Wednesday, February 19, 2014

Iron and Steel - Productivity, Industrial Engineering, Lean Manufacturing in Iron and Steel Mills and Ferroalloy Manufacturing

Steel Making Process

Steel Plant Museum of Western New York





Industrial Efficiency Database - Iron and Steel

Lean Systems in Steel

Running Steel Lean

Enhancing Productivity of hot metal in Blast furnace -A case study in an Integrated Steel Plant
O. Ram Mohan Rao 1*, Dr. K Venkata Subbaiah 2, Dr. K Narayana Rao 3 , T Srinivasa Rao 4

Value stream mapping in a steel company


Roy, R. N and Guin, K.K (1999), "A Proposed Model of JIT Purchasing In An Integrated Steel Plant", International Journal of Production Economics, 59 (1999), PP-179-187.

Corus Automotive Steel Mill Value Stream example by Peter Hines (2005)

Phd thesis lean in Steel
23 companies were sent questionairres. six replies were received. They are in the process of lean implementation.

Strategic Procurement in Tata Steel

Lean Manufacturing Applications in Steel

Edison Materials Technology Center developed and refined, from 2000 to 2005, an innovative technique for making a wide array of hardened steel parts through lean manufacturing of steel.

A method to forge hot metal into nearly perfect parts and hardening them and then  “hard turning”, or machining these after, was discovered to eliminate waste and possibly the need for polluting oils which are used in cutting and grinding. If hard turning could  be applied to manufacture gears and turbine blades, there will be good amount of savings.

EMTC has developed hard - turning technologies and a complete prototype system. The collaborators of the project were Delphi Automotive Systems, Torrington Co., Kennametal, Third Wave, Hardinge, Inc., Masco Tech, Georgia Institute of Technology, and Ohio State University.

The process can slash manufacturing costs by up to 30 percent and save up to $6 billion to the U.S. economy every year.

Cairns Steel Fabricators also doubled its capacity and improved productivity by applying lean manufacturing of steel, . CSF is a company focusing on steel fabrication and erection which employs around 60 personnel and handles 150 tonnes of steel per week.

QMI solutions offered a holistic approach to lean manufacturing to the company.  Efficient use of space and equipment resulted to increased productivity.

CSF positioned individual work areas in specific spots and color - coded tools to ensure they are returned to their proper places. In CSF’s case, it was  improvements in  “little everyday things” that made the system leaner.

Boosting Productivity in Steel and Iron Production Machinery
Requirements for motion control in iron and steel production machinery are challenging including the the need for the highest precision, reliability and productivity, even in harsh environments with high temperature. Moog's 40 years of experience in the industry provides a deep application knowledge that is matched with a proactive approach to offering products and solutions that meet the exact requirements of this industry.
Moog offers a wide range of hydraulic and electric products and solutions to meet an growing range of some of the most demanding applications on iron and steel production machinery. From world-class servovalves to robust controllers, Moog is a leader in providing products that are the most reliable to meet the needs of operations that run 24/7.

Labor Productivity

China Status
Labor productivity is quite low in China's steel industry,Two million people are producing 140m tons of steel in 2001 giving a productivity of 70 tons/ person year. The average global standard is five hundred and forty tons per employee and  the advanced international standard is one thousand tons per employee. For example, China Steel in Taiwan produces 9m tons per year with nine thousand employees (1,000t/person.year).

USA and Japan

In the early 1960s, the Japanese firms required 15 to 30 worker-hours per ton of steel; but by the early 1970s this figure had fallen to about 5 h per ton.
From 1958 to 1964 U.S. labor productivity rose significantly (from a range of 12 to 23 labor-hours per ton in 1958, to a range of 7 to 14 h per ton in 1964). Subsequently, however, productivity stagnated in the U.S. for nearly two decades. Then, with the restructuring activities of the 1980s, labor productivity began to improve again, ultimately falling below 5 h per ton for some producers.
Comparative productivity of Japanese and U.S.
steel producers, 1958-1993
Marvin B. Lieberman and Douglas R. Johnson
Japan and the World Economy 11 (1999) 1-27

Factors Influencing the Work Force in Steel Plants - 1980-95


Vizag Steel Plant achieved labor productivity of 253 tons/man year (2002-03) and is planning for 300 tons/man year.

JSW Vijayanagar Plant - Highest Labor productivity in India
800+ tonnes/person per annum
10 Million Tonees Per Annum plant at single site.


Increased productivity and reduced wear due to AUMUND conveyor at Tata Steel in IJmuiden, UK

A Russian steel producer changed lubricant oil to Mobil Vacuoline 133 and saved $220,000 in SKET 350  rolling mill.

A discussion

No comments:

Post a Comment