Estudo de aumento de rendimento metálico no processo de laminação utilizando metodologia pdca em uma siderúrgica no ceará

Abstract

The rolling process plays a fundamental role in the steel industry, being responsible for transforming raw materials into finished products. However, metal losses throughout the production chain directly impact operational efficiency, making the search for strategies that optimize the metal yield of the material necessary. This paper presents a study aimed at increasing metal yield in the rolling process at a steel mill located in the city of Maracanaú, Ceará, using the PDCA methodology as a basis for diagnosis and implementation of improvements. The work began with the investigation of possible causes that negatively impacted the metal yield indicator, and three main waste points were mapped: stripping shears, cold cutting shears and short bars. To deepen this analysis, tools such as Pareto Chart, Brainstorming, Cause and Effect Diagram, The 5 Whys and 5W2H were applied. Based on the diagnosis, strategic actions were implemented, such as standardization of billets and stripping, equipment calibration and regulation of systems that directly influence the efficiency of the rolling mill. These initiatives were systematically monitored to ensure their effectiveness and promote adjustments when necessary. The results proved the effectiveness of the measures adopted, reflected in the increase in metal yield in the gauges analyzed individually, in addition to the improvement in the overall indicator, which exceeded the 2023 indexes. The optimization of the production flow also resulted in greater production predictability and reduced waste. Finally, all improvements were standardized in the company's system, ensuring the stability of results and strengthening the culture of continuous improvement. The study demonstrates that the structured approach provided by PDCA is an efficient model for the evolution of production processes in rolling.