Boost your production
Stability is everything in metals production – improve safety, productivity and product quality by standardization of operations. Standardized production (and LEAN) is probably the most successful principle out there to achieve a high productivity and product quality. The principle may also be applied to liquid metals processing, although some special consideration is required. The symptoms Is your production suffering from all those minor disturbances difficult to explain? Is there an unexplored potential difficult to pin-point? Are production disturbances accepted and handled as “normal problems”? -“We would have reached our goals if only not….” Liquid metal production is complex and sometimes difficult to grasp. The integration of events within and between process steps, a strong time dependence, and requirement of expert skills to understand the processing complicates matters. The cure We know that a standardization of operations will help to reach a new level of performance – if you only do it right. Standardization of production of liquid metals requires some special tricks and a thorough understanding of the processing requirements. If the text-book LEAN-production method is applied failure will be likely. Make sure to adapt your production system to the handling of liquid metals! The reward Based on our previous experience we know that standardized production in production of liquid metals will eliminate some production disturbances totally and significantly reduced most of the, reduce process-related product quality problems down to 50%, run a much smoother operation, and increase operator safety. …when it is done right! The typical methods for standardized production is not well-suited for liquid metals processing – although the principles apply perfectly – and we have seen many failures and lost hopes. We can help you to fit your production system to liquid metal processing. The road forward Stability is everything! Without stability metals production will never take off. Analyze your production and processing and define your overall production principles. Promote stability over productivity, and productivity will boost. Standardize your production! Avoid solving problems – build a production system instead. Redefine processing and make sure all operations are standardized and in line with the basic production principles. Define an organization where mandates and information channels are clear. Promote a work schedule according to; measure, analyze, decide, change. Finally, implement it! Improve your production! The foundation has been established. Now tune operations and processing principles to improve stability and productivity further. Make sure to make improvement within the framework of your production system. No short-cuts and special fixes! How we do it Metsol has contributed in larger lean production projects where major routines and behavior changes have been implemented on the steelmaking shop floor. We typically act as the link between operators and management carrying information both ways, coaching and making sure things improve and follow the principles defined. We make sure everything is implemented where the effects will be seen; on the shop floor. No more nice plans and principles implemented all the way into the office folders… Close cooperation with production key personnel ensures a sound production concept, thus avoiding flaws usually experienced when concepts are designed in an office off-site. Please bear in mind standardization is a redefinition of most plant activities – operations, processing and production – and the road there is not straight. Everything is connected and sometimes an adjustment in one end gives unexpected results in the other – metals production is complex. Metsol will not only implement the methods together with your staff, we will also ensure that the end result is metallurgical sound. After all, we do this to improve the good tonnes out. How do we get started? In most cases an on-site visit over a few days is the best approach. During this period we meet the production management and then spend most of our time on the shop floor. At the end of our visit a short report will list the observed strength and weakness of the processing and production, and suggest a plan to implement the standardized work methods. A final heads-up Please do not confuse this concept this with LEAN-methods typically found in manufacturing industry (e.g. Toyota). Although we share the same basic principles, liquid metal processing is a special case and needs to be treated as such. If the standard methods found in the literature are applied as is you will have a very hard time to obtain acceptance among the operators, the overall purpose will be off target, and expected results will most certainly not be reached. We know why and have a better solution.
Metallurgical Specialists Services
Our metallurgical experts have lifetime experience from metals production. This might come in handy when you seek a second perspective or an independent opinion. Metallurgical knowledge has been conveyed from our experts to assist clients in many different cases of metals processing and production. Can you put a price on experience? Is the production or processing suffering and there is no answer to be found? Maybe time for a second opinion. Allow us to dig into your operations and find the remedy. Is your multi-million dollar project dependent on the success of advanced metallurgical processing or complicated production – maybe time to allow an independent audit to ensure the technology will be feasible? Are you experiencing frequent processing problems that no one seems to resolve – allow a second opinion and expert advice to ensure you are on the right track? Is your product sold to those complicated metallurgists – we will assist you to sort out your selling points? Is a major equipment failure making the company bleed and the insurance company representative go ballistic? Have faith, we will analyze the problem, find the likely cause, and work out a remedy. Our offer We offer experienced specialists in metals processing and production who can perform advanced analysis to your advantage. If liquid metal is part of your problem – we will solve it for you. We are metallurgists. Who are these guys? Feel uncertain if we measure up to the task? No worries, you will not risk anything. Allow us to offer a solution where you only pay based on the outcome. No risk and nothing to lose – what are you waiting for? What you get The ultimate goal of most of our projects is of course a higher productivity, higher safety and higher product quality – or a less risky road towards those targets. Bottom line – we offer the metal production management a good night sleep with less worries. How do we get started? Contact us for an initial discussion. No request is too small or too big, we always welcome your call – including requests from mid-20th century school teachers…
Metallurgical Processing Services
Balance material selection and handling to increase your ladle performance and increase productivity. Honestly, …when was the last time that the ladle performance and handling was reviewed in detail? …you accept that ladle performance could be better, but nothing is critical right now? …you have no clue what we are talking about, the ladles just work? Our offer We are metallurgists – we realize the importance of well-functioning ladles in a high-productivity metal production plant. The ladle fleet is more than a lubricant that keeps the metal moving towards the casting operations – it is close related to the processing operations and the plant logistics, and, represent a significant part of the operational costs. This is a rather complex system that needs to be reviewed whenever the production or processing changes. What you get We will review your ladles with a processing and production (logistics) perspective to suggest actions to obtain a more well-balanced system with respect to: Specific processing requirements Production logistics Ladle maintenance operations Brickshop tasks Ladle refractory configuration A well-balanced ladle system will definitely have a higher stability with less process/production disturbances – usually at a considerably lower operational cost. How do we get started? Are you expecting more out of your ladle fleet? We will help you to sort out your needs and suggest suitable actions. Contact us for an initial discussion.
