Press Room Strip Inventory Analysis

Kyle JironIE 496Spring 2015

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German based company

Purchased American Brass plant of Buffalo in 2006

Manufacturer of rolled metals (brass and copper)Aurubis Buffalo

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Use lean principles to increase efficiencies in Press Room procedures and reducewaste throughout the systemObjective

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Reduce Press Room strip holding inventory

Develop better strip ordering practices

Decrease WIP throughout system

Project Goals

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Gantt ChartProject Timeline

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Current level: 1.4 million lbs

Target levels: 800k lbs

Revised: 1 mil +/- 200k lbs

Holding Inventory

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521 Coil cuts in holding inventory1.36 million lbs

121 Cuts aged two months or older278,634 lbs

Holding Inventory

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Process Map (Light vs. Intermediate vs. Heavy)

Lead Times

Formula

Strip Ordering

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Light Gauge

Orders open for 6+ weeks in advanceProcess Map (220s) & Lead Times

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Intermediate Gauge

Orders open 5+ weeks in advanceProcess Map (260s) & Lead Times

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Heavy Gauge

Orders open 4+ weeks in advanceProcess Map (260s) & Lead Times

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Order 6 days out

13 bars per order

Ordering Formula

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About 1 million lbs of coil in system throughout slitters and annealers leadingup to the Press Room

Inventory in System (WIP)

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Current: 1 million lbs in WIP

Goal: 400,000 +/- 150,000 lbs

Inventory in System (WIP)

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Changing the Kanban from being locatedat the casting area to being located beforethe 44 roll in the plant

New Kanban System

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