Quality Control Of Steel Round Pipe

Abstract
International technical Company is a leading steel producer in Jordan by producing 2
types of quality steel products, namely Round pipe and Galvanized pipe. The market
demand for steel products, especially those with a diameter of 20 mm, about 60% of the
total production.

This study aims to analyze the level of defects that occur in the production of steel Round
pipe in International technical Company , how to apply statistical process control, and
how to improve the causes of product defects.

The research method used is statistical process control, check sheets, , Pareto charts,
control chart ( X-R chart and p chart), cause and effect diagrams.

The results of this study indicate that steel Round pipe has three types of defects, namely
caliper , Slag Inclusion , and Incomplete Fusion. The highest defect occurred in 392 units
of caliper, the second defect was Slag Inclusion with 165 units and the last defect was
Incomplete Fusion of 76 units of the total production in October 2022 of 9964 units.
Sec 1: Introduction
1.1 Background
In the process of creating a quality product according to the standards and tastes of
the consumer, unwanted deviations are often made by the company which leads to
defects of products which will surely be very harmful to the company. To overcome
this, one of the measures that can be taken is to implement a quality control
system in order to reduce product defects to zero defect level.

One of the activities in creating quality to meet standards is to implement an

appropriate quality control system, with clear objectives and stages, and to provide
innovation in preventing and solving problems faced by the company. Quality
control activities can Helping companies maintain and improve the quality of their
products by controlling the level of product damage (product defect) to zero defect
level.

1.2 Our Company

international technical Metal Industries company ITC was founded in Jordan in 2010
for the manufacture of steel products within the specifications of global and local
scales, one mouse Group of Companies.

And taken location for manufacturing in the Almuwaqar, the largest Jordanian
industrial cities, the company has occupied what is the rate of 5% of the area of the
city, through the creation of super-sized manufacturers are strips and pipes factory.
1.3 Problem Statement
Many companies have implemented certain business strategies but are still unable
to achieve optimum results. One of the causes of this is the quality of the products
needed. If the issue remains left, it does not rule out the possibility that the
company will experience a decline in sales which has an impact on the decline in
profitability so that if left unchecked it will paralyze the business of the company.
Therefore, the company must pay attention to the quality of the product it
produces in order to get a competitive advantage in competing.

1.4 Data Collection Methods

The data collection method used in research by visiting factory and Conducting
interviews with specialists and observing directly of production line that are that
object of research.

1.5 Critical To Quality

Durability

Diversity

Price
Sec 2: Methodology
Visit Factory Identification of problems Start

Data collection
Observation
- production Volume

Interview - The number of defective products

- 25 Sample of Round pipe (Diameter)

End Conclusions Data Analysis

Sec 3: Data Collection

Day # of Sample X1 X2 X3 X4 X5
1 1 20.05 20.01 20.05 20.01 20.05
2 20.03 19.92 20.03 20.06 20.01
3 19.97 19.93 19.97 20.02 19.97
4 20.01 20.01 20.05 20.01 20.04
5 19.92 19.91 19.89 19.93 19.91
2 6 19.93 19.88 19.92 19.90 19.93
7 20.01 20.04 20.05 20.01 19.98
8 20.06 20.02 20.03 20.06 20.05
9 20.02 20.01 19.97 20.02 19.99
10 20.00 19.92 20.01 20.01 20.01
3 11 20.04 19.93 19.92 20.06 19.92
12 20.02 20.01 19.99 20.02 19.93
13 20.01 20.06 20.01 20.01 20.01
14 19.99 20.01 20.06 20.06 20.06
15 20.02 20.00 20.01 20.02 20.01
4 16 20.03 20.02 19.97 20.00 20.02
17 20.04 19.98 19.96 20.03 20.00
18 20.05 20.01 19.93 20.04 19.99
19 20.03 20.06 20.01 20.00 19.99
20 19.97 20.02 20.06 20.01 20.05
5 21 20.09 20.08 20.11 20.10 20.09
22 20.01 20.04 19.99 20.02 20.03
23 20.00 20.02 20.00 19.99 20.03
24 19.99 20.01 19.97 19.98 20.01
25 19.98 19.96 20.00 20.01 20.05
Table 1: sample of Round pipe (Diameter 20mm)

