Deepak GORAD report on tqm implementation in L&T PLANT.

1. NCRD STERLING INSTITUTE OF MANAGEMENT STUDIES
Submitted by:
Submitted to:
Deepak R Gorad
Marketing [C-9] Prof. Rajiv Wad
TQM
Project

2. Total Quality Management
Continual Improvement of
The Quality Management System
Plan : Establish the objectives and processes necessary to deliver
precise results, in accordance with the Customer's
requirements and the organization's policies.
Do : Implement the processes.
Check : Monitor and measure processes and products against policies,
objectives and requirements for the product to ensure strict
adherence to them and detailed reporting of the results.
Act : Take action to continuously improve process performance.
Management
Responsibility
PLAN
DO ACT
CHECK
Resource
Management
Measurement Analysis
and Improvement
Product
Realization
The P-D-C-A Cycle

3. 05
Total Quality Management
TQM or Total Quality Management is designed to create a
comprehensive and all encompassing module which aides in achieving
Manufacturing Excellence. Every element of this term speaks of an
important aspect.
Total : Made up of the whole
Quality : Degree of excellence of a product or service
Management : The art and science of planning, controlling,
directing
…. therefore, TQM is the art & science of managing
the whole to achieve excellence
The TQM System
Continuous Improvement
Process
Improvement
Total
Involvement
Customer Focus
Objective
Principles
Leadership Education and Training Supportive Structure
Communications Reward and Recognition Measurement
Elements
Electric ARC Furnace

4. Total Quality Management
TQM is an approach to quality assurance that emphasizes a thorough
understanding by all members of a production unit, of the needs and
desires of the ultimate service recipients and a viewpoint of wishing to
provide service to internal, intermediate service recipients in the chain of
service.
TQM, as defined for ISO 8402
Management approach of an organization centers on quality, based on
the participation of all its members aiming at long term success through
customer satisfaction and benefits to all members of the organization and
the society. TQM is the mutual co-operation of everyone in an
organization and associated business process to produce products, which
meet the needs and expectations of customers. Total Quality Management
is both a philosophy and a set of guiding principles for managing an
organization efficiently.
Quality Management
Quality Management has four levels: Inspection, Control, Assurance and
Total Quality Management (TQM). Quality inspection and quality control
rely on supervision to make sure that no mistakes are made. The basic
approach to quality is inspection, detection, and correction of errors. The
next level quality control is to inspect, correct, investigate and find the
causes of problems; and take action to prevent errors from re-occurring.
Both methods rely on supervision and inspection. The third level quality
assurance includes the setting of standards with documentation and also
the documentation of the method of checking against the specified
standards.
Quality inspection, control and quality assurance are aimed at achieving
an agreed consistent level of quality, first by testing and inspection, then
by rigid conformance to standards and procedures; and finally by efforts
to eliminate the causes of error so that the defined accepted level is
achieved.
Total Quality Management is a comprehensive and integrated way
of managing any organization in order to:
a) Meet the needs of the customer requirements.
b) Achieve continuous improvement in every aspect of the
organizational activities

5. Certificates & Licenses
Certificates
1. ISO 9001 : 2008 Quality Management System
2. ISO 14001 : 2004 Environmental management System
3. OHSAS 18001 : 2007 Occupational Health and Safety Management
System
4. TUV approved Total Management System
BIS Licenses
1.IS: 1786/2008 HSD Bar: Grade : Fe - 415, Fe - 415D, Fe - 500,
Fe - 500D, Fe - 550, Fe - 550D, Fe - 600
2. IS: 2062/2006 structural Steel Grade E 250 A
3. IS: 2830/1992 - Carbon Steel Cast Billet for General Engineering
Grades A, B & C
4. IS: 2831/2001 - Carbon Steel Cast Billet for Low Tensile
Structural Steel
Control Room - DRI Plant
Spectrometer
Universal Testing Machine

6. Production Flow Chart
Integrated Steel Plant
Iron ore Coal Dolomite (Flux)
DRI
Electric Arc Furnace (EAF)
Continuous Casting Unit
Reheating Furnace
Rolling Mill
Thermex Unit (QST)
Cooling bed
Finished Stock Yard for
TMT Bars
Billet
Sponge Iron
Heated Billet

7. DRI Plant
Stock house
I/C (0-8 mm)F/C (4 -18 mm)
Return for crushing Return for screening
Crusher house Transfer house
Ground hopper Iron Ore
(5 to 40mm)+Dolomite
Ground hopper
Coal (0-150mm)
Dolomite
OreSize
(5-18mm)
Kiln (reduction)
Cooler
Product separation bin
Lumps
(5-20 mm)
Sponge Iron
(stored with heat
No. marking)
Char
(unburned coal)
Sponge Iron
Char
(unburned coal)
Fines
(0-5 mm)

