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Steel company reduces losses in use of cold rolling area by 7%

Steel company specialised in manufacturing rolled products reduces the loss in use of its rolling mill by applying CONCOR© methodology.

7% improvement in use of the cold rolling area
Team training through systematic work
Stabilisation of the process
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NEEDS

  • To find a solution to the multiple losses in use attributable to a wide range of breakdowns and problems in production operations.
  • To improve the day-to-day management of the facilities.
  • To reduce the number of urgent corrective actions and increase the number of preventive and improvement actions.

IMPROVEMENT PROCESS

  • Splitting up the area into three zones and setting up three teams.
  • Collecting and analysing data by zones.
  • Daily cycle of incident analysis and problem solving using SCRA and CEDAC.
  • Daily, weekly and monthly monitoring of results.
  • Implementing OOC (5S).
  • Implementing autonomous maintenance.
  • Reviewing and reinforcing specialised preventive maintenance.
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5S - Greater productivity - A better workplace

A basic discipline to promote the culture of improvement in the organisation, based on people ownership, to improve their workplace environment by systematically applying the 5S-based OOC (Organisation, Order and Cleanliness) method.
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Kaizen

Based on team analysis of indicators and on systematic resolution of process incidents in two improvement cycles (SDCA-PDCA): short cycle, on a shift or daily basis; and long cycle, on a weekly or monthly basis.
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Improving the effectiveness of plant and facilities

Based on people involvement in process control and systematic reduction in breakdowns.
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Systematic problem-solving techniques

SCRA (Symptom, Cause, Remedy and Action) system for solving acute and/or temporary problems / Quality Story - CEDAC - A3 for chronic problems.
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