James D.

Jabiniao
MITO 102

Background and Rationale

Company A an ISO 9001:2015 certified started operation on April 18, 1977. Much earlier
however, Company A mother Company B has been engaged in the Philippines through the iron
ore export and pellet production projects in the 1950s.

This long history of cooperation for over half a century has established a firm and reliable
relationship between mother Company B and the Philippines from an economic and social
contribution point of view.

Company A produces sintered ore for charging into the blast furnace. In the steel industry
works, there are 3 stages of manufacturing namely, Ironmaking, Steelmaking, and Rolling
processes respectively. Company B has to employ excellent technology in all of these processes
to produce high-quality steel products. However, high-quality steel products also demand high-
quality raw materials in the same manner that a delicious cuisine is produced from well treated
and high-quality ingredients.

Company A has a high responsibility to produce sintered ore with excellent quality and in
the required quantity. In coping with the recent high steel demand in the world, Company A
guarantees a stable supply to customers based on strong competitiveness.

The ISO 9000 family of quality management systems (QMS) is a set of standards that

helps organizations ensure they meet customer and other stakeholder needs within statutory and
regulatory requirements related to a product or service. ISO 9000 deals with the fundamentals of
QMS, including the seven quality management principles that underlie the family of standards.
ISO 9001 deals with the requirements that organizations wishing to meet the standard must
fulfill.[1]

Over a million companies benefit from a quality management system certified according
to ISO 9001, enjoying peak process performance and an international competitive advantage.
ISO 9001 certification ensures that quality orientation is lived by each of your employees every
day. [2]

An organization applying for ISO 9001 certification is audited based on an extensive

sample of its sites, functions, products, services, and processes. The auditor presents a list of
problems (defined as "nonconformities", "observations", or "opportunities for improvement") to
management. If there are no major nonconformities, the certification body issues a certificate.
Where major nonconformities are identified, the organization presents an improvement plan to
the certification body (e.g., corrective action reports showing how the problems will be
resolved); once the certification body is satisfied that the organization has carried out sufficient
corrective action, it issues a certificate. The certificate is limited by a certain scope (e.g.,
production of golf balls) and displays the addresses to which the certificate refers. [1]
 An ISO 9001 certificate is not a once-and-for-all award but must be renewed, in
accordance with ISO 17021, at regular intervals recommended by the certification body, usually
once every three years.[38] There are no grades of competence within ISO 9001: either a
company is certified (meaning that it is committed to the method and model of quality
management described in the standard) or it is not. In this respect, ISO 9001 certification
contrasts with measurement-based quality systems. [1]

Company A has A Plant C inside its premises that produces Burnt lime for use in
Sintering Process. Burnt lime is frequently added in sintering mix because it has a strong positive
effect on sinter productivity when it promotes micro pelletizing in mixing drum, keeps the gas
permeability good during the sintering process, and improves sinter strength.

The production of burnt lime involves calcination, or the decomposition of calcium

carbonate in limestone by heating. Calcination is carried out in a kiln heated to high
temperatures.

Figure 1: Quick Lime process

Plant C has standard for Size fraction of quicklime to be used in sintering process. This is
done thru a crushing equipment. In The Past 11 months Plant C has not been able to attain the
standard set which is Less than 1mm. although no study on the effect of not attaining the size
fraction in sintering process.

Figure 1: Quick Lime process showing source of problem

 These Non-Attainment has been called out in the last audit conducted by SGS. Company
A and Plant C has already committed to resolve this issue.

It is of Utmost importance that this issue be resolved prior to ISO Audit. Failure to do so
may result in the issuance on MNC or Major NonConformance. A major nonconformance is
classified when there is an absence or a complete breakdown in your QMS, preventing you from
meeting the ISO 9001 requirements. Examples would include a failure to take corrective or
preventative action, not implementing a part of the standard, or not implementing a procedure.
[3]

In Worst Case scenario Company A May Fail its ISO Accreditation. The immediate
consequences of a failed ISO audit are related to the cost of addressing areas of non-compliance.
Most business that attempts ISO certification continue to do so after an audit failure, so the
impact of failure depends on the action required to address non-conformances.

This Study aims to find the possible causes on why the non-attainment of target occurred
and stabilize the output of the crushing equipment.

Statement of the Problem

Quick lime Physical quality target was not attained for the past eleven months despite
implementing existing countermeasures.

Objectives of the Study

1. To Conduct Data Gathering and Analysis of Operational Parameters and Chemical

Quality to check relationship to product quality output.
2. To Conduct Crushing Equipment efficiency check and inspection of components.
3. To conduct POT TEST to determine the effect of low physical quality Quicklime to
Quicklime fineness.
4. To conduct review and revision of QMS if necessary.

Significance of the Study

This study aims to show that Company A and Plant C is strictly adhering to Company
QMS. This is by showing that Company and Plant C are working to find solutions to current
problem faced. The Researcher hopes that in the next audit he can present this study and help in
explaining why the non-attainment occurred. Also, the researcher hopes to uplift the morale of
all the Personnel involved in Plant C Operation.

Scope and Limitation

This Study covers only the Operation of Plant C and Its Physical quality output. This
Only focuses on the output of crushing Operation. The data which this research is based is from
the past eleven months only any results prior to the period mentioned is not included in this
research.

Methodology

Operational Data Can be extracted thru DCS and Chemical Quality can be gathered thru a
written request to Laboratory department. See Steps and Sources Below:

Figure 3: Steps in Data gathering

Equipment Inspection and Checking can be conducted simultaneously with Maintenance

Personnel. Below are the items or parts of the equipment to be checked.

1. Ring Chute length

2. Inner and Outer Cage clearance
3. Motor Speed
4. Drive and Driven Pulley size
Ring Chute

References

1. https://en.wikipedia.org/wiki/ISO_9000
2. https://www.tuv.com/philippines/en/iso-9001-certification.html?
wt_mc=SEA.Ads.Google.PH22_S01_CAP.PH22_S01_CAP_GA.textad.ISO9001ExactM
atch&cpid=PH22_S01_CAP_GA
3. https://www.standardfusion.com/blog/the-cost-of-a-failed-iso-audit/