Productivity Improvement Through Scrap Reduction In Rebar Manufacturing By Using Taguchi Loss Function (Case company Steely RMI –Rolling -2)
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Date
2022-11
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Addis Ababa University
Abstract
There are approximately ten active rebar manufacturing industries in Ethiopia. Most of them use imported raw materials in the form billet, but during production, these imported raw materials are not fully converted to final products, resulting in many losses, like those produced in parting billets into two parts, hard-scale, head-tail cuts, cobble, and off-cuts. So among these losses, off-cut and head-cut take on much more weight. The goal of this research is to increase raw material productivity by reducing the major losses caused by head-cut and off-cuts. And the methods this paper uses are Taguchi loss functions to show the saved off-cuts, electric, and furnace fuel consumption. and a JavaScript application to display a preview of the number of products in a given raw material size. In the results, get the optimum or productive length of raw materials for every product type, such as
The optimum length of billet for ɸ10=5619mm the remain length of billet 6377mm used for ɸ12 rebar from 12 meter length of billet
The optimum length of billet for ɸ12=6457mm the remain length of billet 5539mm used for ɸ24 rebar from 12 meter length of billet
The optimum length of billet for ɸ14=6122mm the remain length of billet 5874mm used for ɸ24 rebar from 12 meter length of billet
The optimum length of billet for ɸ16=5817mm the remain length of billet 6179mm used for ɸ24 rebar from 12 meter length of billet
The optimum length of billet for ɸ20=5661mm the remain length of billet 6335mm used for ɸ20 rebar from 12 meter length of billet
And reduce the length of head-cut then make it uniform .In the current situation, the total percentage of losses for the case company is 6.7% of the weight per billet, and the research improved these losses by 2.23%; therefor, the material productivity increased by 4.5%, and the saved electric power is 2172.25 kwh and the saved furnace fuel consumption is 897.53 liters are per shift.