3. Inspection During Production

ProjectUTKARSH Business Blue Print Document

BSPL_BBP_QM0003_1.0Inspection During Production

Module Quality ManagementProcess Inspection During ProductionSub Process / No N/A Process Ref BSPL_AS-IS_QM0001_1.0

BSPL_AS-IS_QM0002_1.0BSPL_AS-IS_QM0003_1.0BSPL_AS-IS_QM0004_1.0BSPL_AS-IS_QM0005_1.0BSPL_AS-IS_QM0006_1.0BSPL_AS-IS_QM0007_1.0BSPL_AS-IS_QM0008_1.0BSPL_AS-IS_QM0009_1.0BSPL_AS-IS_QM0010_1.0BSPL_AS-IS_QM0011_1.0BSPL_AS-IS_QM0016_1.0

Description Inspection During Production

Document Change Control

Release Description By Date

BSP_BBP_QM0003_1.0 Page 1 of 20


General Requirement/ Expectations

Inspection/testing, which are being carried out during production for different

Semi-Finished or Finished products at the following sections:

Blast Furnace

Ingot Manufacturing Process (SMS – 1)

Concast Blooms & Slabs Process (SMS – 2)

Blooming Mill Process

Billet Mill Process

Wire Rod Mill Process

Merchant Mill Process (Long, Round & Light Structurals)

Rail and Structural Mill Process

Plate Mill Process



Process Flowcharts



Explanation of functions and events

1.0 Blast Furnace: Master Data:

Material Master for various Raw Materials consumed at Blast Furnace

should have the Quality Management view created.

Transaction code: MM01

o Inspection type ‘08’ should be activated in the Quality

Management View of the Material Master, which indicates “Stock

Transfer Inspection” for Raw Materials received at Blast Furnace.

o Inspection type ‘03’ and ‘89’ should be activated in the Quality

Management View of the Hot Metal.

Master Inspection Characteristics, parameters which are to be analyzed,

should have already been created.

Transaction code: QS21

Sampling Procedure should have been already created to calculate the

sample size.

Transaction code: QDV1

Master Inspection Characteristics and Sampling Procedures created are

assigned in the Inspection Plan.

Transaction code: QP01

Process:

When Raw Materials are received in Bunkers at Blast Furnace, they are

sampled and analysed before charging into Blast Furnace.

Whenever the materials are received at Blast Furnace an inspection lot is

created automatically.

Transaction code: QA03

Quality Inspector selects the concerned Inspection Lot from his worklist.


Records the results as per analysis.




Quality In Charge then decides to accept or reject the inspection lot.


2.0 SMS – 1: Master Data:

Material Master for all different Grades of Ingots should have the Quality

Management view created.



Management View of the Material Master, which indicates

“Inspection during Production” for the Ingots.

o Inspection type ‘89’ should be activated for Hot Metal.





sample size.



assigned for concerned quality operations in the Routing, which will be

created in Production Planning Module.

Transaction code: CA01

o The operations in the Routing concerned for Quality in SMS - 1

section would be the following

Liquid Period

Teeming

Process:

Whenever a sample is sent from Mixer (One-Three Sample per Shift), an

inspection lot is created in the system.




Results recorded at Mixer for the sample collected are entered in HMMS.

The final results analysis at Mixer for the sample is then transferred to SAP

through an interface.

Usage Decision is taken to accept this inspection lot created at Mixer.


Daily Steel Order for Ingots will be created in SAP as Production Orders.

In-process Inspection Lot will get created in the system automatically,

when these production orders for Ingots are released.

Quality Inspector records the analysis results into HMMS system for Bath

Sample, Slag Sample and observations during Teeming.

The final results for each of these samples are captured into SAP against

the inspection lot number and the operation number by interfacing with

HMMS system.

After recording results for Teeming, Usage Decision is made whether to

accept the inspection lot or not based on the results recorded for all

operations.




3.0 SMS – 2: Master Data:

Material Master for all different Grades of Concast Blooms/Concast Slabs





“Inspection during Production” for the Material.

o Inspection type ‘89’ should be activated for Hot Metal.





sample size.






o The operations in the Routing concerned for Quality in SMS - 2


Converter: Bath Sample and Slag Sample

Argon Rinsing Unit

VAD

RH Degasser

Tundish

SBSY for Concast Slabs

Process:

Whenever a sample is sent from Mixer (One-Three Sample per Shift), an

inspection lot is created in the system.




