2020 - USA
Phase 1 Mill Optimization: Customer collaboration at the heart of Russula
In a crisis, changes are more evident. For a rolling mill these changes may result in lower inventory and reduced size and quantity of orders, as end users migrate purchasing habits to an as-needed basis. Inevitably, this means more product changeovers; smaller lots only decrease mill utilization. Today’s mills need flexibility.
Consequently, Russula created a Rolling Technology Center exclusively dedicated to improving operational efficiency in long product rolling mills. The group draws upon decades of experience and specialized knowledge in high-speed bar and wire rod production.
All projects are conducted with extensive customer collaboration. In understanding our customers’ needs, the Rolling Technology Center offers tailored solutions to address mill inefficiencies. Caught in the day to day distractions and demands of production, it can be difficult for mill operations and maintenance teams to find available time together to develop a cohesive plan to improve mill efficiency.
At Russula, we have found that for these types of projects, it is more effective to bring key mill stakeholders off-site to discuss, collaborate and co-develop an action plan to address general mill inefficiency issues.
Wire Rod & Bar Mill Optimization Project | Phase 1: Concept Development
The operations team of a large steel producer in the US visited the Russula Technology Center for one week to begin this process. During that time the operational approach of the mill was discussed in great detail.
Over a period of forty years, shifts in the product mix and the rapid addition of higher carbon steel products had had a negative impact on mill efficiency. Driven by new sales opportunities, the transition to produce high-grade steels was implemented ad hoc. New products were added on the production schedule as quickly as possible, without fully considering how these changes would impact overall operations long term. High carbon products were challenging to produce at first because of the stringent quality standards, and the way they were fit into the existing schedule.
Together, the mill operations team and Russula team created the overall concept of the mill optimization project. Divided into four phases, the project scope included the collaborative development of an optimized process pass design for the mill, a full guide design review, new speed and setup sheets and Russula on-site assistance for the hot commissioning of the optimized design.
Phase 1
Phase 2
Phase 3
Phase 4
During Phase 1, the team created a basic concept flow diagram of the new production model. At the end of the week, the operations group was given the results of the collaborative process, an operating blueprint they could take back to the mill and review with their production team. The entire flow diagram was posted in several common areas of the mill where all floor operators were invited to review it and provide feedback.
The workforce has decades of experience, and we want their input and buy-in, nothing design wise was set in stone. If the basic concept required further changes, we discussed all ideas and questions, and incorporated positive feedback into the next phase of the project.
Leveraging the expertise of the operators working on the mill floor is critical to the overall approach, because they work the process day in and day out, they see potential problems from a novel point of view.
