INDEX
PART SUBJECT PAGE

Quality Policy Total Quality Management Total Quality Management Vision

A1 A2 A3 A4 A5 A6

A

List of Technical Personnel Responsibility Matrix Total Quality Management System Cycle

B

Manufacturing Process Production Flow Chart

B1 B2

Inspection Process Inspection Process Flow Chart Stage-wise Inspection Guidelines Stage-wise Inspection Forms

C1 C2 C3 C7 C12 C13 C14 C15 C16

C

Scope and Responsibility of Quality Management Department Product Realization Process & Interaction Control of Non-Conforming Product Inspection and Testing Equipment Manufacturing and Testing Codes and Standards

Approved by : MD Issued by : MR Issue : Issue Date : # 01 A1 . sales and delivery. # 5. # QSM/ SSIL /5. • Continuous improvement in process. TMT Re-Bars.3/00 Page : A1 Title: Management Responsibility Quality Policy Shyam Steel Industries Ltd is committed to • Satisfy customer through compliance of their needs. by delivering premium quality MS Billets. quality.Shyam Steel Industries Ltd Quality System Manual ISO CL NO. CRS TMT ReBars and others Structural Steel products in a cost effective manner on time & every time.3 DOC. All members of the organization are developed by effective implementation and upgradation of the Total Quality Management System. CRS Billets. NO.

Total Quality Management is a comprehensive and integrated way of managing any organization in order to: a) Meet the needs of the customer requirements. Quality inspection. and take action to prevent errors from re-occurring. through which the company seeks to meet and satisfy customer requirements through the entire chain of internal and external customers and suppliers. Quality Management Quality management has four levels: Inspection. which meet the needs and expectations of customers.Quality Assurance inspection and control setting of standards with documentation and also the documentation of the method of checking against the specified standards.Quality Control is to inspect. The third level. and finally by efforts to eliminate the causes of error so that the defined accepted level is achieved. A2 . investigate and find the causes of errors and correct problems. The following is the definition given in ISO 8402: Management approach of an organization centers on quality. There are many interpretations and definition of TQM. Total quality management is both a philosophy and a set of guiding principles for managing an organization efficiently. The next level. Both methods rely on supervision and inspection. The most basic approach to Quality Inspection is detection and correction of errors. based on the participation of all its members aiming at long run success through customer satisfaction and benefits to all members of the organization and the society. b) Achieve continuous improvement in every aspect of the organizational activities.Total Quality Management Total Quality Management is the process. then by rigid conformance to standards and procedures. Assurance and Total Quality Management (TQM). control and quality assurance are aimed at achieving an agreed consistent level of quality. first by testing and inspection. Control. TQM is the mutual co-operation of everyone in an organization and associated business process to produce products.

Total Quality Management Vision Customer satisfaction Organizational performance Product quality Employee treatment Social responsibility A3 .

) 10 Years 7. Inspection-in-Charge Diploma Engineer 7 Years A4 . Production Manager B. Designation Executive Director Qualification B. Lab-in-Charge (Metallurgy) Diploma Engineer 7 Years 12.) TQM. Works Manager B.). ASNT Level-II 15 Years 6. Quality Control Manager B.List of Technical Personnel Sl. Lab-in-Charge (Chemical) M.No.E (MECH.E (Mech.E (Mech. Maintenance Manager B. Quality Assurance Manager B.) 10 Years 5. General Manager B E(Met) 25 Years 3. Lab-in-Charge (Physical) Diploma Engineer 7 Years 10. MBA 5 Years 4. Shift-in-Charge (Production) Diploma Engineer 7 Years 9.E (Prod. 1.E (Elec.SC 7 Years 11.E (Mech.) 7 years 8.) Experience 30 Years 2.

