A time-consuming audit process
The smelter occupies a huge area of land, and potlines are nearly a kilometer long. Tomago’s 840 pots are extremely important to the business, as any instability could cost the company millions of dollars. As such, it’s important to find and resolve problems—an uncovered pot, for example, or a broken part—as quickly as possible.
That’s why each of the 840 pots receives an audit every single day. Throughout the day, teams walk from their desks to the pots to collect data in order to analyze pots for any potential issues.
Before implementing K2, each person had to write down data from the pot with a pen and paper, return to their desk, and enter data into a shared spreadsheet. Someone else would then need to access the data to produce a report.
This process could be extremely tedious. First, jotting down data with a pen and paper is difficult with the required PPE, which includes bulky gloves. This meant data could occasionally become difficult to read or inaccurate. Second, potline operators, their supervisors, and the teams conducting the audits all required a report after each daily audit, which could take several hours to produce and email.