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Storck, Joakim
Publications (9 of 9) Show all publications
Storck, J. (2012). Product variety, flexibility and energy use in hot rolling mills. In: ElMaraghy, Hoda (Ed.), Enabling Manufacturing Competitiveness and Economic Sustainability: Proceedings of the 4th International Conference on Changeable,Agile, Reconfigurable and Virtual production (CARV2011),Montreal, Canada, 2-5 October 2011. Paper presented at 4th International Conference on Changeable, Agile, Reconfigurable and Virtual Production (CARV 2011) , Montreal, October 2-5, 2011 (pp. 80-85). Montreal: Springer, 2
Open this publication in new window or tab >>Product variety, flexibility and energy use in hot rolling mills
2012 (English)In: Enabling Manufacturing Competitiveness and Economic Sustainability: Proceedings of the 4th International Conference on Changeable,Agile, Reconfigurable and Virtual production (CARV2011),Montreal, Canada, 2-5 October 2011 / [ed] ElMaraghy, Hoda, Montreal: Springer, 2012, Vol. 2, p. 80-85Conference paper, Published paper (Refereed)
Abstract [en]

Hot rolling consumes one third of the energy in a steel plant. Increasing product variety slows down production flow, causing heat losses and increased reheating energy consumption. A system dynamics model was developed to evaluate how flexibility influences energy use. Results indicate that world best practice requires high flexibility and low to intermediate product variety. Up to 28% less reheating was needed for low product variety, but no improvement was obtained for high product variety; a flexible steelmaking process for efficient production of small batches of steel would be required. The strategic nature of process flexibility investments is discussed.

Place, publisher, year, edition, pages
Montreal: Springer, 2012
Keywords
Steel, product variety, flexibility, energy efficiency
National Category
Manufacturing, Surface and Joining Technology
Research subject
Research Profiles 2009-2020, Steel Forming and Surface Engineering
Identifiers
urn:nbn:se:du-6001 (URN)10.1007/978-3-642-23860-4_13 (DOI)978-3-642-23859-8 (ISBN)
Conference
4th International Conference on Changeable, Agile, Reconfigurable and Virtual Production (CARV 2011) , Montreal, October 2-5, 2011
Available from: 2011-10-14 Created: 2011-10-14 Last updated: 2023-03-09Bibliographically approved
Storck, J. (2011). Stålforskningsdagar 2011: Materialteknik vid Högskolan Dalarna. Falun: Högskolan Dalarna
Open this publication in new window or tab >>Stålforskningsdagar 2011: Materialteknik vid Högskolan Dalarna
2011 (Swedish)Book (Other academic)
Place, publisher, year, edition, pages
Falun: Högskolan Dalarna, 2011
Keywords
Metallbearbetning, stål
National Category
Materials Engineering
Identifiers
urn:nbn:se:du-6000 (URN)
Available from: 2011-10-14 Created: 2011-10-14 Last updated: 2023-03-09Bibliographically approved
Storck, J. (2010). Exploring improvement trajectories with dynamic process cost modelling: a case from the steel industry. International Journal of Production Research, 48(12), 3493-3511
Open this publication in new window or tab >>Exploring improvement trajectories with dynamic process cost modelling: a case from the steel industry
2010 (English)In: International Journal of Production Research, ISSN 0020-7543, E-ISSN 1366-588X, Vol. 48, no 12, p. 3493-3511Article in journal (Refereed) Published
Abstract [en]

Improvement trajectories are sequential managed chains of improvement initiatives required to handle changes in competition and market. This paper presents a five-step framework, based on dynamic process cost modelling, which was developed during a four-year research project at a major stainless steel producer, to support the selection of an improvement trajectory based on strategic requirements to combine high product diversity with cost reduction. The framework aims to develop insight into what manufacturing capabilities are required to reach the strategic goals by combining system dynamics simulation with process cost modelling and visual exploratory data analysis in an iterative modelling procedure. The applicability of the five-step framework is demonstrated through a case study from the steel industry, in which a goal driven analysis is used to assess process requirements based on performance and market considerations.

