LEAN and Mean?

LEAN and Mean?

LEAN production is a methodology dating back to the 1950ies but is yet not fully implemented in liquid metals processing despite the obvious advantages obtained in other industries. This is to us a mystery that needs to be resolved. Why do you as a manager hesitate to take your production several steps up the ladder of efficiency and product quality? There better be a good reason for this… Ok, we agree – liquid metals production is far from a car manufactoring production line. We acknowledge this but would also like to emphasize that the LEAN fundamental principles apply regardless. These are true in any type of production, you just need […]

Manage your production! (3 of 3)

Manage your production! (3 of 3)

Step 3 of 3 – Manage Your Production (Get the Good Tonnes Out – Step 3 of 3) Managing a well-functioning metals production is maybe far from the efforts required to bring it there but, nevertheless, it requires systematic and active work to make sure it stays in shape. This post focuses on the third step out of three in our series Get the Good Tonnes Out; Manage your production. If you feel you are yet not there, maybe you would be better off to first read the posts “Understand Your Production (part 1 of 3)” and “Take Control over Your Production (part 2 of 3)”. If not, then obviously you have […]

Take control! (2 of 3)

Take control! (2 of 3)

Step 2 of 3 – Take Control over Your Production (Get the Good Tonnes Out – Step 2 of 3) Taking control is defined as “the power to influence or direct people’s behaviour or the course of events” according to Oxford Dictionaries*. This definition is spot-on matching the production manager’s role; to influence and control in order to build an organization following production strategies chiseled out over the years. Unfortunately it is easy to derail and suddenly you find yourself as a manager to be controlled by the production instead of vice versa, which of course is a dangerous path. This post focuses on the second step of three in our […]

Understand Your Production (1 of 3)

Understand Your Production (1 of 3)

Step 1 of 3 – Understand Your Production (Get the Good Tonnes Out – Step 1 of 3) Liquid metals processing is complex. We are the first to acknowledge this. In fact there are few similarities between traditional manufacturing industry and liquid metals processing. Having said that, we still believe it is possible to stay in control and be proactive; it is just a little bit more complicated. This post reviews the first step of three in the series Get the Good Tonnes Out and focuses on the importance of understanding you production. In fact, this is absolutely fundamental to be able to form a rock-solid foundation to build upon. […]

Stuck in second gear?

Stuck in second gear?

Are you (and your production) stuck in second gear? We believe that most managers in the metals industry have a hard time to keep up with even the daily tasks. The more long-term planning and evaluations are likely to be out of scope for months. This is not viable over time and detrimental to the company. Productivity and quality will suffer and many decisions are made without really knowing what direction to go. But have faith – there are ways out of this treadmill: Step 1 – Make sure you understand you production. Step 2 – Take control of the production. Define a strategy for production according to your views. […]

Do you really need ladle management?

Do you really need ladle management?

Ladle management system is usually not top-ten on the investment priority list due to more urgent needs. But reconsider, at a small cost you will obtain full control and traceability on the critical events performed using the ladles. This will boost ladle performance and make most ladle-related production issues diminish. Besides, it will be hard to find a shorter ROI. We are talking weeks not years. Software is cheap, software services even cheaper and ladle refractory and ladle related costs represents a considerably expense in your production. So, I guess we stand corrected and rephrase our question; “Do you really need…” will be substituted by “What functionalities do you need in your ladle management […]

Slag Carry-Over – the Last Unknown?

Slag Carry-Over – the Last Unknown?

Slag carry-over in ladle refining operations is most likely one of the last unknowns in metals processing. No-one can for certain tell that the carry over amount is under control and does not influence on processing and product quality. We know for sure that the variation in sub-sequent processing operations due to uncontrolled slag carry-over is larger thn you would expect with very unfavorable consequences: Processing instability increases and targets are missed. Product quality suffer. This paper elaborates on the influence on processing, production, and product quality by slag carry-over in ladle refining operations. You will be surprised that something unknown and usually poorly controlled influences so strongly on your […]

Stability is Everything

Stability is Everything

Have you checked out this week’s production report? What about those few hick-ups that you could have been without? Disturbances generate production instability – a state that is never of any good for your tonnage throughput, product quality or operator safety. On the following pages we will elaborate further on the importance of stability to be able to improve production further. We sort out the terms and definitions related and show how to obtain stability by a correct processing and production design. This is the second part in our white papers series on how to take the first step towards world’s class metals production. In the first part, “Get the Good […]

LadleSlag

LadleSlag

Ladle Deslagging Control LadleSlag technology package monitors ladle deslagging operations and ensures that excessive slag carry over is avoided. Deslag evaluates the slag content and feeds information to the operator when a sufficient deslaging has been achieved. Why LadleSlag? Are you experiencing uncontrolled sulphur increases in the BOF? Are you experiencing uncontrolled reoxidation during ladle treatment influencing on product quality? Do you feel a need to narrow down process variations and operator dependency? Do you need to decrease your metal losses during deslagging? If you associate with any of the above, LadleSlag will assist you in solving your problem. Slag carry-over The problem with slag carry over is well known in steelmaking operations, occurring […]

LadleSafe

LadleSafe

LadleSafe infrared monitoring of your steel ladles minimises the risk of liquid steel breakout and maximises your ladle refractory lifetime. Why LadleSafe? Are you constantly concerned about the potential risks of metal breakouts? Are you feeling that your ladle refractories sometimes could last a few more heats, but you must take safety first? Would you feel more confident in pushing the ladle refractory lifetime if a system scanned every ladle before it was sent to the casting bay? If the answer to any of the above is YES, LadleSafe will assist you to increase performance and safety. Ladle Breakout The risk of a ladle breakout will always be present in […]