Original Date: 08/26/1996
Revision Date: 01/18/2007
Information : Plating Lines Area Team
The platers area team served as a pilot program for Total Quality Management (TQM) efforts within the Tin Mill at Weirton Steel Corporation (WSC). The team meets daily to review the reports that include yield data, reject numbers, delay times, scrap rates, and other indicators that reflect line performance. Problem areas are discussed and potential solutions are developed. The team has successfully demonstrated the effectiveness of this concept.
The area team developed standard operating procedures (SOPs) for each operational position. They reviewed total process flows through the various lines in the plating areas and documented operational procedures. They examined each process and developed key process parameters, specified acceptable ranges, established specific measurements, noted required documentation, and identified responsibility areas. This effort also includes examination of all elements for the input and output streams. Weekly oil and chemical treatment reports are developed. Each SOP is given a unique number, and specific-detailed operational procedures are documented. Set points have been developed for all plating lines that established a control range to offer guidelines for operators. These set points can be adjusted for future updates as changes occur. Operator-quality sheets which document process information are completed for each turn. All reports and documentation are used by the team to develop process improvement recommendations. As long as costs are justified within a two-year or less payback, recommendations under $1 million can be approved locally without the endorsement of the Board of Directors. Larger efforts, however, require a higher-level corporate approval.
In 1996, 16 individual projects were completed, and 20 third and fourth quarter projects were identified and prioritized. Those completed projects have demonstrated the effectiveness of the platers area team by surpassing its overall cost reduction goal for the year.
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