VSRD International Journal of Mechanical, Civil, Automobile and Production Engineering, Vol. !o. " June #$% e&ISS!

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RESEARCH ARTICLE

INCREASING PRODUCTIVITY BY REDUCING PRODUCTION LEAD TIME : A CASE STUDY OF NCRM DIVISION, BHUSHAN STEELS LTD. KHOPOLI, MUMBAI, MAHARASHTRA
1Vinod
1

Ar !", #S!n$%%& Sin'( C(!)(!n !nd *A+(i,(%- Y!d!&

Lecturer, 2Head of Department, 3Assistant Professor, 1,2,3Department of Mechanical Engineering, J. .!. "hargone, Madh#a Pradesh, $D A. %&orresponding Author ' ar#a.mech()*gmail.com

ABSTRAC T
To survive in todays competitive business world, companies require small lead times, low costs and high customer service levels. As such, companies pay more effort to reduce their manufacturing lead times. The productivity improvement in steel industry can be approached by different methods. The objective of this research is to study plant layout of NC ! "Narrow cold rolling mill division# of $hushan steels %td. !umbai based on the layout planning for increased productivity. &n this case study, amount of time required in rollin g coil production are studied. The detailed study of the plant layout such as operation process charts and flow of material charts has been investigated. The new plant layout has been designed and compared with the present plant layout. The thesis showed that new plant layout significantly decrease the distance of material flow from pic'ling process until pac'ing in pac'ing department. Keywords : Bhushan Steels Ltd., Rolling Coil, Existing Plant Layout, Proposed Plant Layout, Reducing Lead Ti e, Producti!ity.

1. INTRODUCTION $hushan (teel %td formerly 'nown as $hushan (teel ) (trips %td. is a globally renowned one of the leading pioneer in (teel &ndustry. Company has remar'able contribution in cold rolled mild steel coils. Company has established plant in !aharashtra at !umbai "*hopoli#. $ac'ed by more than two decades, of e+perience in (teel ma'ing, $hushan (teel is now &ndias ,rd largest (econdary (teel -roducer Company with an e+isting steel production capacity of . million tons per annums "appro+.# This paper will show how the waste reduction can be made throughout the proposed plant layout by using wor' stud y in NC ! "Narrow Cold rolling mill division#. &t analy/es the processes involved in manufacturing and identifies the 'ey areas of wastage and possible solution to overcome them. This research is based on a case study of $hushan steels %td. *hopoli. !umbai, &ndia This is a part of a larger research in which the object is to identify, develop and stimulate the development and more efficient production process for use throughout the manufacturing company. &n the e+isting plant layout there are some processes which ta'e the e+tra time and it can be reduced b y proposed plant layout of $(% *hopoli. 2. OBJECTIVE 0nderstand the -lant %ayout of the NC ! 1ivision, $hushan steels.

&dentify the process which waste time and eliminate them. 1evelop of 2future plant layout of NC ! 1ivision.

Vinod Ar2a, San/iv Singh Chauhan and A bhi-he3 4adav &ncrease the productivity

VSRDIJMCAPE, Vol. III 5VI6, June #$% 0 %)*

1evelop an action plan to achieve the higher -roduction and lead time reduction.

3. RESEARCH METHODOLOGY According to the current plant layout3 as we seen in the below process chart3 there are different operations performed on the rolling coil. According to the process chart the coil transfer to the pic'ling department from the ware house. The coil unloads to the pic'ling department and pic'ling process performed on it. After the pic'ling process the coil again load on the trolley and transfer to the rolling line path. 4hen the coil riches to the rolling mill path it unload from the pic'ling line trolley and load to the trolley of mill path. Now the coil riches to the mill by the mill path and coil unload to the rolling mill. After the rolling process the coil transfers to the annealing path. The coil is unloaded from the trolley and loaded to the trolley of annealing path trolley and riches to the annealing department. After the annealing process the coil is transfer to the s'in pass and then to the slitting department. The slitting is the final process of the coil and the coil transfer to the pac'ing department. As we seen in the above process when the coil is transfer to the mill from the pic'ling department, the coil has to unload from the current trolley to the another trolley because of the deferent path of rolling mill thats why the coil unloaded and loaded to the different path and the time required to sent the coil to the mill from the pic'ling department is increased. After the rolling process the coil sent to the annealing department and the