# QSM/ SSIL /5. NO.5 DOC. No 1 2 3 4 5 6 ACTIVITY Quality System Control of Documents Control of Records Management Responsibility Resource Management Complete Awareness Training Customer Related Processes Purchase Production Maintenance Identification & Traceability Preservation of Products Control of Monitoring & Measuring Devices Monitoring and Measuring Internal Audit Control of Non-Conforming Products Data Analysis Corrective Action Preventive Action DR CR MD DR DR DR DR DR DR GM DR DR DR DR DR DR MR DR DR DR DR DR DR WM DR DR DR DR CR CR MKT CR CR DR CR CR CR PUR CR CR DR CR CR CR PROD CR CR DR CR CR QA DR CR DR CR DR STORE CR CR DR CR CR MNT CR CR CR CR CR 7 DR DR CR CR DR - CR CR - - 8 9 10 11 12 13 DR CR - CR DR CR CR CR DR - CR DR CR DR DR CR - DR CR DR CR DR CR DR DR DR CR CR CR DR DR DR CR CR DR CR CR DR - 14 15 16 CR DR CR DR DR CR CR DR CR DR CR CR DR DR CR DR DR CR DR CR CR CR CR CR 17 18 19 Legend CR CR DR - CR CR DR CR DR CR DR CR DR DR DR DR DR DR DR DR DR CR CR CR - Direct Responsibility Contributory Responsibility Approved by : MD Issued by : MR Issue : Issue Date : # 01 A5 .5/00 Page : A6 Title: Management Responsibility Authority & Communication Responsibility Matrix Sl.Shyam Steel Industries Ltd Quality System Manual ISO CL NO. # 5.

Total Quality Management Continuous Improvement of The Quality Management System Management Responsibility Plan Resource Management Do Measurement Analysis and Improvement Act Product Realisation Check A6 .

1) In the DRI plant. temperature equalizing takes place at round 600ºC. whereas the core temperature remains the same. The inclination and the rotary motion of the kiln ensure that the raw materials move from the feed end to the discharge end of the kiln and during this movement the actual reduction of iron ore to iron takes place. Billets from SAIL as well as from our own plant at Durgapur are brought to Howrah plant and rolled into specific structural sections. various necessary ferro alloys are added to it. The Billets thus manufactured are re-heated to a temp.Description of Manufacturing Process The Durgapur Steel unit of the Company is a highly sophisticated integrated steel plant comprising (i) DRI Unit (ii) Steel Melting Electric Furnace (iii) Continuous Billet Casting Plant and (iv) Rolling Mill. The reduction is carried out in a rotary kiln (which is inclined and rotates at a pre-determined range of speeds) at a stipulated temperature (850ºC -1050ºC). Germany under the brand name of “Thermex”. In the case of manufacturing TMT Re-Bars. the re-bars are guided through a specially designed proprietary Thermex pipes in which water quenching is done under controlled conditions. the “Thermex Process” as explained below is followed : From the finishing stand of the rolling Mill. This process is a patented technology from HSE. This hot metal is then tested for its chemical composition.(6) 2) In the SMS plant. Depending on the existing chemical components.(4) Fe3O4 + CO Fe0 + CO = 3Fe0 + CO2 -------. It has been setup in collaboration with world-renowned technologies from Concast AG-Zurich and HSE Germany. sponge iron along with pig iron in a close range of ratio is charged in the furnace. The material gets melted at a temp.(5) = Fe + CO2 ----------. production of sponge iron using a solid reductant involves reducing iron ore (lumps/pellets) with a carbonaceous material like coal or lignite. of 1500º-1600ºC. This makes the surface of the re-bar a hardened structure called martensite and the core remains soft and is known as ferrite-pearlite. Then at the cooling bed. The surface temperature of the hot re-bars falls drastically from 900ºC to around 400ºC on account of the intense and uniform cooling. of 1200ºC in the re-heating furnace and are rolled into specific sections of finished material in the Rolling Mill Unit. After the alloy addition. The material discharged from the kiln is taken to a rotary cooler for cooling and the cooled product is separated from the coal char. the hot metal is oxidized and then sent to the concaster plant. This process increases the tensile strength of the material while keeping high ductility and weldability. There the molten steel in casted into Billets. B1 . The basic reactions involved are as follows : 3Fe2O3 + CO = 2Fe3O4 + CO2 ----. Structural Steel of medium section is rolled at the Howrah Unit.

Production Flow Chart Integrated Steel Plant Iron ore Coal Flux DRI plant Stock yard Pig Iron Electric furnace Concast plant Rolling mill Despatch for Howrah Unit Rolling mill unit-2 Finished stock yard for TMT Re-Bars Finished stock yard for Structural Steel B2 .

