Statistical Analysis Ferrous Metallurgy

& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

For Responsible Consumption and Production

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 … Sustainable Statistical

Process Control
Green – Lean - Clean
SSPC
Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 1
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 2
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

‫اﻟﻧظﺎم اﻟﻣﻔﺗوح‬
Input
‫رﺗﺑﮫ ﻣﺧﺗﻠﻔﺔ ﻟﻠﺻﻠب ﻣن ﺣﯾث اﻟﺧواص‬ Output
... ‫اﻟﻛﯾﻣﯾﺎﺋﯾﺔ و اﻟﻔﯾزﯾﺎﺋﯾﺔ و اﻟﻣﯾﻛﺎﻧﯾﻛﯾﺔ‬
... ‫ﺗﺑﮫ ﻟﮭﺎ ﺧواص ﻣﺣدده‬Process
‫وﻛل ر‬
‫ﻟﻼﺳﺗﺧدام ﻓﻲ ﻣﺟﺎل ﻣﺣدﻣددﺧﻼت‬ ‫ﻣﺧرﺟﺎت‬
Open system
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 3
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Material

Machine Milieu

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ Men Inputs Technology

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 4
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Products

Waste Outputs Emission

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Losses

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 5
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Statistical Process Cotrol ‫اﻟﻧظﺎم اﻟﻣﻐﻠق‬

SPC
Output
Process

Closed Sustainable Process Feedback

Reports
Indoor Control Outdoor Control
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬ Time / Material Quality / Cost
… Vision 2050 …

(Social Cost)
Green – Lean - Clean
Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 6
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Sustainable
Production Process
Model

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 7
Eng. Dr. Hesham Saad
 Sustainable production / manufacturing Process

emission
… Vision 2050 …

Zero
Atmosphere

emission Green – Lean - Clean

treatment facility ‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬

recovery
recovery
Material

Heat
emission
reuse

Recoverd Material
Waste Material
Operation Waste material treatment facility Zero waste
Natural Material
Production facility
Waste Water
Waste Water treatment facility
Zero discharge
Recycled Material
reduce
recycle

Product Reuse Recover Lithosphere

Scrapping
Scrap
treatment facility
Hydrosphere
Reduce Recycle
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Time
(TC)

Cost Material
(CC) (MC)
Control

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …
Quality Env
(QC) (EC)
Green – Lean - Clean
Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 9
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

UTF Yield
OSPE Availability performance Quality Eco efficiency

= x x x

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

Overall sustainable Process Eco-Effectiveness, OSPE
… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 10
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Downtime Pareto Chart

100.0%
UTF
Availability
600 88.9% 90.0%
86.3%
83.6%
80.4% 80.0%
500
73.0%
70.0%
65.7%
400 60.0%

Duration ratio
52.3% 50.0%
300
38.9% 40.0%
19.7%
200 30.0%
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
131 127
20.0%
89 89
… Vision 2050 … 100 74
49 49 10.0%
21 18 17
0 0.0%
10 5 20 15 25 30 45 35 40 Other
Green – Lean - Clean Duration min

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 11
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Yield
moving average_ T/month performance
20000.000

15000.000 UCL
11034.645
Ton / month

10000.000

5000.000

0.000

LCL
-5000.000
‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬
-10000.000
… Vision 2050 …

eb 2
ov 1

-N 022
-D 021

2
-M 022
1
ug 1

ug 2
-Ju 21

-Ju 2
1

-M 022

2
ep 1

ep 2
pr 2

2
20

2
2

02
31 -202
2

2
31 202
31 -202

31 -202
2

2
30 -202

30 -202
30 202

28 -2 0
30 -2 0
31 l-20

31 l-20
0

30 -20

30 -20
20

-2
-2
2

2
n-

n-
-

ct-
-

ay
ar

ov
ct

n
ec
-Ja
-Ju

-Ju
-O

-O
-A
-N
-A

-A
-S

-F

-S
31

31

30
31

31
Month
Green – Lean - Clean
Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 12
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Quality

Stastical Process control , SPC

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 13
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

Eco efficiency

Sustainable , Stastical Process control , S_SPC

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 14
Eng. Dr. Hesham Saad
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 15
Eng. Dr. Hesham Saad
 SPC

Environment Regulations and laws , Limits Upper Control Limit , UCL

Measurement
clarify Technology efficiency
Process average

3 Zeros, (Zero waste , Zero emission & Zero discharge)

Goals upper Limits, GUL Time Lower Control Limit , LCL

Out of control
… range …
 S_SPC

Environment Regulations and laws , Limits Upper Control Limit , UCL

Measurement
clarify Technology efficiency
Process average

3 Zeros, (Zero waste , Zero emission & Zero discharge) Lower Control Limit , LCL
Goals upper Limits, GUL
Time

Three Out of control

One Two
sigma … range …
sigma sigma
 Statistical Analysis Ferrous Metallurgy
& Postgraduate
Data representation Dr. Mahmoud Sabry Diploma

‫اﻟﻲ ﻋﺎﻟم اﺧﺿر ﻣﺳﺗدام‬

… Vision 2050 …

Green – Lean - Clean

Master's student
‫ اﻟﻲ ﺗﺻﻧﯾﻊ أﺧﺿراء ﻣﺳﺗدام‬... ‫واﻟﺗﺣول‬ 19
Eng. Dr. Hesham Saad