Keywords
cost analysis; manufacturing strategy; simulation; process industry; system dynamics; exploratory data analysis
National Category
Materials Engineering
Research subject
Steel Forming and Surface Engineering, Operativa strategier för förbättrad produktivitet vid tillverkning av rostfria band
Identifiers
urn:nbn:se:du-4207 (URN)10.1080/00207540902725288 (DOI)000276471900007 ()2-s2.0-77951109178 (Scopus ID)
Available from: 2009-09-22 Created: 2009-09-22 Last updated: 2023-04-20Bibliographically approved
Storck, J. (2009). Product variety and upstream versus downstream flexibility. In: Rosén, B.G. (Ed.), Proceedings of the International 3'rd Swedish Production Symposium: . Paper presented at Swedish Production Symposium , Göteborg, December 2-3, 2009 (pp. 304-309). Göteborg
Open this publication in new window or tab >>Product variety and upstream versus downstream flexibility
2009 (English)In: Proceedings of the International 3'rd Swedish Production Symposium / [ed] Rosén, B.G., Göteborg, 2009, p. 304-309Conference paper, Published paper (Refereed)
Abstract [en]

Niche market steel producers tend to manufacture a wide range of products that are sold in low quantities. Current steelmaking—continuous casting (SCC) technology forces producers to operate according to combined make–to–stock/make–to–order order policies and keep in–process inventory. This leads to intermediate cooling of workpieces, high energy consumption, and high inventory and reheating costs. This paper evaluates links between product range and process flexibility upstream and downstream form the customer order decoupling point. The operational capabilities that result from improved process flexibility make diversified low cost steel production possible. At the same time the environmental sustainability of production can be improved. The strategic importance of process flexibility improvements are discussed with reference to the concept of competitive frontiers.

Place, publisher, year, edition, pages
Göteborg: , 2009
Keywords
Product variety, flexibility, steel industry, simulation
National Category
Materials Engineering
Research subject
Steel Forming and Surface Engineering, Operativa strategier för förbättrad produktivitet vid tillverkning av rostfria band
Identifiers
urn:nbn:se:du-4320 (URN)
Conference
Swedish Production Symposium , Göteborg, December 2-3, 2009
Available from: 2009-12-04 Created: 2009-12-04 Last updated: 2023-03-09Bibliographically approved
Storck, J. (2009). Strategic and operational capabilities in steel production: Product variety and performance. (Doctoral dissertation). Stockholm: KTH
Open this publication in new window or tab >>Strategic and operational capabilities in steel production: Product variety and performance
2009 (English)Doctoral thesis, comprehensive summary (Other academic)
Abstract [en]

Steel producers that employ niche market strategies are continuously seeking to reduce production cost while maintaining adiverse product mix. The business model is typically based onmarketing of high–strength special or stainless steels. However,the desire to avoid direct cost competition is over time gradually leading towards increased product variety and smaller ordervolumes (tonnes per order) for each product.

This thesis analyses how production cost is linked to productvariety in steel strip production. Results are based on new modelsfor assessment of opportunities for performance improvement inhigh product–variety steel production.

The need for flexible production processes increases with increasing product variety. Operational capabilities linked to processflexibility determine the extent to which steel producers caneliminate in–process inventory and accomplish close coupling between process steps. Niche market producers that invest inprocess flexibility improvements can lower production costs bothdue to reduced work–in–process and lower energy consumption.An additional benefit is reduced environmental impact.

The following problems are addressed:

• Development of a method to assess the influence of productvariety on performance in steel production.

• Development of models of continuous casting and hotrolling that account for product variety and cost effectswith consideration of varying degrees of process flexibility.

• Development of a strategy process model that focus on thestrategic value of operational capabilities related to processflexibility.

Investments in operational capabilities regarding process flexibility have a strategic impact. An appreciation for the effectsof process flexibility should permeate the organisation’s daily work since the accumulated contribution of many, seemingly unimportant, incremental changes significantly influences thestrategic opportunities of the company.

Abstract [en]

Stålproducenter med nischmarknadsstrategier försöker ständigt sänka sina produktionskostnader samtidigt som en varierad produktflora bibehålls. Affärsmodellen bygger i typfallet på försäljning av höghållfasta specialstål eller rostfria stål. Strävan att undvika direkt priskonkurrens leder dock med tiden gradvis till ökad produktvariation och mindre ordervolymer (ton per order)för varje produkt.

Denna avhandling analyserar hur produktionskostnaden är kopplad till graden av produktvariation vid tillverkning av band.Resultaten bygger på nya modeller för utvärdering av förutsättningarnaför prestandaförbättring i stålindustri med stor produktvariation.

