Finish with chemicals

Hydrochloric acid pools where steel is cleaned

One of my favorites projects when I was working in one of the steel factories of Arcelormittal was changing the method of cleaning steel.

The challenge: adapt a new way of mechanical cleaning addressing the obstacles that arise within the work culture by changing the way of doing the processes along with the technical implications of a new technology in the steel industry.

As Industrial Engineering Analyst, my role in this project was to track this implementation for compliance and provide ideas for the optimal use of resources.

New mechanical method to clean the wire instead chemical method

The most difficult part of the process was to change the culture of the work more than the own technical change by itself.

How to deal with such a disruptive change with people who has been working 30 years in the same position doing the same things every day?

Improving the management of how to do things with:

- Motivation

- Incentive: increased productivity award.

- Training, Procedures, Best Practices, SOP's

Results?

With these improvements, both technical and managerial, we achieved:

- Reduced consumption of hydrochloric acid.

- Reduced consumption of zinc phosphate.

- Reduced water consumption.

- Reduction of sludge and hazardous effluents.

- Reduction of gaseous emissions.

- Reduction of steel scrap in machines and environment.

- Profit of subproduct (steel dust) previously considered waste with its cost of treatment and disposal.

- Higher environmental / occupational safety from unplanned events or emergencies.

With the use of a fewer resources, the company can produce the same product quality by developing an eco-efficient business.

Investments to improve this implementation is also highlighted as part of the creativity and resource management among areas rather than buying more robust equipment or investing in more advanced technologies.