Kaizen Implementation in Rolling Mill: A Case Study

Abstract

The operational issues in the Rolling Mills industries such as productivity; resource consumptions; wastes creation and breakdown etc., bound the researchers to do research in rolling industries. That is why, it has never been taken in the mainstream for the research work. The present paper aims to enhance the operational efficiency and efficacy of rolling mill industry with Kaizen implementation. The existing data such as miss roll production, spare part consumption, productivity and breakdowns were collected for the study. These data further used for finding the operational efficiency of rolling mill and while analyzing it were observed that the rolling mill is performing lesser than its original working capacity. Thus, Kaizen approach was suggested for the implementation in rolling mill industry and on analyzing the data after the Kaizen implementation, it is observed that the productivity of rolling mill goes by 30% increment whereas the 70% decrease reported in miss roll. In addition, the spare part consumptions are also reduced because of lesser number of breakdowns.