A Dynamic Cost Model for the Effect of Improved Process Flexibility in Steel Plants

  • Conference paper
Manufacturing Systems and Technologies for the New Frontier
  • 2760 Accesses

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.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Subscribe and save

Springer+ Basic
EUR 32.99 /Month
  • Get 10 units per month
  • Download Article/Chapter or Ebook
  • 1 Unit = 1 Article or 1 Chapter
  • Cancel anytime
Subscribe now

Buy Now

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 239.00
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

Preview

Unable to display preview. Download preview PDF.

Unable to display preview. Download preview PDF.

Similar content being viewed by others

8 References

  1. Ohno, T., 1988, Toyota Production System: Beyond large-scale production, Productivity Press, New York.

    Google Scholar 

  2. Hopp, W.J., Spearman, L., 2000, Factory Physics: Foundations of manufacturing management, 2nd ed., Irwin/McGraw-Hill, New York.

    Google Scholar 

  3. Liker, J.K.,, 2004, The Toyota way: 14 Management principles from the world’s greatest Manufacturer, McGraw-Hill, New York.

    Google Scholar 

  4. 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.

    Article  MATH  Google Scholar 

  5. Shingo, S., 1985, A revolution in manufacturing: The SMED system, Productivity Press, Cambridge, MA.

    Google Scholar 

  6. 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.

    Google Scholar 

  7. 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.

    Google Scholar 

  8. De Toni, A., Tonchia, S., 2005, Definitions and linkages between operational and strategic flexibilities, Omega, 33:525–540.

    Article  Google Scholar 

  9. 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.

    Article  Google Scholar 

  10. Dorn J., Shams, R., 1996, Scheduling high-grade steelmaking, IEEE Expert, 11/1:28–35.

    Article  Google Scholar 

  11. 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.

    Article  MATH  Google Scholar 

  12. 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.

    Article  MATH  Google Scholar 

  13. Cowling, P., Rezig, W., 2000, Integration of continuous caster and hot strip mill planning for steel production, Journal of Scheduling, 3:185–208.

    Article  MATH  Google Scholar 

  14. Singh, A.K., Srinivas and Tiwari, M.K., 2004, Modelling the slab stack shuffling problem in develo** steel rolling schedule and its solution using improved parallel genetic algorithm, Int. J. Prod. Econ., 91:135–147.

    Article  Google Scholar 

  15. Forrester, J.W., 1961, Industrial Dynamics, MIT-press, Cambridge, MA.

    Google Scholar 

  16. Sterman, J.D., 2000, Business Dynamics: Systems thinking and modeling for a complex world, Irwin/McGraw-Hill, New York.

    Google Scholar 

  17. Law, A.M., Kelton, W.D., 2000, Simulation modelling and analysis, 3rd ed. MacGraw-Hill Int.

    Google Scholar 

  18. Storck, J., Lindberg, B., 2007, Dynamic cost modelling in steel production, submitted to Int. J. Prod. Econ., December 2007.

    Google Scholar 

  19. Leden, B., 1986, STEELTEMP — A program for temperature analysis in steel plants, Scand. J. Metall., 15:215–223.

    Google Scholar 

  20. Munther, P., Lenard, J.G., 1995, Tribology during hot, flat rolling of steels, CIRP Annals, 44/1:213–216.

    Article  Google Scholar 

  21. Pellizzari, M., Molinari, A., Straffelini, G., 2005, Tribological behaviour of hot rolling rolls, Wear 259:1281–128

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Editor information

Editors and Affiliations

Rights and permissions

Reprints 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)

Publish with us

Policies and ethics

Navigation