Justifying the purchase of a Rollshop Management System(RMS) to senior management can often be a difficult task for rollshop personnel. However, the MSW RMS offers many benefits which help to make a compelling case for its introduction.
The RMS enables optimisation of spending on rolls by providing accurate roll performance figures. Roll performance reports can be generated using the industry standard metrics of tonnes or metres rolled per mm of stock reduction. These reports allow for comparison of rolls from competing suppliers and also for comparison of rolls comprised of different materials. Purchasing the best performing rolls can make a very significant difference to the financial and operational performance of both the mill and the rollshop. Furthermore, analysis of stock loss due to roll damage events helps to provide a complete picture of roll performance. Providing such complete performance data to roll suppliers helps to drive the process of reducing roll prices and improving roll technology.
The RMS also achieves cost reductions by minimising roll stock usage. Optimal re-mating of rolls and analysis of damage histories between roll types and roll suppliers encourage less wastage of roll stock and allows fewer replacement rolls to be ordered.
Further cost reductions can be achieved for Chocks and Bearings Maintenance. The RMS allows chock, bearings and all other roll assembly components to be maintained on the basis of usage in the mill (tonnage, meterage, logged hours) rather than merely on the basis of elapsed time. This means that only those components due for maintenance will be maintained resulting in substantial cost savings. Furthermore, component failure and wear analysis helps both to fine-tune maintenance targets and to identify the best performing component types and suppliers.
Reduction in mill incidents and down-time via better performing rolls (in damage terms) and preventative maintenance of roll assembly components (chocks/bearings) can also be achieved. Reducing unscheduled mill down-time by even 1 hour per quarter easily justifies the costs of introducing the RMS.
Improved tracking of operations ensures the smooth running of the rollshop. Real-time tracking of the status of roll assembly components - ground, built, in-mill, out of service, available etc - highlights potential problems.
The RMS provides a full audit-trail of rollshop data. Data on all current and all scrapped roll assembly components is maintained by the system allowing full traceability.