Emirates Global AluminiumAluminium (EGA) is one of the leading aluminium smeltersAluminium smelter in the world and has extensive experience in boost up of aluminiumAluminium metalMetals production. This article details a project in Al Taweelah (AT) Phase 1 potlines to improve reliability of reductionReduction superstructure pot doors. The doors are used for sealing purpose to prevent fumes, gas, and particle emissionEmissions. Keeping the doors in sealed condition is very important to reduce emissionsEmissions and improve the efficiency of hot metalMetals production. Improper door closing is also linked with employee safetySafety as metalMetals splash can occur at any time which is a potential threat and leads into workplace injury. There are 808 tap doorsTap door installed in EGA DX potlines. Multiple failures were observed, which compromised the plant emissionsEmissions and employee safetySafety. Main failures were due to broken hinges, twisted doors due to radiant heat, and door cloth damages. It requires an immediate replacement with new spare door to prevent pot gas emissionsGas emissions, metalMetals splash, and corner anodeAnode abnormal air burning. The improved door system has a single plain with backside reinforcement ribs, flexible handle that is resistant to heat and impacts, catcher plate to hold the door and silicon-coated door cloth for increased life. The new design changes resulted in significant reductionReduction in maintenance costs, gas emissionsGas emissions and improvement in employee safetySafety. This paper details the initial challenges, phases of design, and the successful modification of superstructure tap doorsTap door.