Day Production Number Of Defect (Unit)

(Unit)
1 458 39
2 476 28
3 503 33
4 398 18
5 425 22
6 498 37
7 345 16
8 398 24
9 287 10
10 511 19
11 288 6
12 502 38
13 426 29
14 325 18
15 482 42
16 518 51
17 485 48
18 304 18
19 298 9
20 347 17
21 256 24
22 348 17
23 325 25
24 329 17
25 432 28
Total 9964 633
Table 2: Production Volume and Number of Defect For Round Pipe (Diameter 20mm)
Sec 4: Data Analysis
4.1 Check For Normality
We will check the normality of the data in the Following Figures and find that it is normal.

Fig 1 : Normality test for Variabels data (Table 1)

Fig 2 : Normality test for Attribute data (Table 2)

4.2 Check Sheet
Day Production Types Of Defect Number Sample
(Unit) caliper Slag Incomplete Of Defect Fraction
(Unit) Inclusion Fusion (Unit) Nonconforming
(Unit) (Unit) (%)
1 458 18 12 9 39 8.51
2 476 23 4 1 28 5.88
3 503 19 7 7 33 6.56
4 398 9 3 6 18 4.52
5 425 14 6 2 22 5.17
6 498 22 14 1 37 7.42
7 345 9 2 5 16 4.63
8 398 13 9 2 24 6.03
9 287 8 1 1 10 3.48
10 511 10 6 3 19 3.71
11 288 5 1 0 6 2.08
12 502 21 14 3 38 7.56
13 426 20 7 2 29 6.80
14 325 11 6 1 18 5.53
15 482 29 10 3 42 8.71
16 518 34 16 1 51 9.84
17 485 29 12 7 48 9.89
18 304 7 6 5 18 5.92
19 298 7 2 0 9 3.02
20 347 12 2 3 17 4.89
21 256 18 5 1 24 9.37
22 348 8 2 7 17 4.88
23 325 15 5 5 25 7.69
24 329 14 3 0 17 5.16
25 432 17 10 1 28 6.48
Total 9964 392 165 76 633 6.35
Table 3: Type of Defect For A Round Pipe (Diameter 20mm)

According to the table 3 , It can be seen that the lowest percentage of defect is 2.08%
while the highest Defect is 9.89%. While the average defect is 6.35% which is above the
company's vision of 3%.
4.3 Control Chart
X-bar and R charts are used to monitor the mean and range of a process based on
samples taken from the process at given times (hours, shifts, days, weeks, months, etc.).
The measurements of the samples at a given time constitute a subgroup. Typically, an
initial series of subgroups is used to estimate the mean and range of a process. The mean
and range are then used to produce control limits for the mean and range of each
subgroup.

Since we are pulling a fixed sample size and we have a small sample size of 5, and variable
data, we can use the X Bar- R chart shown in Figure below.

Fig 3: Xbar-R chart for Pipe 20 mm

In the previous figure , We find that two points exit below the LCL in the X bar chart , and
it is likely that because the sample was taken at the beginning of the day where the
machine is at the beginning of its work, and we removed to consider it a Warm Up
Period, so we pet the chart shown in the following Figure .
 Fig 4: Xbar-R chart for Pipe 20 mm

We stayed in phase 1, and after removing the points which are the beginnings of the
days, we got one point out of control above UCL . It is likely that the reason is the
temperature of heating roll is not up to the requirement. we will remove points out of
control from the chart after find out the root cause of the defect as in the following
Figure.

Fig 5: Xbar-R chart for Pipe 20 mm

* Comment:

• Any out-of-control points should be examined for assignable causes

• If assignable causes are found, discard points from calculations and revise the trial
control limits.

• Continue examination until all points plot in control.

• Adopt resulting trial control limits for use.

• According to the western electric Rules, we find that points 5, 6 respectively , it is Out of
control (out of 3 sigma limits).

• According to the third sensitizing Rules, we find that points 21 to 24 respectively , it is

Out of control (out of 1 sigma limits).
* Application P chart for major defect :

Fig 6: P chart for Major Defect

Analysts of the data from samples 16 and 17 indicate problem in :

1- machine (Temperature ) 2-material

this results irregular production Consequently, samples 16 and 17 are eliminated, And
After taking a procedure to improve the process , Now we will take 25 samples, the size
of each sample is 50 (table 4) and we will use the NP chart because the sample size is
constant.

