Metals Industry

New Mill Startup

In support of the vertical startup of a greenfield site for processing rolled steel products, GP conducted a comprehensive, multi-phased training and certification program for new employees of the following lines:

• Continuous Galvanizing Line
• Continuous Cold Mill
• Continuous Annealing and Pickling Line
• Continuous Pickling Line
• Temper Mill
• Hydrogen Annealing Line
• Shipping and Receiving Department

Based upon a systematic approach to training, a needs analysis was performed and resulted in a comprehensive training plan for each finishing line. The training plan provided strategies and time lines for the subsequent design, development and implementation of training for each of the finishing lines.

The training programs include a core knowledge and skills curriculum, line theory of operations, and equipment-specific training followed by a position and task specific on-the-job training (OJT) program. In parallel with the training effort, failure mode effects analysis (FMEA), control plans, and operational and administrative procedures were developed for each line.