same problem is faced there i.e. the coil is again unloaded and then loaded to the trolley of annealing path and again the time increased of sending of coil from mill to the annealing department. After the annealing process the coil is transfer to the s'in pass and then to the C slitting department. 5inally the coil transfer to the pac'ing department. According to the TA$%67& total distance covered b y the coil in NC ! department is 89: !eter and Existing Plant Layout

total time required to cover the distance is ;: !inutes by the e+isting method according to the current NC ! %ayout. As seen in the TA$%6 && the total time required to perform the different operation on the coil is 8<= minutes "..>= hours# b y the e+isting method according to the current NC ! layout.

Fig. 1 : Existing Plant Layout of NCRM Flow Process Chart According o Current Process

Vinod Ar2a, San/iv Singh Chauhan and Abhi-he3 4adav

VSRDIJMCAPE, Vol. III 5VI6, June #$% 0 %))

Pro(osed Plant Layout

Fig. ) : Pro(osed Plant Layout The proposed plant layout shown in figure ,, there are some major difference between in the proposed plant layout and e+isting plant layout. &n the e+isting plant layout the distance between the pic'ling department and ware house is too large which is modified in proposed plant layout. &n the e+isting plant layout there is not a direct path between the pic'ling department and annealing department because of this there are unnecessary loading and unloading of coils ta'e place and e+tra time required to travelling coil from one place to another. There is also too many distance between rolling mill and C slitting machine which increase time of travelling of coil. There is also some e+tra travelling of coil between rolling mill and s'in pass department which required e+tra time. As we seen in figure? , these problems can be eliminated and this time can be saved which is the goal of this thesis to reduce the lead time and increase productivity. There are five major limitations of the e+isting plant layout? The distance between the pic'ling department and ware house ? &n the e+isting plant layout the distance between ware house and pic'ling department is .: meter. There is not a direct path between the pic'ling department to the rolling mill and from the rolling mill to the annealing department ? $ecause of this there is e+tra loading and unloading of the coil which waste the time. The distance between the rolling mill and cold rolling slitting machine is too large therefore the coils which are direct transfer for the C slitting after rolling have to travel a large path. The coils which are required s'in pass after the rolling process have to travel a long path although a new path can be installed between the empty passage between s'in pass and rolling mill. The distance of empty passage between s'in pass and rolling mill can be reduced so that the proposed path can reduce.

4. DATA ANALYSIS a*le 1 : 'istance ra"elled +y Coil in NCRM %Existing& 'istance No. of Re#uired i$e Co"ered ra"eling %Minutes& %Meter& Coil transfer from ware .: 9: house to

!r. No. 8.

.. ,. 9. =. <. >. ;.

pic'ling Transfer to diff. path Transfer coil to mill Transfer to annealing path Transfer to Annealing Coil Transfer to s'in pass Coil transfer to C (litting Transfer to pac'ing dept Total

pac'ing department B 89: !eter := := := := 8= 8= 8: "transfer b y crane# ;: minutes 8: 8: 8: 8: .: .: .: 89: meter After all the allowance in the one shift of ; hours average . coils are pass through these processes. Total travelling time of . coils in one shift B .C;: B 1./ $inutes %-... hours& According to table && Total time required to perform above operations each coil B 8<= minutes for