Results recorded at Mixer for the sample collected are entered in OPEX.

The final results analysis at Mixer for the sample is then transferred to SAP

through an interface.

Usage Decision is taken to accept this inspection lot created at Mixer.


Daily Steel Order for Concast Blooms and Slabs will be created in SAP as

Production Orders.

In-process Inspection Lot will get generated in the system automatically,

when a Production Order for these Concast Blooms and Slabs are

released.

Quality Inspector records the analysis results into OPEX system for Bath

Sample, Slag Sample, Argon Rinsing Unit Sample, VAD Sample,

Degasser Sample, Tundish Sample and at SBSY. The data will get

transferred to SAP System.


After recording results for the final operation, which in this case SBSY for

Concast Slabs and Tundish for Concast Blooms, Usage Decision is made

whether to accept the inspection lot or not based on the results recorded

for all operations.




4.0 Blooming Mill Process: Master Data:

Material Master for all different Grades and sizes of Blooms made from

Ingots should have the Quality Management view created.



Management View of the Blooms, which indicates “Inspection

during Production” for the Material.


Management View of the Ingots, which indicates “Stock Transfer

Inspection” for Ingots.





sample size.






o The operations in the Routing concerned for Quality in Blooming

Mill section would be the following

Soaking Pit

1000 T Shear



Process:

As soon as the Ingots are received at Soaking Pits, an inspection lot will be

created in the system, against which, NOT OK Blooms are sent back to

Stripper Yard.


Production Order will be created in SAP for Blooms.


when a Production Order for Blooms are released.

Quality Inspector records the observations at Soaking Pit and 1000 T

Shear into HMMS.

The observations made at Soaking Pit and 1000 T Shear in HMMS system

is captured into SAP against the inspection lot number generated and

production order for Blooms by interfacing with HMMS system.

After recording results for 1000 T Shear, Usage Decision is made whether

to accept the inspection lot or not based on the results recorded for all

operations.




5.0 Billet Mill Process: Master Data:

Material Master for all different Grades and sizes of Billets made from

Ingots should have the Quality Management view created.






Management View of the Ingots, which indicates “Stock Transfer

Inspection” for the Material.

Master Inspection Characteristics, parameters to be analyzed, should have

already been created.



sample size.






o The operations in the Routing concerned for Quality in Billet Mill


Soaking Pit

1000 T Shear

Process:

As soon as the Ingots are received at Soaking Pits, an inspection lot will be

created in the system, against which, NOT OK Blooms are sent back to

Stripper Yard.




Production Order will be created in SAP for Billets.


when a Production Order for Billets are released.

Quality Inspector records the observations at Soaking Pit and 1000 T

Shear into HMMS.

The observations made in HMMS system is captured into SAP against the

inspection lot number generated and production order for Billets by

interfacing with HMMS system.

After recording results for 1000 T Shear, Usage Decision is made whether

to accept the inspection lot or not based on the results recorded for all

operations.




6.0 Wire Rod Mill Process: Master Data:

Material Master for all different Grades and sizes of Wire Rod Products




Management View of the Billets, which indicates “Stock Transfer

Inspection” at charging table of Wire Rod Mill reheating furnace.


Management View of the Wire Rod Products, which indicates






sample size.






o The operations in the Routing concerned for Quality in Wire Rod

Mill process would be the following:

Re-Heating Furnace

Rolling

Process:

As soon as the Billets are received at Charging Table, an inspection lot will

be created in the system, against which, NOT OK Billets are sent back to

Stripper Yard.


Production Order will be created in SAP for Wire Rod Products.




when a Production Order for Wire Rod Products are released.

Quality Inspector records the observations at Re-Heating Furnace and

Rolling into SAP System.


Quality In Charge then takes Usage Decision for the Inspection Lot.