Production Flow Chart DRI Plant Ground hopper iron ore (5 to 40mm)+Dolomite Ground hopper Coal (0-150mm) Crusher house Return for crushing Transfer house Return for screening Size Ore (5-18mm) Dolomite F/C (4 -18 mm) Stock house I/C (0-8 mm) Kiln (reduction) Cooler Product separation bin Lumps (5-20 mm) Fines (0-5 mm) Sponge Iron (stored with heat No. marking) Char (unburned coal) Sponge Iron Char (unburned coal) B3 .

Sulphur print test Batch number wise stacking at finish stockyard B4 . Macro Examination.Production Flow Chart SMS & Concast Plant Raw Material Yard • Sponge Iron • Pig Iron Chemical analysis and mix finalisation Electric furnace equipped with temperature controllers and pyrometer Chemical addition • Ferro silicon • Silicomanganese • Ferro manganese • Aluminum bar Bath sample checking for chemical analysis Conforms? Yes Hot material shifted from furnace to laddle Concast plant No Sizing in required length Cooling bed * Visual inspection & testing * Dimension. Chemical Composition. N2 content. Bend/Camber.

Production Flow Chart Rolling Mill Raw material yard Raw material inspection: visual & chemical Oil fired furnace equipped with temperature controllers Roughing mill Intermediate mill Finishing mill ** Thermex TMT plant Cooling bed Sizing/straightening Checking of dimension & weight Physical & chemical testing Section & lot wise stacking at despatch yard Despatch ** This stage applicable for TMT Re-Bars B5 .

various ferro alloys are added to it. Depending upon the composition found. Name of the Company Lot No. It is then sent to the Rolling Mill raw material yard. There after. is sent to rejection yard. In the SMS plant. the material is melt at a temperature of 1550ºC. The hot molten metal is then checked for its chemical composition. such tested material is given a Batch Number and stored in Rolling Mill Raw material. Procedure : The sized iron-ore is tested for its Fe content and coal for its ash content and is then charged to DRI plant. The tested material is then colour coded by blue paint and a Batch Number is given. III. The SAIL Billet is identified by Yellow colour code. then visual inspection and chemical analysis of the material is carried out. The finished product is properly tagged which carries the following information : I. During the production process. Any non-conforming material is identified and marked by red paint and sent to rejection yard. This material is then sent to the concaster for casting billets. Size of the product IV.T.Inspection Process Policy : The identification and traceability of all materials and products at all stages are established and maintained. Scope : The process covers identification and traceability of the product from receipt stage. Then the material is oxidized and nitrogen purged. The billets thus produced are then surface checked. Grades C1 . Each such batch weighs 25 M. Rejection. if any. The finished product is then subjected to final inspection and a Lot Number is allotted to it before being stored in the finished product yard. The pig iron is bought from SAIL or its subsidiaries. in-process inspection and final inspection till desptach. The Billets are then sent for production in the Rolling Mill. The sponge iron is then tested for its Fe content and chemical composition and is then identified and marked by a heat number. visually inspected and tested for chemical composition. The conforming material (both sponge iron and pig iron) is taken to SMS plant for charging. inspection at various stages is carried out and any non-conforming product is identified and segregated properly. The material is then tested for its chemical composition and given a heat number. II.

Sponge Iron yard In process inspection * Incoming material temperature. ** Identification mark by batch no. * Outgoing material temperature. and colour-coding. and colour-coding. Final physical and chemical analysis Cooling bed Stockyard C2 . * Section weight. *** Identification mark by batch no.Inspection Process Flowchart Check points Iron ore chemical analysis DRI plant Coal chemical analysis Sponge Iron chemical analysis * Coal yard Iron ore yard * Identification mark by Heat No. SMS plant Pig Iron chemical analysis* Hot metal chemical analysis Billet final analysis ** SAIL Billet surface+chemi cal analysis *** SAIL Billet surface+chemi cal analysis*** Pig Iron yard Billet concaster plant Billet yard Re-heating furnace SAIL billet yard SAIL conversion Billet yard Roughing Mill and Intermediate Mill In-process inspection spliting tendency check In-process inspection section wt. Finishing Mill Cooling Bed Thermex plant Straightening machine Stockyard Identification & marking by lot no. check In-process inspection spliting tendency check In-process inspection (1) Final physical and chemical analysis Identification & marking by lot no. * Equalising temp. * Water pressure. check Roughing mill and intermediate mill Finishing mill Re-heating furnace temp.

