Increasing the efficiency of a small-section shop

Intensive development of the constructional industry for expansion of housing and industrial stock requires an increase in the production of small–section rebars with a linear meter weight of 6 - 8 kg. Such rebars are produced on small-section and small-section wire mills. An increase in the production of small-section building rebars can be implemented in two directions: construction of new high-performance rolling mills; intensification of the work of existing mills due to identification of hidden reserves (“bottlenecks”) and, taking this into account, modernization of equipment and technology. The second direction is less financially costly and requires significantly less time to implement. However, a sound analysis of the constraints is required for making the right decision to improve the existing production. To solve this problem, the authors propose a methodology based on the principles of a clock approach and the necessary calculation formulas which, using the example of a small-section workshop, show the sequence of search and analysis of “bottlenecks”. The paper analyzes the organization of production processes at the areas of a small-section mill and considers in detail two alternative schemes for organizing material flows at the baling area. The actual material presented in tabular forms characterizes the work of the areas of a small-section workshop by cycles and productivity by rebars for different schemes of material flows. The main limiting factor in the small-section shop under study is the baling area. The authors propose organizational and technical measures to improve the organization of material flows and automation of baling lines, evaluate the effectiveness of design solutions and the payback period for investments.

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