Applying industrial management for improving productivity In Dubai steel factory in Sudan

Abstract

The iron and steel industry is an important basic industry of Sudan national economy and plays a vital role in the process of industrialization and urbanization. Prosperity in steel sector reflects positively in national income. Steel industries have many challenges in production processes that hinder improvement of productivity and hence to decrease in efficiency, to notice these challenges facing production of steel industry Dubai steel factory in Sudan was taken as a sample of steel factories .The objective of this study was to define the steel production problems, this was done through construction of comprehensive questionnaire, this questionnaire was design to display the problems based on the analysis of the data.. The questionnaire was divided to two parts one for labors and Foremen, and the other for Engineers and Administrators. The questions were oriented to any part according to their knowledge and also to get correct answers and make strategic plan. Modification routinely used formula in steel bar industry was applied by adding silicon and manganese alloy for bar steel manufacturing, this was done by considering all the variation that effect on steel specification to render it more flexible with high quality and less time for treatment. Three hundred and three reports (have specifications of melting) were taken to study the relationship among all the elements in the report to determine the relation between the elements and the amount of alloy added to melting, the new formula was used in the production line of steel bar. Strategic plan made according to questionnaires data analysis to raise the productivity and finally calculation the productivity for materials, labors and machines. Calculation of productivity for labors, materials and machines v will help Dubai steel factory in Sudan to assess the production and gives three levels of productivity. The results after analysis by SPSS (statistical package for the social sciences) for questionnaires showed that there were deficiency in machinery, unsatisfactory salary, not up to date technology, materials shortage and less skilled employees. In conclusion managerial sector was found to be the most barriers facing Dubai steel factory in Sudan development. The analysis of result by SPSS showed that modifying formula used to produce steel bar has seven variations better than routinely used which had two variations, newly obtained formula had been tested three times in steel bar production process, the result was acceptable compared with routinely used in the factory after analysis the final product. This modifying formula due to its reduced cost of used amounted (silicon and manganese) alloy, less time for treatment and with high quality, is highly recommended to apply in steel bar production, strategic plan made according to data analysis to be matched with existences problems. Productivity calculations for materials, labors and machines provide levels for control the production process and also contribute to make decision in short time.