7.0 Merchant Mill Process: Master Data:

Material Master for all different Grades and sizes of Merchant Mill Products







Management View of the Billets, which indicates “Stock Transfer

Inspection” at charging table of reheating furnaces of Merchant

Mill.





sample size.



assigned for concerned quality operations in the Routing.


o The operations in the Routing concerned for Quality in Merchant

Mill process would be the following:

Re-Heating Furnace



Rolling Stands

Finishing

Process:

As soon as the Billets are received at Charging Table, an inspection lot will

be created in the system, against which, NOT OK Billets are sent back to

Stripper Yard.


Production Order will be created in SAP for Merchant Mill Products.


when a Production Order for Merchant Mill Products are released.

Quality Inspector records the observations at Quality Operations into SAP.


Quality In Charge the takes Usage Decision for the Inspection Lot.


8.0 Rail and Structural Mill Process: Master Data:

Material Master for all different Grades and sizes of Rails and Structurals







Management View of the Blooms, which indicates “Stock Transfer

Inspection” at charging table of Rail Mill reheating furnace.

Master Inspection Characteristics, parameters to be analyzed, should have

already been created.



sample size.








o The operations in the Routing concerned for Quality in Rail and

Structural Mill process would be the following:

Re-Heating

Rolling (Roughing ,Internal Finishing, Hot saw cutting,

stamping & Reworking)

Inspection Bed

NDT

Process:

As soon as the Blooms are received at Charging Table, an inspection lot

will be created in the system, against which, NOT OK Blooms are sent

back to Stripper Yard.


Production Order will be created in SAP for Rail and Structural Products.


when a Production Order for Rails and Structurals are released.

Quality Inspector records the observations at Quality Operations into SAP

System.


Quality In Charge then takes Usage Decision for the Inspection Lot.




9.0 Plate Mill Process: Master Data:

Material Master for all different Grades and sizes of Plates should have the

Quality Management view created.









sample size.






o The operations in the Routing concerned for Quality in Plate Mill

process would be the following:

Re-Heating Furnace

Rolling

Cooling

Finishing Light/Medium/Heavy Plates

Special process rolling (NR, CCR, TCR.)

UTM

Inspection Bed 1

Inspection Bed 2

Inspection Bed 3

Normalizing



Process:

Production Order will be created in SAP for Plates.


when a Production Order for Plates are released.

Quality Inspector records the results value for each of the parameters

assigned for Quality Operations in OPEX and the data will be transferred

into SAP.

Finally Usage Decision is taken for the Inspection Lot.


Inputs – Event Triggers

Production Order Number for all products to be manufactured.

Inspection Lot Number creation is triggered by the release of these Production Orders.

Results are recorded for all Quality Operations which are maintained in Routings for each

of the products manufactured.

Usage Decision is made after the results recording is made for the last operation in the

Routings for an inspection lot.

Outputs

Inspection Lot Number for each production order number.

Results against each of the inspection lot number for analysis.

Process Linkages/Integration points

Inspection Lot Number gets created against each Production Order.

Results recorded at one operation are used for reference for next production operation.

Description of functional deficits



Not Applicable

Approaches to covering functional deficits

Not Applicable

Description of Business Process improvements

Traceability of quality

History of the quality results is available online.

Authorization and user roles

Roles ProfilesQuality Inspector Results Record

Quality In Charge Usage Decision

HODs Usage decision for critical items

NOTE: Roles are defined as per day to day transactions/activities in BSP. Quality Inspector/Quality In Charge/HODs can be any person from RCL/Shop Floor, the one who is responsible and authorized to Enter/View Quality Data in the System.

Reports & Forms Standard SAP Reports:

a. QA33: Display Inspection Lots

b. MCXA: View Inspection lots- material wise

The BSP reports are listed in reports annexure.

Interfaces

HMMS System

OPEX System



Conversions

Master Data in Quality Management, Material Master (QM View), Master Inspection

Characteristics, Sampling Procedure and Inspection Plan will be uploaded into SAP

through conversion programs (Either LSMW or BDC will be used)

Sign-off

Role Name Signature

SAIL Core Team Member Mr. Deepak Banerjee

SAP Consultant Mr. K. Raghavendra Nayak

SAIL Team Lead Mr. S.N. Tiwari

SAP Lead consultant Mr. Rajesh Shinde

Process Owner Mr. Bharat Lal


Documents

3. Inspection During Production