Authors : M. Ravi; Dr. Manoj Bhatia; Dr. V K Jain

Volume/Issue : Volume 10 - 2025, Issue 2 - February

Google Scholar : https://tinyurl.com/mtw3dyr3

Scribd : https://tinyurl.com/4wmem28s

DOI : https://doi.org/10.38124/ijisrt/25feb1233

Google Scholar

Note : A published paper may take 4-5 working days from the publication date to appear in PlumX Metrics, Semantic Scholar, and ResearchGate.

Note : Google Scholar may take 15 to 20 days to display the article.

Abstract : Operational efficiency focuses on refining process parameters, eliminating non-value-adding bottlenecks, and reducing unnecessary time and costs. In the manufacturing industry, operational efficiency refers to the capacity of a company to produce goods and services using minimal resources while maximizing output. The operational efficiency of steel plants is crucial to the overall efficiency of the steel industry, as it reflects the performance of every interconnected unit within the plant’s operations. Steel producers face significant challenges, including fluctuating demand, capital and labour intensity, raw material supply disruptions, tightening environmental regulations, downtime, and the need for optimal use of equipment and resources. Key performance indicators (KPIs) for evaluating the operational efficiency of integrated steel plants include raw material utilization, equipment availability and utilization, quality control, productivity metrics, and financial efficiency. This study analyses these KPIs using data from five integrated steel plants under the Steel Authority of India Limited (SAIL), sourced from SAIL’s annual reports over the last five fiscal years. The findings suggest that fostering strong relationships with suppliers and customers creates a collaborative environment conducive to continuous improvement. Emphasis should shift from volume-based approaches to strategies centered on product quality and customer satisfaction. Regular data monitoring and predictive maintenance offer critical insights into equipment performance, production trends, and maintenance needs, enabling process optimization. Implementing cost control measures in the raw material and iron zones where 60% of production costs are concentrated can significantly impact overall efficiency. Sharing best practices, joint research, and collaborative product development further contribute to mutual benefits.

References :

1. Sun, W., Wang, Q., Zhou, Y., & Wu, J. (Year). Material and energy flows of the iron and steel industry: Status quo, challenges, and perspectives. Department of Thermal Engineering, School of Metallurgy, Northeastern University, Shenyang, Liaoning, China, and School of Engineering, Cardiff University, Wales, UK.
2. Jurnal Minfo Polgan, Volume 12, Issue 1, July 2023. Analyzing the Role of Technological Innovation in Improving the Operational Efficiency of MSMEs. DOI: https://doi.org/10.33395/jmp.v12i1.12791.
3. Sooriyamudali, P., & Dilshani, N. (October 2020). Factors Affecting Operational Efficiency. Presented at VCIRS 2019.
4. (January 2023). Coal, Iron Ore, and Steel - Emerging Trends and Challenges. FIMI.
5. Iron and Steel Technology Roadmap Towards More Sustainable Steelmaking. (Year).
6. IEA Clean Energy Transitions Programme (CETP). Retrieved from https://www.iea.org/areas-of-work/programmes-and-partnerships/clean-energy-transitions-programme.
7. Liu, W., & Kong, Y. (Year). Optimization of the Raw Material Field Layout for Iron-Steel Enterprise. Department of Logistics Management, Liaoning Provincial College of Communications, and Key Laboratory of Data Analytics and Optimization for Smart Industry, Northeastern University, Shenyang, Liaoning, China.
8. Ministry of Steel. (2022-23). Annual Report.
9. (September 2018). Utilization of Steel Plants Waste. DOI: 10.15406/mseij.2018.02.00048.
10. Dutta, S. K., Chokshi, Y., & Sompura, N. (Year). The Maharaja Sayajirao University of Baroda and Government Polytechnic Rajkot.
11. Horst, D. J., & Andrade Júnior, P. P. (2023). Sustainability of the Steel Industry: A Systematic Review. Department of Chemical Engineering, Federal University of São Paulo, and Department of Mechanical Engineering and Sciences, Federal University of Santa Catarina, Brazil. DOI: https://doi.org/10.33263/BRIAC136.525.
12. Chalabyan, A., Mori, L., & Ercammen, S. V. (January 2018). The Current Capacity Shake-up in Steel and How the Industry is Adapting. Metal and Mining Practice.
13. Deshpande, S. 8 Major Challenges in the Steel Industry in India.
14. SAIL Annual Reports, Sustainability Reports, RDCIS Operational Parameters Reports, and Statistical Reports of Individual Plants (2018-2023).