Reinforcing bar is forged steel used in concrete to give the otherwise weak concrete structural tension strength. Reinforcing bar manufacturing is done in a factory using computerised machines to straighten, cut and bend the steel. It is a highly automated process once the bar is loaded onto the manufacturing machinery. These machines are computer controlled and form the bar to the shape and dimensions instructed. The bar specification and dimensions are identified from the engineering drawings by the Scheduler who enters the details into a scheduling software program. The program converts the reo-bar size requirements into computer controlled manufacturing instructions for the machines and a delivery schedule for the production shop.

Our assignment was to identify opportunities to improve the business and streamline the operation from production through to delivery.

Example ACE 3T (Target-Tolerance-Test) Procedure with Reliability Standards: Machine performance is totally dependent on human beings. To address the problem of human error causing equipment failure, an Accuracy Controlled Enterprise sets best practice quality standards and uses 3T Target-Tolerance-Test work task quality control that assures high quality workmanship for high reliability results. Their work procedures are standardised so everyone follows the same methods to produce the same results, their training teaches people how to do craftsmanship work that creates outstandingly reliable plant and machinery. They create the reliability they want and as a result achieve operational excellence.