QUALITY CONTROL IN VESSEL LID

MANUFACTURING

The project report submitted in partial fulfilment for the J Component of

STATISTICAL QUALITY CONTROL
(MEE1034)
by
NAME(S): Roll Number(s):
A.S.Vighnesh 18BPI0012
Kiruba Shanker 18BPI0015
Athithan 18BPI0029
Anirudh 18BPI0037
V.Om karthik 18BPI0060

Faculty In-charge
Dr.SUDHAKARA PANDIAN R
School of Mechanical Engineering
Vellore Institute of Technology

Fall semester 2019-20

NOVEMBER 2019
Table of Contents

Title
Bonafide Certificate
Acknowledgement
Abstract

Ch.No Ch.Title
1. Introduction
2. Scope of the project
3. Statement of the problem
4. Literature review
5. Objectives of the problem
6. Data analysis and interpretation using SQC tools

6.1. Histogram
6.2. Pareto chart and bar chart
6.3. Flow chart for the process
6.4. OC Curve
6.5. Gantt chart
6.6. Ishiwaka diagram for the process
7. Pareto chart and Ishiwaka diagram on
Customer satisfaction
8. Final Outcome
9. Gantt Chart
10. References
 BONAFIDE CERTIFICATE

Certified that the project report “QUALITY CONTROL IN VESSEL

LID MANUFACTURING” is the bonafide work of “A.S.Vighnesh,
Kiruba Shanker, Athithan, Anirudh, V.Om Karthik” who carried the
work under my supervision.

Signature
 ACKNOWLEDGEMENT
We would like to express our special thanks of gratitude to our professor
Sudhakara Pandian R ,who gave us the golden opportunity to do this wonderful
project of Quality Control on ‘VESSEL LID MANUFACTURING’, Who also
help us in completing our project. we came to know about so many new things
we are really grateful for the opportunity. Secondly we would like to thank
SELVAJAYAM INDUSTRIES who provided us the data required for this project
and for their support.
Abstract :
The project is mainly designed to consider the various factors
such as quality and product inspection to decide the quality of
the vessel. In order to do so, we analyze the data presented by
the testing methods and evaluate the quality of the vessel.
This quality assurance is useful for improving the product and
make sure that the product is manufactured as per norms.
The methods used are Descriptive statistics and Statistical
process control (SPC). Hence, we end up successfully
comparing various metal products to improve the quality of
the products.
Introduction:
Statistical Quality Control is a process to maintain and control
the quality of the products and services. Manufacturing of the
vessel lids needs a series of inspection in its quality of its
material, dimensions, design and its capability against the
temperature and pressure. The vessel head(lid) shape is of
different types such as Ellipsoidal head, Hemispherical head
and Torispherical head. Checking the quality of the head’s
design in terms of its dimension is important for preventing
leakages of pressure, temperature and fluid or gas leak.
Ellipsoidal head
This is also called a 2:1 elliptical head. The shape of this head
is more economical, because the height of the head is just a
quarter of the diameter. Its radius varies between the major
and minor axis.

Hemispherical head
A sphere is the ideal shape for a head, because the pressure in
the vessel is divided equally across the surface of the head.
The radius (R) of the head equals the radius of the cylindrical
part of the vessel.

Torispherical head
These heads have a dish with a fixed radius (CR), the size of
which depends on the type of torispherical head. The
transition between the cylinder and the dish is called the
knuckle. The knuckle has a toroidal shape. Types of
Torispherical Heads are.

• Klopper head
This is a torispherical head. The dish has a radius that
equals the diameter of the cylinder it is attached to. The
knuckle has a radius that equals a tenth of the diameter of
the cylinder.
• Korbbogen head
This is a torispherical head also named Semi ellipsoidal
head. The radius of the dish is 80% of the diameter of the
cylinder . The radius of the knuckle is (KR = 0.154 x
D0).

Image source: http://www.wermac.org

SCOPE OF THE PROJECT:
• This project is based upon quality control of the dish
ends manufacturing for the industrial and chemical uses
and it assures the strength of the material used as raw
material.
• We analyse the data in two parts first we go through
industrial prescribed testing methods to analyse the
percent of products that fail to pass inspection at factory
level
• Next we collect data from customers using a survey and
try to identify the percentage of products that fail to pass
customers satisfaction levels, and try to find ways to
improve it.
STATEMENT OF THE PROBLEM:
To increase customer satisfaction with the product and
reducing the overall product failure during product factory
inspection.