Behovet av flexibla produktionsprocesser ökar med ökande produktvariation. Praktiska förmågor kopplade till processflexibilitet avgör till vilken grad ståltillverkare förmår att eliminera mellanlager och åstadkomma en tät koppling mellan processteg.Nischmarknadsproducenter som investerar i förbättrad flexibilitet kan sänka sina produktionskostnader både genom minskad mängd produkter i arbete och reducerad energiförbrukning. Detta medför också minskad miljöbelastning.Följande problemställningar adresseras:

• Utveckling av en metod för att utvärdera inverkan av produktvariationpå prestanda vid ståltillverkning.

• Utveckling av en modell för stränggjutning och varmvalsningsom tar hänsyn till produktvariation och kostnadseffekterför olika grad av processflexibilitet.

• Utveckling av en strategimodell som fokuserar på det strategiskavärdet av operativa förmågor kopplade till processflexibilitet.

Investeringar i operativa förmågor vad avser processflexibilitet är av strategisk betydelse. Förståelse för betydelsen av processflexibilitetbör genomsyra det dagliga arbetet eftersom det samladebidraget av många, till synes obetydliga, små förändringar haren avgörande inverkan på företagets strategiska förutsättningar

Place, publisher, year, edition, pages
Stockholm: KTH, 2009. p. xiv, 126
Keywords
Steel production, system dynamics, product variety, production strategy, cost models
National Category
Production Engineering, Human Work Science and Ergonomics
Identifiers
urn:nbn:se:du-45613 (URN)978-91-7415-507-5 (ISBN)
Public defence
2009-12-18, M311, Brinellvägen 68, KTH, 13:00 (Swedish)
Opponent
Supervisors
Available from: 2023-03-09 Created: 2023-03-09 Last updated: 2023-03-09Bibliographically approved
Storck, J. & Lindberg, B. (2008). A Dynamic Cost Model for the Effect of Improved Process Flexibility in Steel Plants. In: Proceedings of the 41st CIRP Conference on Manufacturing Systems: . Paper presented at The 41st CIRP Conference on Manufacturing Systems , Tokyo, Japan, 26-May, 2008. Tokyo, Japan
Open this publication in new window or tab >>A Dynamic Cost Model for the Effect of Improved Process Flexibility in Steel Plants
2008 (English)In: Proceedings of the 41st CIRP Conference on Manufacturing Systems, Tokyo, Japan, 2008Conference paper, Published paper (Refereed)
Abstract [en]

Reduced setup times in the rolling mill generate flexibility which allows shorter leadtimes through continuous casting and hot rolling. Traditionally known as schedule-free rolling, this flexibility allows the rolling mill to handle variations without the need for buffering. Cost models based on system dynamics methodology are used to assess the economic potential. Effects on inventory, energy and work roll consumptions are analysed. The simulation results show that investments in flexible processes can be evaluated with dynamic cost models. There is an opportunity for significant cost reduction, but also lowered environmental impact due to reduced energy consumption.

Place, publisher, year, edition, pages
Tokyo, Japan: , 2008
Keywords
Hot rolling; Setup time reduction; Cost estimation
National Category
Materials Engineering
Research subject
Steel Forming and Surface Engineering, Operativa strategier för förbättrad produktivitet vid tillverkning av rostfria band
Identifiers
urn:nbn:se:du-3263 (URN)
Conference
The 41st CIRP Conference on Manufacturing Systems , Tokyo, Japan, 26-May, 2008
Available from: 2008-05-19 Created: 2008-05-19 Last updated: 2023-03-09Bibliographically approved
Storck, J. & Lindberg, B. (2007). A cost model for the effect of setup time reduction in stainless steel strip production. In: 1st Swedish Production Symposium: . Paper presented at 1st Swedish Production Symposium, Gothenburg 2007 (pp. 1-8).
Open this publication in new window or tab >>A cost model for the effect of setup time reduction in stainless steel strip production
2007 (English)In: 1st Swedish Production Symposium, 2007, p. 1-8Conference paper, Published paper (Refereed)
Abstract [en]

Setup time reductions facilitate the flexibility needed for just-in-time production. An integrated steel mill with meltshop, continuous caster and hot rolling mill is often operated as decoupled processes. Setup time reduction provides the flexibility needed to reduce buffering, shorten lead times and create an integrated process flow. The interdependency of setup times, process flexibility and integration were analysed through system dynamics simulation. The results showed significant reductions of energy consumption and tied capital. It was concluded that setup time reduction in the hot strip mill can aid process integration and hence improve production economy while reducing environmental impact

