A focus on slitting lines
A common theme among fabricators and service centers is that slitting lines has become a commodity process with very low margins. Considering the staggering amount of manufacturing that has moved overseas recently, it follows that too many slitting lines in the U.S. are chasing too small a market—or, simply put, the slitting market has too much capacity. Carbon steel has been hit the hardest because it requires less advanced technology and often can be processed using unskilled, low-cost labor.
To maintain a manufacturing sector in this country, industry must continually improve in efficiency. Manufacturers and processors can and should specify new machines that run at high speeds and allow quick setups, which are two essential ingredients for efficient operation. If a new slitting line is not in the cards, however, many existing slitting line components can be upgraded to improve efficiency.
Choosing the right components does not necessarily mean choosing the most expensive ones. Coil processors should choose components that match the type of products run, the frequency of setup changes, and the labor available to operate the line. Some of the aspects that affect slitting line efficiency are entry coil storage; coil inside diameter (ID) changes; slitter tooling changeover; scrap handling; and strip tensioning.
A good entry coil storage system can improve efficiency by reducing line downtime and by allowing efficient use of overhead cranes. The ability to stage multiple coils is crucial because it prevents waiting at the line, and it allows the crane operator to retrieve and load coils whenever it is convenient, not when it is necessary. Common coil storage devices are turnstiles, saddles, and turntables.
Turnstiles with four arms are suitable for many slitting line applications. Because they rotate, they allow the line operator to select any coil in any order. However, they support coils by the ID, and may damage thin, heavy coils. Also, it can be difficult to load small-ID coil
Like it or not, slitting lines, like many manufacturing operations, are now competing with low-cost operations on a global scale. Excellent quality and service alone do not guarantee profit or survival. To remain competitive, coil processors must operate their slitting lines at peak efficiency. Keeping a close eye on the main areas that affect slitting line efficiency, and using the most suitable equipment in those areas, combined with proper staffing and training, can help coil processors remain competitive in an increasingly competitive industry.
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