The reconstruction of some of the pots in good condition had been delayed for 1.5 years by the low level of Toba’s Lake at Inalum’s power plant. A novel semi-partial pot repair method in PT Inalum’s aluminum smelterAluminum smelter was examined by this research. Operational efficiency and cost reductionReduction, particularly during power outages or emergency shutdownsForced shutdown, were aimed to be improved by the method. Over a 43-month period, semi-partial repairSemi-partial repair was compared to standard partial and full repairs by the research, with a focus on process duration, material usage, and performance. Minimal disassembly and minor patching were involved in semi-partial repairSemi-partial repair, with much of the pot’s original lining being preserved. It was found by the study that less time and material were required by this method than by partial repair, with reconstruction completed 6 days faster and costs reduced by USD 55,951 compared to partial repairs and by USD 174,426 compared to full repairs. Despite older lining materials being used, stable pot performance and extended pot life were maintained by the semi-partial repairSemi-partial repair. This made it a more cost-effective and efficient alternative to standard partial procedures, ensuring consistent production during power outages or emergency situations while a high quality of the aluminumAluminum produced was maintained.