Keywords
Steel production, hot rolling, continuous casting, manufacturing flexibility, production economy, setup time reduction, lean production, system dynamics
National Category
Production Engineering, Human Work Science and Ergonomics Business Administration
Identifiers
urn:nbn:se:du-45614 (URN)
Conference
1st Swedish Production Symposium, Gothenburg 2007
Available from: 2009-12-04 Created: 2023-03-09 Last updated: 2023-03-09Bibliographically approved
Storck, J. & Lindberg, B. (2007). A lean production strategy for hot charge operation of a steel mill. In: IET Conference publications, Issue 528, 2007: . Paper presented at The IET International Conference on Agile Manufacturing (ICAM'07) , Collingwood College, Durham, U.K., 9-11 July 2007 (pp. 158-167). , 528
Open this publication in new window or tab >>A lean production strategy for hot charge operation of a steel mill
2007 (English)In: IET Conference publications, Issue 528, 2007, 2007, Vol. 528, p. 158-167Conference paper, Published paper (Refereed)
Abstract [en]

This paper aims to show how a strategy based on lean production can aid the implementation of hot-charge operation in steel strip production. Key parameters in a lean strategy for steel manufacturing are identified, and it is shown that lean production targets the difficulties that are traditionally associated with hot charging. Hot charging amounts to a closer level of integration of the continuous casting and hot rolling processes. The conclusions are that implementation of hot charging can be seen as a waste-reduction process within a lean production strategy, and that there are substantial cost savings to be made once the full benefits of a lean production strategy are considered.

Keywords
Steel production, lean manufacturing, waste reduction, hot charging, manufacturing strategy
National Category
Materials Engineering
Research subject
Steel Forming and Surface Engineering, Operativa strategier för förbättrad produktivitet vid tillverkning av rostfria band
Identifiers
urn:nbn:se:du-2909 (URN)10.1049/cp:20070022 (DOI)
Conference
The IET International Conference on Agile Manufacturing (ICAM'07) , Collingwood College, Durham, U.K., 9-11 July 2007
Available from: 2007-08-15 Created: 2007-08-15 Last updated: 2023-03-09Bibliographically approved
Storck, J. & Lindberg, B. (2007). Assessment of best scheduling practice in continuous casting and hot rolling of stainless steel strip by system dynamics simulation. Paper presented at 12th International Conference on Sheet Metal (SheMet 2007), Palermo, Italy, April 1-4, 2007. Key Engineering Materials, 344, 897-904
Open this publication in new window or tab >>Assessment of best scheduling practice in continuous casting and hot rolling of stainless steel strip by system dynamics simulation
2007 (English)In: Key Engineering Materials, ISSN 1013-9826, E-ISSN 1662-9795, Vol. 344, p. 897-904Article in journal (Refereed) Published
Abstract [en]

A rapid flow of materials with little intermediate buffering between steel mill and hot strip mill has many benefits. One is energy savings due to raised charging temperature in the reheat furnaces of the hot strip mill. Another is that tied capital is freed up, thereby improving mill economy. Still, it is not unusual that average lead-time is in the order of days, or even weeks. The aim of the present work was to show how lead-times from casting to rolling could be improved by changes in the scheduling function. A System Dynamics model of a stainless steel strip production facility with continuous caster and hot rolling mill was created. The model was used to study the dynamics of the system in response to changes in parameters that defined the scheduling configuration. More frequent schedule updating generally resulted in less work in process (WIP) and shorter lead times from casting to rolling, with resulting higher charging temperatures. The amount of oscillation in the system was also reduced. More frequent work roll changes were required when scheduling frequency increased, resulting in an increased fraction of setup time in relation to total processing time. Therefore, a development towards increased scheduling frequency may have to be complemented by efforts to reduce changeover times. The conclusion was that dynamic scheduling routines with frequent schedule updating result in better overall performance of the system due to lower WIP and better heat utilization. Dynamic scheduling routines with frequent updates make the system respond better to changes in the system and give better overall performance. The result is lower WIP, increased energy efficiency and less oscillation in the system.

Keywords
Hot rolling, continuous casting, hot charging, stainless steel, production scheduling, simulation, system dynamics
National Category
Materials Engineering
Research subject
Steel Forming and Surface Engineering, Operativa strategier för förbättrad produktivitet vid tillverkning av rostfria band
Identifiers
urn:nbn:se:du-2908 (URN)000247343400110 ()
Conference
12th International Conference on Sheet Metal (SheMet 2007), Palermo, Italy, April 1-4, 2007
Available from: 2007-08-15 Created: 2007-08-15 Last updated: 2023-03-09Bibliographically approved
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