2007-05-24 - Significant time and cost savings were achieved on the Kiln/Multi hearth furnace stream 5 shut, thanks to a coordinated effort from ABB, NZ Steel and its contractors in early May.
Background
In order to ensure continuous improvement, a NZ Steel team contracted the services of ABB to lead the management of Ironmaking’s regular stream (Kiln and Multihearth) shutdowns.
Typically the iron plant shuts down two of the 4 streams each year for around 30 days at a time. Each shut involves a large part of the shut workforce working round-the-clock for most of that duration. The shuts are primarily necessary to replace the Kiln refractorys and to clean out accretion build-up and replace worn rabble arm teeth in the multihearth furnace.
Stream 5 shut
The stream 5 shut was the latest of the three shuts managed in a staged approach by ABB, with the completion of the shut ending an impressive two days (52 hours) ahead of program, with all performance measures met, and major cost savings estimated at over $1million.
The success of the shut was also highlighted by the absence of any lost-time or medically treated injuries over the 60,000 man-hours worked by NZ Steel employees, contractors and ABB.
Overall responsibility for Ironmaking maintenance lies with Ian Renall:
“It is pleasing to see this early success as a result of our vision of engaging a specialist Shut management resource to bring some continuity to key roles within our shut structure.”
The stream 5 shut was managed under the leadership of ABB’s Rajan Manickam:
“The overwhelming support from NZ Steel, coupled with the dedication of the whole shut team and contractors lead us to this success”.