1. No written procedures for setup

Every mill should have written procedures for all operators to follow. And the machine, roller and steel coil are fixed factors in the mill setup equation; the only variable is the human factor. Written procedures also provide a tool for troubleshooting when problems arise.

2. No setup chart

Adjusting the mill during setup loses valuable setup time. Operators must follow parameters of a setup chart.

3. Lack of formal training

Formal training helps operators perform procedures for tube mill operation and maintenance. That can also ensure all operators are on the same track.

4. Disregard of parameters from previous setup

If the tube mill has been set up based on written procedures and setup chart, the operator can write down numbers from the digital readout on the single-point adjustment unit. That can make the next operator operate machine based on it.

5. Mill in poor condition

A poorly maintained mill takes valuable time and scrap during setup and operation. The mill must be dependable so that the operator is not chasing mechanical problems during normal operation and setup. A good maintenance program, as well as rebuilds or upgrades when necessary, is essential.

6. Mill in misalignment

Tube mill misalignment, poor mill condition, and inaccurate setup account for 95 percent of all problems in tube production. Most mills should be aligned at least once a year.

7. Roller in poor condition

Operators must know how much life is left in the roller before the next scheduled rework. Running the roller until it can’t produce tubes anymore not only wastes valuable mill time, but produces scrap and affects delivery schedules. All tube production companies should have a roller maintenance program in place.