Press Room Strip Inventory Analysis Kyle Jiron IE 496 Spring 2015
German based company Purchased American Brass plant of Buffalo in 2006 Manufacturer of rolled metals (brass and copper) Aurubis Buffalo
Use lean principles to increase efficiencies in Press Room procedures and reduce waste throughout the system Objective
Reduce Press Room strip holding inventory Develop better strip ordering practices Decrease WIP throughout system Project Goals
Gantt Chart Project Timeline
Current level: 1.4 million lbs Target levels: 800k lbs Revised: 1 mil +/- 200k lbs Holding Inventory
521 Coil cuts in holding inventory 1.36 million lbs 121 Cuts aged two months or older 278,634 lbs Holding Inventory
Process Map (Light vs. Intermediate vs. Heavy) Lead Times Formula Strip Ordering
Light Gauge Orders open for 6+ weeks in advance Process Map (220s) & Lead Times
Intermediate Gauge Orders open 5+ weeks in advance Process Map (260s) & Lead Times
Heavy Gauge Orders open 4+ weeks in advance Process Map (260s) & Lead Times
Order 6 days out 13 bars per order Ordering Formula
About 1 million lbs of coil in system throughout slitters and annealers leading up to the Press Room Inventory in System (WIP)
Current: 1 million lbs in WIP Goal: 400,000 +/- 150,000 lbs Inventory in System (WIP)
Changing the Kanban from being located at the casting area to being located before the 44 roll in the plant New Kanban System