QS/QA/SI1/00) In-process inspection report (DOC. iron ore. QS/QA/S1/00) In Process Inspection 2A. Non-coking coal Size of coal Size measurement & chemical analysis Size measurement & chemical analysis Size measurement & chemical analysis As per acceptance norms As per acceptance norms As per acceptance norms IS:1350 In-process inspection report (DOC. Iron ore Size of iron ore IS: 5842 IS: 5843 2C.Stage-wise Inspection (Sponge Iron) Sl. No. Sponge Iron Chemical composition Chemical analysis As per acceptance norms IS:10812 Final inspection report (DOC. No. No. dolomite Material composition Visual inspection As per acceptance norms IS:1355.QS/QA/SD1/00) 2B. Dolomite Size of dolomite IS:1760 Final Inspection 3A. IS:1493 & IS:1760 Incoming material inspection report (DOC.QS/QA/S3/00 C3 . No. no. Types of products/ operation Characteristics checked Type of inspection/ testing Frequency of checking Acceptance norms Format of record Incoming Material Inspection 1A.QS/QA/SC1/00) In-process inspection report (DOC. Non-coking coal. No.

QS/QA/B5/00) 2B. Final sample.QS/QA/B6/00) Final inspection report (DOC. (after adding ferro-alloys) Chemical composition IS:2830 IS:2831 Final Inspection 3A. Concast Billet Chemical composition Chemical analysis As per acceptance norms As per acceptance norms As per acceptance norms As per acceptance norms IS:2830 IS:2831 Final inspection report (DOC. No. Concast Billet Surface finish & Visual inspection & dimension of measurement of finish product finish product 3B. Chemical composition Supplier test certificate review/analysis Chemical analysis IS:2830 IS:2831 2C.QS/QA/B5/00) In-process inspection report (DOC. Concast Billet Macro & sulphur Macro examination print test & sulphur print test (if required) IS:2830 IS:2831 C4 . QS/QA/B1/00 QS/QA/B2/00 QS/QA/B3/00 QS/QA/B4/00 In Process Inspection 2A. silico ferro-alloy Material composition Chemical analysis As per acceptance norms IS:13502 & IS:10812 Raw material receiving inspection Report (DOC.QS/QA/B6/00) Final inspection report (DOC.Stage-wise Inspection (M. (DOC. No. No. Pig iron & sponge iron melting scrap. Billet / CRS Billet) Sl. Types of products/ operation Characteristics checked Type of inspection/ testing Frequency of checking Acceptance norms Format of record Incoming Material Inspection 1A.QS/QA/B6/00) IS:2830 IS:2831 3C. No. No. Melting\ bath sample Ferro-alloy addition Chemical composition Chemical analysis As per acceptance norms As per acceptance norms As per acceptance norms IS:2830 IS:2831 In-process inspection report (DOC. No. no. No. No.QS/QA/B5/00) In-process inspection report (DOC.QS/QA/B6/00) Final inspection report (DOC. Concast Billet Physical test (if required) Bend test & camber IS:2830 IS:2831 3D.S.

