Gerdau Internship 2018

Finishing Department

Zach Bowling
August 7, 2018
 Introduction

• Education
– Michigan State University
• Major: Mechanical Engineering
• Super Senior (Graduating December 2018)
– Graduated Detroit Catholic Central in 2014

• Job
– 4th internship, 1st in manufacturing
– Finishing Process Intern

2 Strictly private and confidential

 GM Out-of-Round CIA

• Measurement Capability Analysis

– Conducted Measurement Comparison Study
• Compiled data for new digital indicator and 3-point mic to compare with old gauge
• Oversaw a small team that measured 2000+ parts to verify roundness for OEM
– 125 parts measured with CMM to compare and set a tolerance

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 Turner Line 1: Short Bar Productivity

• Currently, Line 1 is the only line that does not run 12’ bars
– Polisher entry uses two pinch rolls instead of chain-driven roll line
– How can we add length versatility to the line?
• 2 Options

Polisher Entry: Line 1 Polisher Entry: Lines 2 & 3

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Option 1: Pinch Roll Programing

• Control Technician Steve Chase previously adjusted

pinch roll timing to fix issues with 17’-20’ bars
– Program never tested for 12’ bars

• Facilitated a verification trial

– Ran four scrap 12’ bars from the polisher entry to the end-of-line kickoff with the
help of Mike Smith
– Bars stopped right at the second pinch roll, why?
– Hardware and software need adjustment
• Manual operation of second pinch roll successfully pushed bar through
– Programing adjustments will need to be made on transfer table as well
• Bars did not roll evenly
• Too much momentum hitting stop

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12’ Bars On Line 1 Trial: Video

https://youtu.be/1Jq7L-vD8hY

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 12’ Bars On Line 1 Trial: Pictures

Position of Stopped Bar at Pinch Roll 2 Skewed Bars at Transfer Table Kickoff

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Option 2: Physical Modification of Polisher Entry

• “Make Line 1 polisher entry identical to Lines 2 & 3”

– Found a folder of 8 drawings from 2007 with this exact plan
• Why was it never implemented?
• Is it still feasible?
• 74 unique new parts: Cost?

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Line 1 Polisher Entry Proposed Modification:
Top View

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Line 1 Polisher Entry Proposed Modification:
Side View (Facing North)

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Other Work

• CPR Training
• Toured Monroe Plant
• Head change analysis
• Updated Operator Sheets
for Mult-Cut FA
• Product Verification in
Bar Yard
• Line 3 Sensor Mapping

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Summer Takeaways

• Manufacturing
Experience
– Different environment,
different challenges
• In depth learning of the
steel making process
• “Engineering is a giant
balancing act”
• Great Co-Workers

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Thank You!