Group Members:

o Mohsin Fiaz (IEM-21-23)

o Misbah Ul Haq (IEM-21-34)
o Hafiz Usama (IEM-20-06)

Presented To:
o SIR MUNIR
Presentation Topic:

o Simulation Modeling For Quality And

Productivity In Steel Cord Manufacturing
Enhancing Quality and
Productivity in Steel Cord
Manufacturing through
Simulation Modeling

Steel cord is a critical component in radial tires, providing

strength and durability. Improving the quality and
productivity of steel cord manufacturing is crucial to meet
growing demand and ensure consistent tire performance.
This presentation explores how simulation modeling can
help optimize the manufacturing process and drive process
improvements.
The Steel Cord Manufacturing Process
o Thinning Steel Rod o Annealing and Plating o Continuous Process

The manufacturing The drawn wires are The process is highly

process begins with then annealed to continuous, with spools
thinning thick steel rods increase ductility and used to store semi-
into fine wires through a plated to improve finished wire products as
series of drawing steps. corrosion resistance. the manufacturing
progresses.
Research Objectives
Optimize Spool Lengths
The goal is to improve operating policies by
optimizing spool lengths for bunching
operations, which can enhance quality and
productivity.
Utilize Simulation Modeling
Simulation modeling is proposed as the
most suitable approach due to the dynamic
nature of the manufacturing system and
uncontrollable factors like wire fractures.
Reduce Rejected Spools
Reducing the number of rejected spools
containing knots is a key focus, as these
knots can significantly impact quality and
yield.
Enhance Decision-Making
The research aims to provide insights and
suggestions for implementing dynamic
control policies to improve operational
decisions.
Modeling Wire Fractures
1 Significance of Wire 2 Identifying Fracture 3 Simulation
Fractures Patterns Approach
Wire fractures are a Identifying patterns The simulation
significant source of in fracture locations model assumes
knots in the and causes is random wire
manufacturing challenging due to fractures, as this
process, leading to the complex and represents the
rejected spools and dynamic nature of uncontrollable
quality issues. the manufacturing nature of this
system. phenomenon in the
real-world process.
The Simulation Model
1 Input Parameters
The simulation model incorporates key parameters such as usage ratios,
wire densities, fracture ratios, and machine characteristics.

2 Decision Variables
The model allows for the optimization of spool lengths and other
operational decisions to improve productivity and quality.

3 Simulation Outputs
The model provides valuable insights, including accepted and rejected
spools, rejected wire length, and throughput time.
Simulation Results
o Accurate
Performance
Estimation
The simulation model has
proven to be an effective
tool in accurately estimating
the system's performance
and identifying areas for
improvement.
o Operational
Improvements
The simulation results have
provided suggestions for
optimal operational rules
and policies, leading to
enhanced productivity and
quality.
o Dynamic Control
Policies
The feasibility of
implementing dynamic
control policies based on
the simulation insights has
been demonstrated, further
enhancing the
manufacturing process.
Future Research Directions
Model Enhancements
Extending the simulation model to incorporate new features and
capabilities, such as advanced machine learning algorithms for fracture
prediction.

Economic Feasibility
Assessing the economic impact of investing in new manufacturing
technologies and their potential to further improve quality and
productivity.

Collaborative Opportunities
Exploring opportunities for industry-academia collaborations to drive
continued innovation in steel cord manufacturing processes.
Conclusion
1 Enhancing Quality and
Productivity
Simulation modeling has proven to
be a powerful tool in optimizing
steel cord manufacturing
operations and driving process
improvements.
2 Implementing Dynamic
Policies
The feasibility of implementing
dynamic control policies based on
the simulation insights has been
demonstrated, further enhancing
the manufacturing process.

3 Continued Innovation
Exploring future research directions, including model enhancements and
economic feasibility assessments, will drive ongoing innovation in the steel cord
manufacturing industry.
THANK YOU