LITERATURE REVIEW:
The project deals with various problems faced during
manufacturing of metal container lids which need to be of
different materials and specifications based on the order .
Alhozaimy and Al-Negheimish (1999) pioneered the concept
of managing quality scheme for RMC. They focused upon the
aspects of Economy and Quality Assurance by the technique
of Total Quality Management (TQM) and quantified the
benefits of improving the quality of concrete. Tangible
benefits were achieved in all aspects of RMC production and
quality. Sullivan (2011) focused on competitiveness by
increasing performance in the construction industry. He
analyzes three popular programs (total quality management
(TQM), lean production, and six sigma), for the suitability of
implication in construction. Beary & Abdelhamid (2005)
successfully applied the Lean production and Six Sigma
principles for the residential projects using the DMAIC
process. They introduced a production planning model that
reduces variations and defects (muda and mura), and creates a
reliable production planning system. Yatin Damor1, Hemant
R Thakkar2 (dec, 2014 ) wrote a paper improving quality and
productivity in a foundry using lean six sigma techniques
these methods to reduce defects in material and creating a new
process to increase productivity and reducing the percentage
of products with defects and flaws, taking into account the
research paper written by G.Arvinddinesh, A.Prabukarthi,
M.Perumalswamy on the “Productivity improvement in a
pressure vessel using lean principles “ published by
International Research Journal of Engineering and
Technology (IRJET) volume 5 issue 3 in march 2018 , this
research paper is about dealing with the problems faced
during manufacturing considering various methods both
customer enquiry and direct data collection during the
process and using statistical quality control tools to solve
them.

OBJECTIVES OF THE PROBLEM:

To increasing final productivity of the process and increasing
customer satisfaction
 DATA ANALYSIS AND INTERPRETATION USING SQC
TOOL:
SI Company ID/OD CR KR SF Thickness OCF Height material BW
no: name:
(mm) (mm) (mm) (mm) (mm) (cm)

1 SAGHAI ID1400 1400 140 50 8 4450 322 MS 1650

ENGG

2 SAGHAI CD910 898 90 40 6 2860 215 SS 1075

ENGG

3 SAGHAI CD600 FA400 100 15 8 1885 115 MS 734

ENGG

4 SAGHAI CD600 FA400 100 15 8 1885 115 MS 734

ENGG

5 SUMITS 0D700 684 70 35 8 2200 160 MS 830

ENGG

6 MULTI OD400 394 40 30 3 1257 107 SS 500

MECH

7 VRK ENGG OD800 792 80 40 4 2514 194 SS 950

8 PRASANNA OD254 810 4 798 127 MS 360

9 JAYA ENGG OD2400 2880 120 40 5 7543 358 SS 2655

10 JAYA ENGG 0D550 542 50 15 4 1728 118 SS 625

11 ROYAL ID450 520 150 30 6 1452 160 MS 600

RING
TRICHY

12 ACCUSTICS OD577 505 95 25 8 1813 165 MS 710

INDIA

13 ISSAC OD762 671 127 50 8 2395 237 MS 970

ENGG

14 ISSAC OD610 531 100 50 10 1917 197 MS 795

ENGG

15 AKSHARYA OD1000 1300 60 30 6 3143 170 SS 1140

ENGG

16 PLIPSOL OD722 716 60 25 3 2269 162 MS 820

17 PLIPSOL OD740 720 60 25 4 2274 150 MS 850

18 WHALE OD1675 1524 152.4 25 6 5262 338 MS 1890

ENGG

19 WHALE OD1665 1524 152.4 25 6 5233 335 MS 1880

ENGG

20 WHALE OD1675 1524 152.4 25 6 5262 255 MS 1740

ENGG
 • Histogram:

Check sheet:
Check sheet for factory inspection data
No complaints No of Complaints
1 ovality 19
2 punch and pressing mark 17
3 knuckle radius(crack) 14
4 straight face(crack) 7
5 twisting 4
6 minimum thickness 4
7 welding 2
• Pareto chart:

BAR CHART

20

18

16

14

12

10

0
OVALITY PUNCH AND KNUCKLE STRAIGHT TWISTING MINIMUM WELDING
PRESSING MARK RADIUS(CRACK) FACE(CRACK) THICKNESS

1 2 3 4 5 6 7
• Flow chart of the process:

START

KR- Knuckle Radius

CR-Circumference Radius

SF: Straight Face

OCF: Outer
Circumference

Forming Of circumstance
radius

Dyeing process of knuckle radius

To form Straight face and maintain

Outer circumference radius

To maintain height and process

pressing and dyeing

To correct twisting and overlap

 After completing YES
all the above
process ,ifNO
any
defect occurs

No

Polish the shape of the lid to get correct

dimensions

STOP

• OC Curve:
Lot size, N= 7000
n= 400
Acceptance criteria, c 2

PO 100PO Sample size,n nPO Pa 100Pa

0 0 140 0 1 100
0.01 1 140 1.4 0.8335 83.34977381
0.02 2 140 2.8 0.46945 46.94536835
0.03 3 140 4.2 0.21024 21.0237987
0.04 4 140 5.6 0.08239 8.23884036
0.05 5 140 7 0.02964 2.963616388
0.06 6 140 8.4 0.01005 1.004707204
0.07 7 140 9.8 0.00326 0.326166308
0.08 8 140 11.2 0.00102 0.102447077
0.09 9 140 12.6 0.00031 0.031352998
0.1 10 140 14 9.4E-05 0.009396275
 OC CURVE
110

100

90

80

70

60
100 Pa

50

40

30

20

10

0
0 2 4 6 8 10 12
100 PO
 • Gantt chart for the process:

Project Name Task Duration Project Start time Project End time

MANUFACTURING OF VESSELS 09:00 08:00 17:00

08:00 09:00 10:00 11:00 12:00 13:00 14:00 15:00 16:00 17:00 18:00 19:00 20:00

X X X

X X X

X X

X X X

X X

X X

Task Task Description Task Duration Start Time End Time

Task 1 Forming for Circumference radius 02:00 08:00 10:00
Task 2 Dieing process for Knuckel radius 02:00 10:00 12:00
Task 3 Forming Straight face 01:00 12:00 13:00
Task 4 Maintain height and remove pressing and dieing02:00
mark 13:00 15:00
Task 5 Twisting and ovel 01:00 15:00 16:00
Task 6 polishing 01:00 16:00 17:00
• Ishikawa diagram :
PARETO CHART AND ISHIWAKA DIAGRAM ON
CUSTOMER SATISFACTION:
Check sheet:
Check sheet for data obtained through customer survey and
suggestions and complaints box filled by customers

• Pareto chart:
• Ishikawa diagram :
FINAL OUTCOME:
By following new methods, we hope to cut down the 11%
product failure percentage during factory inspection to 5~6 %
and there by reduces the 9% of customer dissatisfaction.

GANTT CHART:
Kiruba shanker
Athithan:
Anirudh
Om karthik
Vighnesh
References:
• D. C. MONTGOMERY, Introduction to Statistical Quality Control, 6th
ed., John Wiley & Sons, 2009 ISBN 978-81-265-2506-5
• Ryan, T. P. (2011). Statistical Methods for Quality Improvement. 3rd ed.
New York: Wiley ISBN: 978-0-470-59074-4
• A. M. Alhozaimy and A. I. Al- Negheimish., “INTRODUCING AND
MANAGING QUALITY SCHEME”
• Douglas M. Hawkins & Qifan Wu (2014) The CUSUM and the EWMA
Head-toHead, Quality Engineering, 26:2, 215-222
• D. Sarkar and G. Dutta, “Design and Application of Risk Adjusted
Cumulative Sum for Strength
• Reynolds, M. R., Jr., Stoumbos, Z. G. (2006). Comparisons of some
exponentially weighted moving average control charts for monitoring the
process mean and variance. Technometrics, 48(4): 550–567.
• Stoumbos, Z. G., Reynolds, M. R., Jr., Ryan, T. P., Woodall, W. H.
(2000). The state of statistical process control as we proceed into the 21st
century. Journal of the American Statistical Association, 95(451):992-
998.
• Lucas, J. M., Saccucci, M. S. (1990). Exponentially weighted moving
average control schemes: Properties and enhancements.
• Hawkins, D. M., Zamba, K. D. (2003). On small shifts in quality control.
Quality Engineering, 16:143–149.
• Woodall, W. H., Mahmoud, M. A. (2005). The inertial properties of
quality control charts. Technometrics, 47(4):425–436.