Abstract
Reduced setup times in the rolling mill generate flexibility which allows shorter leadtimes through continuous casting and hot rolling. Traditionally known as schedule-free rolling, this flexibility allows the rolling mill to handle variations without the need for buffering. Cost models based on system dynamics methodology are used to assess the economic potential. Effects on inventory, energy and work roll consumptions are analysed. The simulation results show that investments in flexible processes can be evaluated with dynamic cost models. There is an opportunity for significant cost reduction, but also lowered environmental impact due to reduced energy consumption.
Access provided by Autonomous University of Puebla. Download to read the full chapter text
Chapter PDF
Similar content being viewed by others
8 References
Ohno, T., 1988, Toyota Production System: Beyond large-scale production, Productivity Press, New York.
Hopp, W.J., Spearman, L., 2000, Factory Physics: Foundations of manufacturing management, 2nd ed., Irwin/McGraw-Hill, New York.
Liker, J.K.,, 2004, The Toyota way: 14 Management principles from the world’s greatest Manufacturer, McGraw-Hill, New York.
Nye, T.J., Jewkes, E.M., Dilts, D.M., 2001, Optimal investment in setup reduction in manufacturing systems with WIP inventories, Eur. J. Oper. Res., 135:128–141.
Shingo, S., 1985, A revolution in manufacturing: The SMED system, Productivity Press, Cambridge, MA.
Storck, J., Lindberg, B., 2007, A lean production strategy for hot charge operation of a steel mill, Proc. of the 2007 IET Int. Conf. on Agile Manufacturing (ICAM’07), 158–167, 9–11 July 2007, Collingwood College, Durham University, Durham, U.K.
Storck, J., Lindberg, B., 2007, A cost model for the effect of setup time reduction in stainless steel strip production, Proc. of the 1:st Swedish Production Symposium, Stahre, J. (Ed.), Chalmers University of Technology, Göteborg.
De Toni, A., Tonchia, S., 2005, Definitions and linkages between operational and strategic flexibilities, Omega, 33:525–540.
Lee, H.S., Murthy, S.S., Haider, S.W., Morse, D.V., 1996, Primary production scheduling at steelmaking industries, IBM J. Res. Dev., 40/2:231–252.
Dorn J., Shams, R., 1996, Scheduling high-grade steelmaking, IEEE Expert, 11/1:28–35.
Tang, L., Liu, J., Rong, A., Yang, Z., 2000, A mathematical programming model for scheduling steelmaking-continuous casting production, Eur. J. Oper. Res., 120:423–435.
Tang, L., Liu, J., Rong, A., Yang, Z., 2000, A multiple traveling salesman problem model for hot rolling scheduling in Shanghai Baoshan iron & steel complex, Eur. J. Oper. Res., 124:267–282.
Cowling, P., Rezig, W., 2000, Integration of continuous caster and hot strip mill planning for steel production, Journal of Scheduling, 3:185–208.
Singh, A.K., Srinivas and Tiwari, M.K., 2004, Modelling the slab stack shuffling problem in developing steel rolling schedule and its solution using improved parallel genetic algorithm, Int. J. Prod. Econ., 91:135–147.
Forrester, J.W., 1961, Industrial Dynamics, MIT-press, Cambridge, MA.
Sterman, J.D., 2000, Business Dynamics: Systems thinking and modeling for a complex world, Irwin/McGraw-Hill, New York.
Law, A.M., Kelton, W.D., 2000, Simulation modelling and analysis, 3rd ed. MacGraw-Hill Int.
Storck, J., Lindberg, B., 2007, Dynamic cost modelling in steel production, submitted to Int. J. Prod. Econ., December 2007.
Leden, B., 1986, STEELTEMP — A program for temperature analysis in steel plants, Scand. J. Metall., 15:215–223.
Munther, P., Lenard, J.G., 1995, Tribology during hot, flat rolling of steels, CIRP Annals, 44/1:213–216.
Pellizzari, M., Molinari, A., Straffelini, G., 2005, Tribological behaviour of hot rolling rolls, Wear 259:1281–128
Author information
Authors and Affiliations
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2008 Springer-Verlag London Limited
About this paper
Cite this paper
Storck, J., Lindberg, B. (2008). A Dynamic Cost Model for the Effect of Improved Process Flexibility in Steel Plants. In: Mitsuishi, M., Ueda, K., Kimura, F. (eds) Manufacturing Systems and Technologies for the New Frontier. Springer, London. https://doi.org/10.1007/978-1-84800-267-8_9
Download citation
DOI: https://doi.org/10.1007/978-1-84800-267-8_9
Publisher Name: Springer, London
Print ISBN: 978-1-84800-266-1
Online ISBN: 978-1-84800-267-8
eBook Packages: EngineeringEngineering (R0)