Mechel’s Izhstal Introduces Lean Production Technologies
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Mechel’s Izhstal Introduces Lean Production Technologies

Mechel Group’s Izhstal plant is implementing a lean production system aimed at increasing operational efficiency and reducing costs. The goal of the project

Mechel Group’s Izhstal plant is implementing a lean production system aimed at increasing operational efficiency and reducing costs. The goal of the project is to increase productivity through the use of lean manufacturing techniques that optimize the production process, minimize all types of losses, and also involve each employee in the improvement process. The implementation of the project involves the introduction of lean manufacturing tools: 5C systems for organizing and rationalizing the workplace, improvement methods, quick changeover, universal equipment maintenance, and improvement of production analysis.

Mill 450 of the rolling shop became the pilot site for the implementation of lean production. The project is designed for two years. For its implementation, a specialized structural unit and several working groups have been created, which closely interact with the attracted experts of the Kaizen Center.

Within the framework of the project, an examination of the current state of the production system of the enterprise and an analysis of the efficiency of using the resources of the mill 450 are carried out. The flow of the production process was presented in a graphical form. To inform the mill employees about the implementation of lean manufacturing tools, a special information stand was installed. Izhstal conducted an initial audit on the 5C system, developed plans for the implementation of the system at reference workplaces and optimization of the mill.

The implementation of lean production methods showed positive results at the pilot site, in connection with which the plant decided to scale this project to the workshop for repair and maintenance of rolling production, sales service and logistics of sales of finished products.

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