Mobarakeh Steel Complex (M.S.Co.) extended its production lines in the year 2000 to increase the production rate. In many lines, old systems were matched with the new ones. However, in some others, there were some difficulties working old machines together with the new ones to overcome which specific plans were necessary. Nevertheless, there exist some machines with serious challenges in the course of operation. One of these is "twist roll machine" (TRM) in the 5-stand tandem mill which is used to rotate the sheet to 90 degree. In many modern continuous steel production lines, the twist roll machine (TRM) is used to change the direction and to reduce the production line. erious deficiencies including high wear rate of the machine rollers and increase in the maintenance expenses occur due to prolonged contact of the rollers with the sheets. After all, the most important problem is formation of marked defects on the sheet leading to low quality of the sheet surface at exit from the rolling mill. Several pin-on-disc wear tests were carried out on rollers to determine the wear rate as well as the friction coefficient of contact with St12 and to study the variations of which with changes in speed and the applied force. The results were obtained for two different polyethylene rollers to investigate the effect of material on the wear parameters. Based on the wear test result the tribology property of polyethylene can be different in wear test speed and pressure applied. The machine geometry and conditions of contact between the sheet and the rollers were further studied by modeling the whole system in CATIA. Accordingly, practical suggestions to minimize deficiencies due to the quality of contacts with different rollers were proposed. To analyze the contact forces as well as stress distribution throughout the sheet, finite element simulations were done in ABAQUS for different operational conditions in terms of the sheet width and speed, and the bridle rolls tension.Moreover, proper amount of the bridle rolls tension to prevent local plastic deformations and hence formation of marked defects on the sheet was determined for different operational conditions. Finally, to more effectively reduce the rollers wear rate, a new arrangement was suggested for machine roll series. As well, in order to identify sheet movement, stress distribution in the sheet and rollers and how its contact with various parts of roller finite element analysis was done. Consequently, the effects of wear characteristics of roller material, roller arrangement and also bridle roll tension for any width and various thicknesses of sheet passing through twist roll were evaluated. Based on these results, this FEM simulation shows fewer defects on the TRM and sheets. Key words: Twist Roll Machine, Wear, Roller, Continuous Cold Rolling Mill