A Disciplined Approach to Reliability
(Room 316)
16 May 16
11:30 AM
-
12:00 PM
Tracks:
Cost of Equipment Reliability, Project Planning & Execution
With current challenges in the steel industry, it is critical to increase efficiency in all processes of manufacturing in order to achieve sustainable profits. To this end, US Steel uses a discipline approach to identify improvements and sustain them, called "The Carnegie Way”. The Carnegie Way uses Lead Six Sigma tools in conjunction with a cultural change to bring all personnel together to bring US Steel back to the iconic corporation it once was. The Carnegie Way method was used to improve reliability at US Steel Granite City Works (GCW) Hot Strip Mill (HSM) on table rolls. SKF worked with US Steel to learn and define the problem, offer solutions and then validate the solutions. SKF with its six sigma approach to reliability is very complementary to The Carnegie way. This paper outlines the best in class approach to reliability in the validation of reliability programs.
Background: SKF with multiple platforms of knowledge in seals, bearings, lubrication systems, condition monitoring and sensors were all employed to offer solutions and more importantly, to validate them. US Steel with its Carnegie Way guided SKF where to focus its efforts. The team identified the specific data evidence required to proving realistic cost savings. These savings were based on a reduction in bearing failures derived from overhead and unplanned maintenance costs. Additional savings were also realized in the reduction of grease consumption without jeopardizing the bearing. The approach led to two unique sealing solutions, the use of shaft sleeves for cost avoidance of reworking roll necks and to validate required amounts of grease.