Defective steel wire rod which does not allow high speed drawing
Case in which a company cannot deliver good quality because defective steel wire rod. They also are not able to operate at high speed.
10 000 tons/month low carbon steel. Integrated company from steel making, ingot cast and rolling wire rod. They had a clean steel (low level of non-metallic inclusions) and a good carbon and manganese spread control. Wire rod surface quality were very defective:
Scam, Out of round, Polygon like shape, Very loose and entangled coil.
Bought 5 fast and modern drawing machines for up to 8860 ft/min or 45 m/sec.
Problem: The wire rod mill manager had a very strong power over the entire organization and he states strongly “The wire rod is the best of Europe, so if you have problems is because you do not know how to draw wire”.
In this case, there were no chance of improvement, since nobody inside organization dared to challenge the opinion of that manager and wire rod quality is never enough for high productivity and efficiency.
Something alike and frequent is happening in the wire drawing companies:
A high level manager is buying the wire rod, and nobody inside the organization dares to complain against the wire rod supplier.
The purchase is based solely on price and good relationship with supplier.
These 5 machines were able to run at top speed but wire breaks and early die wear appeared frequently
50 % productivity and efficiency were the result of this situation