Determining best practice production in an aluminium smelter involving sub-processes based substantially on tacit knowledge: an application of Communities of Practice

This paper considers the difficulties associated with a production process that contains a sub-process that is not fully understood and for which data for many parameters are only able to be approximately obtained. The aluminium smelting industry epitomizes such a situation. Here, the critical sub-process that exemplifies these difficulties is the actual heart of the smelter, the electrolytic processing of alumina. This sub-process of aluminium production is at best ‘fuzzy’ and relies on the smelter operators to use their experience and tacit knowledge on a day-today basis, that is, the sub-process involves ‘alchemy’. In this paper, this is referred to as the tacit knowledge problem. The impact of such sub-processes on production is significant.