# of sample Sample size Number of # of sample Sample size Number of

Defect Defect
1 50 1 14 50 2
2 50 2 15 50 2
3 50 0 16 50 0
4 50 3 17 50 1
5 50 4 18 50 0
6 50 1 19 50 4
7 50 1 20 50 2
8 50 0 21 50 3
9 50 5 22 50 5
10 50 3 23 50 1
11 50 4 24 50 2
12 50 1 25 50 0
13 50 1 total 1250 48
Table 4
 Fig 7: NP chart for Major Defect

4.4 Pareto Chart

Pareto analysis is a factual strategy in basic leadership utilized for the determination of a
set number of errands that create noteworthy general impact.

It utilizes the Pareto Rule (otherwise called the 80/20 lead) the possibility that by
completing 20% of the work you can produce 80% of the advantage of doing the whole
employment.

Fig 7
The collected data was generated in the form of a Pareto chart, which is illustrated in
Figure 7. In particular, the caliper and Slag Inclusion . this two type of defect contributed
to over 88 percent of the overall number of defects. Therefore, the improvement team
and organization decided to focus on the reduction of this defects.

4.5 Cause and Effect diagram

Fig 8

There are main causes of caliper and Slag Inclusion defects , which are caused by human
factors , raw materials, machines. The following is an explanation of each of the factors
that contribute to the defect.

a. Man: Human factors related to labor such as lack of skills, physical fatigue and accuracy
in the manufacturing process.

b. raw materials: materials have an important role because good production are
influenced by good raw materials as well.

c. Machine : Machine factors that affect defective products are problems in the

operation/use of tools/machines such as corrosion of the Rolls .

4.6 Process Capability
Process Capability For Attribute Data Process Capability For Variabels
total number of defects
DPU= total number of units
μ = X = 20.0073, USL =20.05 ,
LSL =19.95
633 σ = R / d2 = 0.0676/2.326 --- (d2 from
DPU= 9964 Table , n=5)

DPU=0.0635 σ = 0.029
Cp = (USL – LSL) / 6S
DPMO = Cp = (20.05 – 19.95) / 6*(0.029)
total number ofr defects = 0.534
total number of units∗number of opportunities Cpk = Min [ ( USL – μ)/3S , (μ-
LSL)/3S ]
633 Cpk=
DPMO = 9964
∗1000000
Min[(20.05-20.0048)/3*0.029 , (20.0048-
19.95)/3*0.029]
DPMO = 63529 Cpk = Min[ 0.459 , 0.609 ] = 0.459
4.7 Log Book
Date Time Types Of Defect Number Of
caliper Slag Incomplet Defect
(unit) Inclusion e Fusion (Unit)
(unit) (unit)
1/11/2022 8 AM 2 3 0 5
2/11/2022 12 PM 1 1 4 6
3/11/2022 2 PM 0 5 1 6
4/11/2022 12 PM 4 2 2 8
5/11/2022 5 PM 3 0 0 3
6/11/2022 1 PM 2 3 3 8
7/11/2022 9 AM 5 5 2 12
8/11/2022 3 PM 4 1 0 5
9/11/2022 2 PM 1 5 1 7
10/11/2022 8 AM 1 2 0 3
11/11/2022 12 PM 2 1 4 7
12/11/2022 4 PM 3 0 1 4

Sec 5: Conclusion
A good quality control system is a necessary component in the production of good Round
steel pipe , Quality means money. Therefore, a factory must be able to produce an
acceptable quality level as agreed between the manufacturer and the customer. quality
control system makes sure the end product meets the quality requirements by using good
raw materials, improving the qualification of workers, who perform the production
process, and the selection of the appropriate production measuring method also the
maintenance of machinery and equipment.

Based on the results of data processing and analysis of the data obtained, it can be
concluded the following:

1. The type of caliper defect is a major defect in the production process of Round steel
pipe .

2. There are three main factors that cause defects in the production process of
International technical Co. , namely materials, humans (employees), and machines.
While the additional factor causing disability is the work method.
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