Selected Case Studies

Client: Various clients
Region: Pakistsan & Uzbekistan
Period: 2020 - 2024
Role: Basic Engineering Consulting

Context
Several greenfield steel plant projects were evaluated as part of long-term capacity expansion strategies in emerging markets.

Challenge
Early-stage project planning required realistic layouts, capacity definitions and reliable investment cost estimates for decision-making.

My Role
I supported the projects through basic engineering studies focusing on rolling mills and associated facilities.

Approach
Development of plant layouts, definition of annual production capacities, planning of auxiliary facilities and estimation of investment costs based on practical engineering experience.

Result / Impact
The studies provided a solid technical and economic foundation for further project development and investment decisions.

Client: Hyundai Special Steel
Region: South Korea
Period: 2016 - 2019
Role: Technical Consulting

Context
A newly commissioned steel plant complex was developed to supply high-quality steel products for the local automotive industry.

Challenge
The plant required support during commissioning to establish stable processes, implement quality standards and ensure product approval for demanding automotive applications.

My Role
I supported the project as technical consultant during commissioning, quality system development and product qualification.

Approach
Technical assessment from casting to rolling and downstream processing, evaluation of plant equipment and HR capabilities, introduction of standards, and systematic analysis of material defects. Benchmarking against European automotive standards was a key element.

Result / Impact
Improved process stability, enhanced defect detection capabilities and successful support of product homologation and approval for automotive customers.

Client: ZENITH Steel
Region: China
Period: 2015
Role: Technical Consulting

Context
ZENITH Steel aimed to supply automotive steel products to the domestic Chinese market and evaluated the suitability of its existing facilities for advanced thermomechanical rolling processes.

Challenge
The challenge was to determine whether current equipment, process control and quality standards met the requirements for modern automotive lightweight applications.

My Role
Independent consultant responsible for technical assessment and benchmarking against European automotive steel standards.

Approach
Fact finding from raw steel to final rolling, review of rolling technology and process control, and comparison of achieved product properties with international standards.

Result / Impact
The study provided a clear technical assessment of existing capabilities and defined concrete improvement measures required to meet automotive customer expectations.

Client: NISCO - Nanjing Iron & Steel Corporation
Region: China
Period: 2013
Role: Technical Consulting

Context
A major Chinese steel producer supplying automotive steel required an independent review of its production capabilities and quality performance from raw steelmaking to final products.

Challenge
Recurring material defects and quality deviations limited competitiveness in demanding automotive applications and required systematic root cause analysis.

My Role
I acted as independent technical consultant supporting fact finding, defect analysis and capability assessment.

Approach
Evaluation of process routes, material flows and quality assurance systems. Identification of defect sources along the production chain and comparison of technical capabilities against international benchmarks.

Result / Impact
Clear identification of quality-related weaknesses and practical recommendations for process and organizational improvements, supporting the development of more competitive automotive steel grades.

Client: ACOS FINOS PIRATINI (Gerdau Group)
Region: Brazil
Period: 1993
Role: Technical Consulting

Context
An integrated steel plant producing wire rod, bar and semi-finished products required an independent technical assessment as a basis for future expansion planning across the entire value chain.

Challenge
The plant needed a clear evaluation of its existing raw steel, rolling and finishing capabilities, including identification of bottlenecks and development potential for future capacity and product improvements.

My Role
I supported the project as an independent consultant, conducting a comprehensive fact-finding assessment from raw steel production to final products.

Approach
On-site analysis of production facilities, process routes and product portfolio, combined with technical discussions with plant management and operational teams. Evaluation focused on technical capability, process integration and future expansion options.

Result / Impact
The assessment provided a structured basis for strategic decisions on plant expansion and modernization, including clear technical recommendations for future development.