Effects of power interruptions on quality and production in a galvanizing plant Case study: roofings rolling mills ltd, Namanve, Kampala

Abstract

Steel is the most used engineering material industries. In Uganda, Roofings Rolling Mills Ltd (RRM) is the largest steel manufacturer; with mega industrial undertakings which is in line with national economic development strategy as it employs 2,000 people in the country. However, this is undermined by the negative effects of electric power interruptions. Thus, evaluation of the effects of power interruptions on quality and production in the sheet galvanizing plant was done in accordance to specific objectives to; determine the process parameters that influence the galvanizing; determine the effect of power interruptions on the process parameters; and assess the cost implications of power interruptions on the galvanizing line at RRM. During this study, the most affected processes were identified, damages were quantified and costs related to this effect were determined. To this effect the organization can negotiate for tax reduction levy due to the losses caused by power interruptions. The methods used were quantitative and qualitative, for determining the parameters influencing galvanizing. The various types of rejects, their causes and evaluating how power interruption affects quality and production which in turn affects the organizations performance. This was a success by participatory observation in accordance to a checklist, literature reviews and relating these to the set standards (ISO, ASTM, AGA, UNBS, etc.). To obtain results data analytical techniques (tables, regression analysis and Anova). Analysis have shown that, to obtain high quality products, there is need to ensure that parameters for galvanizing are in accordance to standards. The study showed that color coating and cold galvanizing are the most affected processes. The study shows the different effects of power for 2016 and 2017 on cold galvanizing line as; rejects from 5% to ( 25.35% and 0.77%), machine efficiency from 94% to (87.76 and 91.7%), production efficiency from 92% to (69.17% and 78.8%) for these years respectively. These resulted to increase in production costs, from UGX 7.5 billion per annum to UGX ≈ 8.65 billion per annum, amidst other investment challenges affecting the organization’s performance. For improved performance, the affected lines need alternative power sources supplied to help always clear the products online in case of any power interruption, there is need to have alternative power to clear product on line and conduct risk assessment for the safety of workers, equipment and machinery during power interruptions. Furthermore, it’s recommended, that the organization applies for connection to stable power supply line that will reduce on production losses. This will lead to more profits for the organization, thus economic benefits to the government and fulfilling “Uganda’s Vision 2040.’’