Plano de gerenciamento de materiais de reposição para mitigação de falhas no processo de resfriamento em linhas produtivas de uma aciaria

Abstract

Cooling in the continuous casting process is essential for the solidification of liquid steel in a controlled manner. Failures in cooling pumps can interrupt the flow of water, resulting in inadequate cooling and increasing the downtime of a melt shop. The availability of suitable replacement materials for the water pumps is fundamental to maintaining the efficiency of the production lines. In this study, a spare materials management plan was implemented for cooling pumps in a steel mill, with the aim of reducing recurring failures. To analyze the causes of these failures, methodologies such as the Ishikawa Diagram and the 5 Whys Method were applied, which enabled critical factors to be identified, including the use of inappropriate materials. Based on this information, a materials management plan was drawn up, which included the creation of a detailed inventory with the technical specifications of the components, theclassification of replacement items by criticality, the implementation of maintenance plans and regular audits to monitor the effectiveness of the system. The results showed a significant reduction in machine downtime, from 878 minutes to 123 minutes over the 6-month period, representing a decrease of approximately 85.9%. These results reinforce the importance of effective materials management and the correct availability of spare parts for maintaining operational efficiency, highlighting the importance of proactive maintenance practices and strict quality control of materials.