Build your production
Investments projects in the liquid metals processing area require special skills and experience. We offer technical and metallurgical assistance during all phases of an investment project. Buy skills and experience! To invest in larger processing equipment for liquid metals production requires special skills and previous experience from similar projects. Without experience it will be difficult to understand the different steps and practices applied by international equipment suppliers: What technical and commercial information is required during the initial pre-project steps? How do I make sure the supplier quotations are comparable? How should the technical and commercial buying process be outlined? What is expected from you and what to expect from the supplier during the design phases? What information should I share? What is the consequence of obligations not fullfilled from our side? How do I make sure that the supplier equipment fulfills the performance stated in the contract? How do I make sure our investment fulfills the objectives presented to the management? There is an always an obvious risk of misunderstandings and mistrust due to lack of definitions in larger technical projects, which might have a negative effect on the project outcome. Thus, there is an increased risk that your investment will not meet your expectations, the price will exceed budget, and you will not meet the deadline. Make sure that you take control of the project before someone else will. Your special needs The existing crew is up to over their ears in day-to-day activities. There has been a long time since large processing equipment was purchased. The step-by-step activities necessary to perform for a successful upgrade of processing equipment are unclear to you. The new equipment needs to fit future requirements and at the same time integrate into existing production? You need experience in how to handle the international metals processing equipment suppliers and get the most out of the project Liquid metal production is complex and sometimes difficult to grasp. Upgrading of equipment in the production requires a broad understanding in processing, production, automation, and international industrial project handling. Our offer Our staff has life-time experience from international metallurgical investment projects in steelmaking and ferro-alloy production – both from the buyer and seller side. We can guide you through the process and assist with the steps necessary to obtain a successful project: Feasibility study Technical Purchasing Design phases Implementation Cold and hot commissioning Performance testing Ramp-up If necessary we can also manage projects although this is not our focus area – we are metallurgists. The reward Making sure investment projects follow the foreseen path, fulfilling technical objectives and deadlines are crucial to keep project costs down: Minimize the risks and make sure to get the most out of the projects – make sure overall objectives are fulfilled. Lean on experience and trust that your investment is state-of-the-art and meets the requirements. Stay in control and know where you are and where you are going. If not, someone else will. How do we get started? Are you considering altering your processing and production? Typically, a technical feasibility study including a cost estimations is good way to start. Then you know your options to make the correct decisions – we will help you. Please contact us for a discussion of your plans.
Evaluate your production
Are your operations and logistics up to standard? We analyze and pin-point the areas that could easily be improved. Do you know where you are? Are you really sure that your processes and production are up to standards? Which parts of your production is performing well and where have other been more successful? There is only one way to know – analyze and measure and then compare with similar production units. Our offer The Metsol staff have in-depth knowledge of most liquid metals processing units and production systems. We will assist you in an analyzing performance and bench-mark with similar production units. The reward Knowledge will make you confident in future decisions – knowing where you are standing helps you to know where to go. A thorough bench-mark will help you to focus on the real problem areas and make sure all parts of the production is up to standards. What you get All data analyzed will be presented in a thorough report. Process and production performance, given as selected key performance indicators, will be plotted relative comparable production units. A summary will pin-point strengths and weaknesses. How do we get started? Contact us for an initial discussion on your needs and expectations.
Build your people
Knowledge improve your organization’s skills and motivation. Metsol offers tailored operator training in metals production. Build your staff capacity! Knowledge is easy to carry but can you bear the load of being without? We believe strongly in the potential of evolving your success through others growth – make sure they make the right decisions. Scrutinize yourself When was the last time your staff had the chance to develop and obtain new knowledge and a different perspective? Are you convinced that your production staff holds the knowledge necessary to avoid those crucial mistakes so costly in metals production? Are your engineers ready to embrace your new plans or should a special training campaign make them better prepared? When was the last time you did serious training together with your staff discussing processing and production? Our offer We are metallurgists – we offer training in most fields of metals production as long as the metal is liquid (or just recently casted…). Operator training is the most common request from clients. Metsol offer special courses adapted to your needs. We mix your special processing and production requirements with fundamental metallurgical knowledge, to meet the needs of the participants daily tasks. Engineer training is typically more specialized towards a specific topic, e.g. standardized processing, logistics, and production or investment project handling, and is designed upon request. What you get Our course delegates gives us very positive feedback. We guarantee a more motivated staff with a new positive perspective and ready to be an even more professional employee. How do we get started? Are you considering development yourself or your staff? We will help you to sort out your needs and suggest a suitable training program. Contact us for an initial discussion.