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Scrap Reduction in TMT Reinforced Bar Production by the Application of Lean Techniques
Sabiya. K1, M. Shilpa2, S. Appaiah3 

1Ms. Sabiya K, Industrial Department of Engineering and Management, M S Ramaiah Institute of Technology, Bangalore, India.
2Dr. M. Shilpa, Industrial Department of Engineering and Management, M S Ramaiah Institute of Technology, Bangalore, India.
3Dr. S. Appaiah, Department of Industrial Engineering and Management, M S Ramaiah Institute of Technology, Bangalore, India.

Manuscript received on 16 March 2019 | Revised Manuscript received on 21 March 2019 | Manuscript published on 30 July 2019 | PP: 3483-3487 | Volume-8 Issue-2, July 2019 | Retrieval Number: B2898078219/19©BEIESP | DOI: 10.35940/ijrte.B2898.078219
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© The Authors. Blue Eyes Intelligence Engineering and Sciences Publication (BEIESP). This is an open access article under the CC-BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/)

Abstract: Lean aims to eliminate the non-value-added activity which affects the cost of production along with the scrap rate Lean is often considered as a collection of tools and practices for superior operational and financial performance, through process improvement. Lean is an improvement concept for operational performance in the manufacturing environment. In this work, lean techniques are applied to the manufacturing of random rods at a leading manufacturing company of Thermo Mechanically Treated (TMT) reinforced bars to reduce the scrap. The hot billet coming from the extrusion machine is sent to the rolling mill machine where the TMT bars are produced; this consists of three stages – roughing mill, shear cutting, and programming logical controller. During the shear cut operation performed on the billet, a large amount of scrap was being generated. To reduce this scrap and the non-value-added activities, lean techniques have been applied. Also, the size of the billet was changed to produce maximum yield. With this, the scrap rate at the rolling mill machine has significantly decreased leading to a notable reduction in the cost of production.
Index Terms: TMT Bars, Shear Cut Operation, Lean Technique, Scrap Reduction.

Scope of the Article: Operational Research