Total time required to perform above operations for . coils in one shift B 8<=C. B ))/ $inutes %0.0 hours& According to the e+isting plant layout 8<: minutes "..<<< hours# are spent on travelling the coil and ,,: minutes required to perform above operations from ware house to pac'ing department in one shift for average . coils. i$e re#uired to (erfor$ing o(eration %fro$ ware house to (ac1ing de(art$ent& *y (ro(osed $ethod: As we seen in the below table7&&& there are four operations are eliminated b y proposed method. According to the table7 && the total time required to perform above operations is 8<= minute "..>= hours# for each coil. According to the table7&&& the total time required to perform the same operations is 120 $inutes for each coil thus b y the proposed method -/ $inutes can saved during the total process on each coil. As we discussed above that average . coils are processed in one shift of ; hours. Total time required to perform the above operation for . coils in one shift by proposed method B 89=C. B -3/ $inutes %2.4) hours& a*le ) : i$e Re#uired o Perfor$ing ,(erations %Pro(osed& !r. ,(erations i$e %Minutes& No. 8. 0nload coil to !achine := .. -ic'ling process .: ,. %oad coil on trolley 8: =. 0nload Coil to !ill := <. olling Coil 8=7.: >. %oad coil on trolley := 0nload Coil to annealing ;. := dept. @. %oad coil on Trolley := 8:. 0nload coil to s'in pass := 88. ('in pass .: 8.. C (litting .: %oad coil on trolley to 8,. := pac'ing department

a*le - : i$e Re#uired o Perfor$ ,(erations %Existing& !r. No. 8. .. ,. 9. =. <. >. ;. @. 8:. 88. 8.. 8,. 89. 8=. 8<. 8>. 8;. No. of ,(erations 0nload coil to !achine -ic'ling process %oad coil on trolley 0nload coil from current trolley %oad coil for mill path 0nload Coil to !ill olling Coil %oad coil on trolley 0nload Coil from trolley load Coil to Another trolley 0nload Coil to annealing dept. %oad coil on Trolley 0nload coil ('in pass C (litting %oad coil on trolley 0nload to pac'ing dept -ac'ing Coil Total i$e %Minutes& := .: 8: := := := 8=7.: := := := := := := .: .: := := 8= 8<= "..>= Aours#

5. EXPERIMENTAL RESULTS Time required to performing operation "from ware house to pac'ing department# by 6+isting method? According to the table & Total time of travelling of one coil from ware house to pac'ing department B ;: !inutes Total distance covered by one coil from ware house to

Vinod Ar2a, San/iv Singh Chauhan and Abhi-he3 4adav

VSRDIJMCAPE, Vol. III 5VI6, June #$% 0 #$%

89. 8<.

0nload to pac'ing dept -ac'ing Coil otal

:= 8= 120 $inutes %-.21 hours&

a*le 2 : i$e !a"ed +y Pro(osed Method o Perfor$ 'ifferent ,(erations i$e re#uired i$e re#uired for i$e sa"ed *y for o(erations *y o(erations *y the (ro(osed existing $ethod (ro(osed $ethod $ethod in one in one shift in one shift shift %4 hours& %4 hours& %4 hours& ,,: minutes .@: minutes 9: minutes "=.= hours# "9.;, hours# ":.<< hours# According to the ta*le5 26 2/ $inutes can *e sa"ed for a*o"e o(erations in each shift *y (ro(osed $ethod. 6. CONCLUSION A layout project will always reach a Gcreative phaseH where it is due to the e+perience possessed by the user of the model, how good the result will be. &n this project there are major changes in plant layout but also a potential for improvements. &n another company this would have been different. This ma'es it obvious that a good model can be very helpful, especially in the early stages of the project, but it is not sufficient to reach an optimal solution. In one hand technical limitations and space requirements and on the other hand a lac' of willingness to do e+tensive investments stands in between the e+isting layout and serious potential future improvements. The finishing section proved to be fit to meet the future changes without any serious adaptations at all. This means that it will be hard to motivate e+pensive investments. Aowever, this research has shown that there are potential for significant improvements without huge investments. The distance travelled b y the coil for major operations can be saved 9: minutes Jshift. 7. REFERENCES
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