No. indicator Pressure recording through pressure indicator At an interval of two hours At an interval of two hours 2D. 2C. indicator Temp. recording through temp. %Cr. specification no. No..Proof Stress C5 . QS/QA/04/00) Final inspection report (Doc. 3B. S. recording through temp. %S & %P 0. No. No. 2B.. Despatch report (Doc. QS/QA/03/00) martensitic rim &light ferrite pearlite core. No.QS/QA/03/00) Surface characteristics report (Doc. recorder two hours Temp.%Cu. 3F. No. At an 4 kg/cm2 to interval of 14kg/cm2 two hours Final Inspection 3A.2% P. 100% IS:2830 IS:2830 IS:2830 IS:2830 Incoming material inspection report (DOC.QS/QA/03/00) Final inspection report (Doc. of Re-Bar at the inlet point of the quenching box Temp. 3D. no.QS/QA/03/00) Final inspection report (Doc. grade. Each bundle of bar must have metal tag indicating lot no. TMT Re-Bar Do Do Do Do Do Do Surface finish Standard weight Requirements of Bond Material composition Mechanical properties Bendability & rebendability Macro structure Visual Weight per metre length by electronic balance Determination of surface characteristics *Chemical analysis %C.S. UTS. 3E.In process inspection report 900ºc (DOC No.Stage-wise Inspection (TMT & CRS TMT Re-Bar) Sl. size. batch no. 3C.. 1B. 3G. trademark. P. No. % Elongation Bend & Rebend test Macro test by etching with 1% nital solution 100% Every 2 hours One sample per lot One sample per lot Every 2 hours Every 2 hours One sample per lot IS:1786 IS:1786 IS:1786 IS:1786 IS:1786 IS:1786 Final Inspection Report (Doc. Front end & back end of Billet Reheating of Billet Thermo mechanical treatment Thermomechanical treatment Thermomechanical treatment Splitting tendency Visual inspection Sheering of front end & back end Temp 1220ºc to 1270ºc Min temp. No. of Re-Bar at the outlet point of the quenching box Water pressure Temp. Do Identification & marking Visual 100% *Note CRS TMT Re-Bar .%CRE. QS/ST/02/00) 3H. QS/QA/01/00) In Process Inspection 2A. 2E.QS/QA/02/00) Max temp980ºc Min temp480ºc Max temp520ºc Temperature of Checking of At an billet at the temperature through interval of discharge end temp. Own billet/ SAIL billet Surface defect Material composition Visual inspection Chemical analysis 100% One sample per Heat no.QS/QA/03/00) Dark Macro test report tempered (Doc. Types of products/ operation Characteristics checked Type of inspection/ testing Frequency of checking Acceptance norms Format of record Incoming Material Inspection 1A. .

Billet. Surface defect material composition Visual inspection chemical analysis 100% IS:2830/2831 Incoming inspection as per report form acceptance (DOC. GQS/QA/03/00) Dimension of finished product Material composition Physical properties Measurement of finished product Chemical analysis Physical test C6 . GQS/QA/03/00) Dimension of finished product Material composition Physical properties IS:2062 Physical test Do 3B. & slab. Round. No. bloom.GQS/QA/02/00) Final Inspection 3A. square bar & flat Surface finish section weight Visual inspection sectional weight of finished product IS: 2062 IS: 1875 IS: 1148 IS: 1730 IS: 1732 IS: 1730 IS: 1732 IS: 2062 IS: 1875 IS: 1148 IS: 2062 IS: 1875 IS: 1148 Final inspection report from (DOC.2062 As per IS:2002/1852 acceptance /808 norm As per acceptance norm As per acceptance norm As per acceptance norm 100% As per acceptance norm As per acceptance norm As per acceptance norm As per acceptance norm Do Final inspection report (from DOC no. Types of products/ operation Characteristics checked Type of inspection/ testing Frequency of checking Acceptance norms Format of record Incoming Material Inspection 1.Stage-wise Inspection (Structural Steel) Sl. no. QS/QA/01/00) norm In Process Inspection 2. Front end & back end Splitting tendency Visual inspection 100% Cut the front In process inspection report & back end (DOC. Angle. channel & joist Surface finish section weight Visual inspection sectional weight of finished product Measurement of finished product Chemical analysis 100% IS. no. No.

QS/QA/S1/00 Date of inspection Quantity received Visual inspection Tested by Lot No. (s) Qty.no.Inspection Doc. QS/QA/SC1/00 Issued for production on Heat no.Incoming Material .no.no.Sponge Iron Date of testing Heat No (lorry no) C7 . QS/QA/B1/00 Quantity received %C Chemical Analysis %S %P %Fe Tested by Issued for production on Batch no. issued Chemical Analysis .no. issued Chemical Analysis .) Type of material In Process Inspection Doc. QS/QA/SD1/00 Issued For production on Heat no.I. QS/QA/S11/00 Chemical Analysis (%) Fe SiO2 Al2O3 S P Alkalies Moisture Size Issued for production on Heat no. Date of testing Lot no.Iron Ore Date of testing Lot no.Dolomite Chemical Analysis %Mgo %Cao %Sio2 %P %Alkalies %L.O. Chemical Analysis . (s) Qty.Non-Coking Coal Chemical Analysis (%) Ash Volatile matter Fix. Date of testing Lot no.no. carbon S Moisture Size Doc. Size Doc. QS/QA/S3/00. issued Final Inspection Doc. (s) Qty. (lorry no. Chemical Analysis .

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