Research Paper on Scrap Reduction in TMT Reinforced Bar Production

In this work, we studied a manufacturing of random rods at a leading manufacturing company of Thermo Mechanically Treated (TMT) reinforced bars to reduce the several types of scrap like Head and End cut, Cobbles, Random rods, Melting rods and chopping. The hot billet coming from the extrusion machine is sent to the rolling mill where the TMT bars are produced; this consists of seven stages – scrap handling, Induction furnace, Continuous casting machine, Reheating Furnace, Rolling mill which contain 18 stands in which 6- Roughing, 6- Intermediate and 6- Finishing ,shear cutting and programming logical controller. During the shear cut operation performed on the billet, a large amount of scrap was being generated. To reduce this scrap and the non-value-added activities, techniques have been applied. Also, the size of the billet was changed to produce maximum production. With this, the scrap rate at the rolling mill has significantly decreased leading to a notable reduction in the cost of production.