1. This study analyzed quality control of steel rod production at Petra Steel Industries in Jordan. Data on diameters of 25 steel rod samples was collected and analyzed using statistical process control charts.
2. The control charts showed some samples were out of control based on Western Electric and three-sigma rules, indicating potential issues in the production process.
3. Following improvements, the control charts showed the production process was within control limits, demonstrating an increase in process regularity and quality. The changes improved both the average quality and standard deviation of production.
1. The Hashemite University
Department of Industrial Engineering
Quality Control of Steel
industries
Dr. Raed
Athamneh
Done By
Almas Tawfiq Abualenin /
1931894
Raghad Ibrahim Alkhalailah /
1933608 Rofaidh Wajeeh Alnajjar /
1932462 Taima sohaib abu alia /
1932956 Marina raja Sweidan /
1931924
Layan Hussam Samhan / 1932817
2022
2. 1.Petra steel industries are one of the companies engaged in steel construction
which is located at Jordan, the methods used are Statistical Process Control and
New Seven Tools. This method is used to find out the most dominant causes of
rod product defects and to find out proposed improvements to prevent product
defects from occurring.
2.in maintaining the quality produced, the company is still not careful in
maintaining quality during the production process. Therefore quality must be
maintained and to minimize defects in the product, the first thing to do is to
predict the defect then test it using a statistical test. Furthermore, making the
improvement plan collected to process the data using the control Chart X and S
is data on production and diameters products .
3.Important results that this study applying these charts to the samples that were
taken from the end line product is that the manufacture paste conformity for
the specified specifications for the properties of Steel construction, the
presence of several deviations outside the upper control limit represented by
lack of conformity of defective units.
ABSTRACT
3. 1: Introduction:
1.1 Overview
Nowadays, business development is getting tougher even though it is in an economic condition
that tends to be unstable. This has an impact on business competition that is getting higher and
sharper, both in the domestic market and in the international market.
One way to win the competition or at least survive in the competition is to give full attention to
the quality of the products produced by the company so that they can outperform the products
produced by competitors. Quality problems have led to the company's overall tactics and strategies
in order to have competitiveness and survive against global competition with other company's
products.
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.
This is what the Research will deepen about how to apply Quality Control in a Steel
manufacturing company, namely Petra steel industries. , This project focus on the Steel
manufacturing process, due to Because of the importance of this product, and also because it uses
from all people in all sectors and not specialized for one sector.
In analyzing the application of Quality Control in the Petra steel industries company,. It is
applies a standard system in the production process without statistical quality control, While the
method used in the Research is to use a statistical process approach.
Iron is made from the process of mixing iron with carbon, but in small quantities that do not
exceed the permissible percentage, which is equal to (2%), which produces a material of immense
strength, and it has more flexibility called also steel. It is possible to add other elements to give
additional properties, and it has several types that are classified into groups of them.
4. 2)Profile Company (PETRA STEEL INDUSTRIES):
Petra steel industries. Is one of the largest Jordanian companies in the
manufacture of modern, high quality rod specializing construction rod and
the company employ more than 28 model for the production rod. Petra
steel industry produce wide range of rod for general construction and huge
tank design (oil and water). It was established in 2001 in Jordan.
3)Problem Statement:
This factory imports raw materials(12*12cm, and length 8m) from a
company neighboring to it (Ramallah), and it remodels it to different
dimensions, according to demand. the company looking to manufacturing
100% of their product beside of improve the quality of the products and
monitor production processes accurately and to reduce defects, in order to
be one of the worldwide competitor.
5. 2: Literature Review:
quality is the overall characteristics and nature of a product that affects its ability to
satisfy the needs stated or implied (Kotler 2002, P67). Also , quality is a dynamic
associated with products, service, people, process, and environment that meets or
exceeds expectations (Goetsch and Davis 2004, P47). product quality is a compatibility
of product use (fitness for use) to meet customer needs and satisfaction( Juran Hunt,
1993, P32).Crosby (1979, P58) states that quality is conformance to requirements,
which is in accordance with what is implied or standardized.
Quality control is a way so that product specifications set as a standard can be
reflected in the product or the final result (Assauri, 2004, P210). Also , Quality control is
a tool for management to improve product quality if needed, maintain high quality and
reduce the amount of damaged material. (Reksohadiprodjo and Gitosudarma, 2000,
P245).
The purpose of quality control is so that the final product has specifications with
established quality standards and so that the cost of product design, inspection costs,
and production process costs can run efficiently (Prawirosentono, 2002, P75).
According to Gerald Smith (1996, P1) Statistical Process Control is a collection of
production methods and management concepts that can be used to obtain efficiency,
productivity and quality for producing competitive products with maximum levels,
where statistical process control involves the use of signal-signal statistics to improve
performance and to maintain control of production at a higher level of quality.
6. 3: Methodology:
3.1 Methodology point
The purpose of this research is to analyze the construction rod produced by company PETRA, it can be
analyzed that as the main assessor of product quality is the consumer, the factor that becomes
consumer value is product quality.
The reader will see how decisions about sample size, sampling interval, affect the performance of a
control chart.
