An extensive amount of work has been completed to improve reliability and decrease variability within the casting operation at the No. 7 blast furnace by using the CIP process. This process enabled us to break down the interdependence of issues into components that could be attacked systematically enroute to continuous improvement. Quality control and refinements to taphole clay, preventative maintenance and modifications to existing equipment and a common goal supported by all casthouse personnel have been the avenue with which the improvements have been driven. A sidebar to a discussion on improvements would be incomplete without mentioning the improvement in safety within the casthouse (Figure 8). Attitude, awareness, housekeeping, inspections, proactive repairs and work done by safety committees (continuous improvement) have all been key contributors to the success. Due to current furnace conditions, a substantial amount of time and effort is spent maintaining the improvements already in place. Without the CIP process and improvements already made, furnace productivity would have suffered.
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