Stabilization of the Power Off and

Evolution of the Metallic Yield

in Melt Shop

GERDAU Chile

Evolution of Power Off and Metallic Yield Gerdau Chile 1

GERDAU CHILE Colina Plant

Location: Santiago - Chile

Start up: 1999
Collaborators: 400
Capacity (t/year):
MELT SHOP : 520,000 t
ROLLING MILL : 370,000 t

Evolution of Power Off and Metallic Yield Gerdau Chile 2

 Objective

1. Present the evolution of Power Off and Metallic

Yield in the melt shop of Gerdau Chile

2. Showing the main factors for its stabilization and

improvements

3. Disseminate good practices, promoting the

exchange of experience and Benchmarking

Evolution of Power Off and Metallic Yield Gerdau Chile 3

 Historical evolution of the Power Off
- Leveling
- Stabilization
1st
- Maintenance
Missions
- Dedusting System
to BSW
2nd stage
Missions
to BSW
Benchmarking
Program
Riograndense

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 Historical evolution of Metallic Yield

2009

Evolution of Power Off and Metallic Yield Gerdau Chile 5

Historical evolution of the Power Off - Metallic Yield
Investment accompanying operational performance 2002-2012

360.000 t 450.000 t 520.000 t

Evolution of Power Off and Metallic Yield Gerdau Chile 6

 Stabilization of the Power Off and
Improvement of the Metallic Yield
Genesis: Gerdau Industrial Committee of the year 2010 and see
presentations of SR and BSW. Goals: Be a melt shop with Power Off of
reference and be within the top 10 plants in Metallic Yield.

Focus: Reinforced steel strong goal: Power Off (productivity) and Metallic
Yield (cost), challenging and comparatives with our Benchmarks.

Plan: Coordination with Process Owner and missions toward and from SR.
Internal consulting with focus on metallic yield. Working at EAF chemical
package.

Team: Multidisciplinary with characteristics of multipliers, broadcast of good

practices and knock down of "paradigms.

Evolution of Power Off and Metallic Yield Gerdau Chile 7

 Stabilization of the Power Off and
Improvement of the Metallic Yield
High Performance Team: Achieve the objectives with
excellence in terms of effectiveness and efficiency

It shares a common goal with challenging

Objectives and Goals
goals, deployed and sense of belonging

Organizational
Physical and financial resources. Culture
Context

Comunication Effective, honest and open

Flexible and assertive to respond to changes in

Adaptability
the environment. Knock down of "paradigms"
Work Environment
Contributes to team motivation
and successes Celeb.

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 Stabilization of the Power Off - Gerdau Chile

1st
Missions
to BSW 2nd stage of
Missions to
BSW PDCA and
Benchmarking
SR

Evolution of Power Off and Metallic Yield Gerdau Chile 9

 Stabilization of the Power Off - Gerdau Chile

8th

3rd 2013

Evolution of Power Off and Metallic Yield Gerdau Chile 10

Evolution of the Metallic Yield Gerdau Chile

Skills + Training + Motivation + Trust = Commitment

Street
Paving
Stage 1
Scrap
Paving
yard (1)
BPB
Stage 1
Street
Paving
Paving
BPB
Scrap
yard (2)

Evolution of Power Off and Metallic Yield Gerdau Chile 11

Evolution of the Metallic Yield Gerdau Chile
2009 25th

8th
2013

Evolution of Power Off and Metallic Yield Gerdau Chile 12

 Keys to Success
Management Improvement : Breaking Paradigms

4 bucket inhibit to reach a Power Off lower than 12 min/col:

Power Off records have been reached with 4 bucket

Metallic Yield depends only of the Scrap Yard: Working with

chemical package and operational practices rose 4 points

It is impossible with current scrap have yields above 85%:

Key: Curiosity with knowledge

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 Main Actions Exchange between Gerdau Chile - SR

Stabilization Process

Observation: Identify problems and seek solutions to the root

causes with special attention to the paradigms

Establish a culture of excellence and challenge the team

Integration between the operation and maintenance team is

essential to the continuous improvement of the results

Training, motivation and team experience play a vital role

Evolution of Power Off and Metallic Yield Gerdau Chile 14

It is impossible only if you believe it is

Evolution of Power Off and Metallic Yield Gerdau Chile 15

 Conclusions
Safety: Actions without risking the safety of people and equipment

Planning: Define key indicators (belonging) with a challenging but

achievable goal, associated with productivity and business (EBITDA)

Culture of Excellence : Believe in people, Provoke challenges, Support

Build trust. Establish "anchor phrases that Identify the team.
decision making,
Recognition and celebration of results to facilitate the Breaking of
Paradigms

Work Environment: Having an environment with positive emotional ties,

team with skills, trained, motivated, confident, informed and with culture of
excellence, have a strong commitment to challenges

Benchmarking and Exchange : Positive synergy to the organization

Evolution of Power Off and Metallic Yield Gerdau Chile 16

 ANDRES Barrientos
Melt Shop Manager Planta Colina

Contact:
Phone: +56 2 26779309
e-mail: andres.barrientos@gerdau.com

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