This project was accomplished completely according the following methodology:
1.Choosing a Steel manufacturing as a case study to investigate the implementation of quality control
chart due to its large production size.
2.Gathering complete information about the factory, its working status, production lines
3.Using Minitab software to analysis the data
4.Preparation of Fish Bone diagram for the listed causes
5.After implementation the next step is to monitoring of all the measures for achieving the objective
The case study assumed that monitoring charts are an accurate tool for controlling product quality.
The case study used the analytical descriptive method, The A random sample, was taken from the
production line, the number of samples (25) construction rod in end line, The sample size is 5 pieces
and Monitoring charts were used to analyze this data Minitab program.
7. 3.2 Data Collection Methods
The data collection method used is research by observing
directly in companies that are the object of research, the
following data collection techniques carried out are:
a. Observation
Is a process of collecting data by making direct observations of
the object under study related to primary data which
includes:1. Production Process 2. Causes of Disability
8. b. Interview
Is a way to get data or information directly by holding a question and answer directly
with people who know about the object of research. In this case it is and employees of
production operators in the company Petra.
Type of Data:
The types of data in this study are as follows:
1.Primary data , Primary data in this study include: Production data
2.Secondary data , Secondary data in this study include: Causes of disability
We have specialized in this Study in:
•diameters: (10)mm
11. After conducting a normality test on the above data, it was found that the data follow a normal distribution
12. 5.2 Control Chart
X-bar and s charts are used to monitor the mean and variation 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 standard deviation of a
process. The mean and standard deviation are then used to produce control limits for the
mean and standard deviation of each subgroup. During this initial phase, the process
should be in control. If points are out-of-control during the initial (estimation) phase, the
assignable cause should be determined and the subgroup should be removed from
estimation.
Comment:
- According to the western electric Rules, we find that
points 6, 17, and 22, respectively , it is Out of control
(out of 3 sigma limits).
According to the third sensitizing Rules, we find that points 12 to 16, respectively , it is Out of control (out
of 1 sigma limits).
-17 of 25 points plot below the center line, while only 8 plot above.
-Following 11th point, 5 points in a row Decrease in magnitude, Down.
13. *Phase 1 Application of 𝑿
̅ and S charts:
-Determined from m initial samples
•Typically 20-25 subgroups of size n between 3 and 5
- 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.
•If no assignable cause is found, there are two options.
1.Eliminate point as if an assignable cause were found and revise limits.
2.Retain point and consider limits appropriate for control.
If there are many out-of-control points they should be examined for patterns that may identify underlying process problems.
*Phase 2 - Monitoring the process:
- Based on the graphics generated from processing with Minitab 18
software, it provides information that the upper control limit value
(UCL) is 0.04552, the average S is 0.02179
14. and the lower control limit value (LCL) is 0.0. then from the graph above it can be concluded that the production
process of Rod steel diameter 10mm is within control limits.
- We Found The center line before the improvement process -which indicates an increase in the standard
deviation as a measure of the dispersal of the production process- while the upper and lower control limits
converge to the center line after the improvement process, which indicates an improvement in the regularity of
the production process, and this means that the production process improved at the two levels, the average
(quality production process) and the standard deviation (regularity the quality of the process).
5.3 Check Sheet & Pareto Chart
25 / 8 / 2022 Frequency PETRA
Defect Type 8 AM 10 AM 12 PM 2 PM 4 PM Total
Furnace 50
Roll Speed 35
Edge cracks 24
End Cutting 17
Strapping
Machine
8
Others ---- ---- 7
16. 5.5 Process Capability
is the ability of a process to produce a product/service that suits the needs/requirements
of the consumer or expected specifications. Statistical Process Control (SPC) is unable to
Analyze quantitatively a process that is ongoing, because SPC only Monitor/monitor the
ongoing process. To find out a process running capable/not (producing products/services
that match their specifications).
The Cp and Cpk statistics assume that the population of data values is normally
distributed. Assuming a two-sided specification, if μ and σ are the mean and standard
deviation, respectively, of the normal data and USL, LSL, and T are the upper and lower
specification limits and the target value, respectively, then the population capability indices
are defined as follows.
18. 6: Conclusion:
Based on the results of data processing and analysis of the data obtained, it can be concluded the
following:
1.The type of Edge cracks defect is a major defect in the production process of Rod steel.
2.There are three main factors that cause defects in the production process of PETRA Co.
, namely materials, humans (employees), and machines. While the additional factor causing disability is
the work method.
3.There is no doubt, that the good design of the product, 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, and the verification
of the devices used affects the quality of the production process, which leads to reducing the actual
spread of the production process and improves its ability to achieve the established specifications.
7: References:
1Montgomery, Douglas C. Introduction to statistical quality control. John Wiley & Sons, 2020
2R. Ginting, "Proposed Improvement of Flour Quality by using New Seven Tools Method (Case Study :
XYZ Company)," IOP Conference Series: Materials Science and Engineering, 2020.
3S. N. Pramono, "The use of quality management techniques: The application of the new seven tools,"
International Journal of Applied Science and Engineering, pp. 105-112, 2018.
