Spaghetti diagram
- Focus groups
- Trystorming
- Financial modeling
Summary of outcomes
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Cost targets met through efficiencies in manufacturing cell
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Ongoing mV savings per annum of approx. $40,000.00+ per year even after the implementation of the project
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Maintaining the personnel and skill base in the local area
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Investment in the local economy
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Better spread of any capital investment
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Better weld characteristics and weld times in reconstruction
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Better control over the supply process and not having to hold inventory
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Reduced CO2 emissions due to recycling