Key Takeaways
Problem: Frequent strip breakages and stoppages in a Bangladesh cold rolling mill.
Diagnosis: 360° assessment identified process and procurement issues.
Solution: Optimised rolling patterns, lubrication, and roll specifications.
Enhancements: Improved pickling line and implemented alternative roll sourcing.
Impact: +30% productivity, USD 35M revenue increase, 3 new SOPs approved.
Revenue increase from operational improvements
Overview
A client operating a cold complex plant in Bangladesh faced frequent production stoppages and strip breakages in their cold rolling mill, impacting operational efficiency. The client engaged Steel Hub to conduct a comprehensive 360° diagnosis to uncover the root causes of these issues. This assessment led to a series of targeted implementation projects aimed at delivering operational excellence.
Challenge
- Frequent strip breakages and mill stoppages were causing significant productivity losses and impacting customer delivery schedules.
- Addressing this complex, multi-faceted issue required a comprehensive 360° diagnosis of the entire cold rolling mill operation, including operator practices and procurement processes.
Solution
- Diagnose the root causes of frequent steel breakages and stoppages in the 20-Hi and 6-Hi rolling mills, and implemented customised solutions to improve their productivity and reliability.
- Conducted a deep-dive analysis of quality and production reports to segment areas with the highest occurrence of production stoppages and steel breakages.
Results
- New HRC Specification: SAE1006 IF (<0.2 mm), SAE1006 MODIFY (>0.2 mm).
- Cold Roll: Optimised tension, rolling patterns, and lubrication. Led training, including an Italy site tour.
- Roll Specs: Improved hardness, roughness, and wear. Developed alternative roll sourcing for 6-HI & 20-HI mills.
- Pickling Line: Enhanced acid bath and tracking for HRC quality.
- Outcome: +30% productivity (620,000 tonnes/year), USD 35M revenue increase, 3 SOPs approved.