8. 10
No
Yes
Billet
EAF & Concast Plant
Raw material Yard Sponge Iron
Charging at Electric Arc Furnace
Melting
Chemical Analysis and Mix Finalization
Carbon Charging Refining Oxygen Charging
Chemical Addition as Per Requirement
Bath sample checking for chemical analysis
Conforms?
Deslagging
Hot material transferred from furnace to ladle (Tapping)
Concast plant
Sizing in required length
Cooling bed
Visual Inspection & Testing
Batch number wise stocking at finish stockyard
CRS grade addition
of Cu (Copper) and
Cr (Chromium)

9. Rolling Mill
Raw material (Billet) yard
Raw material inspection: visual & chemical
Reheat Furnace
Roughing mill
Intermediate mill
Finishing mill
Thermex Unit (QST)*
Cooling bed
Sizing
Checking of dimension & weight
Physical & Chemical testing
Section & lot wise stacking at despatch yard
* QST - Quenching and Self Tempering

10. 12
Shyam Steel's Durgapur unit is a automated integrated
steel plant comprising of:
= DRI Unit.
= Steel Melting Shop equipped with Electric Arc Furnace.
= Continuous Billet Casting Unit; and
= Rolling Mill with Thermex system.
It has been setup in Collaboration with World-
renowned companies viz; Concast AG-Zurich and HSE
Germany.
1) DRI Unit: In the Direct Reduced Iron (DRI) plant,
production of sponge iron using a solid reductant
involves reducing iron ore (lumps/pellets) with a
carbonaceous material such as coal. The reduction
is carried out in a rotary kiln (which is inclined and
rotates at a pre-determined range of speeds) at a
stipulated temperature (8500°C -10,500°C). The
inclination and the rotary motion of the kiln ensures
that the raw materials moves from the feed end to
the discharge end of the kiln and during this
movement the actual reduction of iron ore to iron
takes place. The material discharged from the kiln
is taken to a rotary cooler for cooling and the
cooled product is separated from the coal char.
The basic reactions involved are as follows:
3Fe2O3 + CO = 2Fe3O4 + CO2 (1)
Fe3O4 + CO = 3FeO + CO2 (2)
FeO + CO = Fe + CO2 (3)
2) Electric Arc Furnace: Steps involved in an Arc
Furnace can be summarized as follows:
a) Charging: The charge is prepared according to
the proposed chemistry for the targeted grade.
Sponge Iron and other ingredients along with
lime in a close requisite ratio is charged in the
Arc Furnace.
b) Melting: Melting is accomplished by injecting
energy to the charge materials in the form of
electrical energy through three graphite
electrodes. Carbon injected inside the furnace
reacts with oxygen producing CO, which
bubbles through the bath creating foamy slag.
The excess CO reacts with oxygen, converting
to CO2 again generating heat. Oxygen will
react with several components present in the
bath including silicon; manganese; phosphorus
and sulphur. The oxides thus formed will end up
in the slag. In arc furnace charged materials gets
melted at about 1800°C.
Production Process
DRI Plant EAF

11. Once sufficient charge has been melted and
enough space has been created, second charge
can be taken and the process is repeated. Once
the final charge has been melted and is reached
at melt stage, temperature measurement is taken
and sample is drawn for determining the
amount of oxygen to be blown during refining.
c) Refining: Refining means reduction of
undesirable elements in steel like sulphur,
phosphorous etc and also bringing down the
carbon to required levels.
Phosphorus and sulphur which cannot be
removed in Induction Furnace, can be easily
removed in EAF. Phosphorous is removed in the
early stage of refining. Sulphur is removed as
sulphides in slag and is better achieved during
reducing stage.
Aluminium, silicon and manganese react with
oxygen before carbon to form oxides which
goes into the slag. CO, which is produced due
to the reaction of carbon with oxygen, bubbles
through the bath causing the slag to foam and
has many beneficial effects. The foaming also
helps in bringing down nitrogen and hydrogen
levels in steel. At the end of refining stage
temperature measurement is done and sample
is drawn for analysis.
d) De-slagging: De-slagging is the process by
which the slag layer above the steel is removed
from the furnace. This process is important for
removing impurities from the molten material.
The furnace is tilted towards the slag door for
slag removal. Phosphorus is transferred to the
slag, during the early stage of the heating while
the temperature is relatively low. The first de-
slagging (at the beginning of refining) removes
a substantial portion of the phosphorous as
P2O5, thus preventing phosphorous reversal to
the metal. Typically during the refining stage,
the furnace may be de-slagged several times.
e) Tapping: After reaching the required
temperature and composition, the tap hole is
opened and metal is tapped into the ladle and
sent to continuous casting unit for casting of
billets. During the tapping process bulk alloys
are added based on the bath analysis for the
desired steel grade. De-oxidizers may be added
to the steel to control the oxygen content, prior
to further processing. This is commonly referred
to as killing of steel. This is done by adding
aluminum or silicon in the form of ferrosilicon
or silicon manganese.
A typical construction of Arc Furnace has shown
below:
Concast

12. 14
3) Continuous Billet Casting: Molten steel from
EAF is tapped into a ladle and taken to the
continuous casting machine. Liquid steel flows out
of the ladle into the tundish and then into a water-
cooled mold. Solidification begins in the mold. The
continuous billets coming out from the CCM is
sized according to the length required.
4) Rolling Mill with Thermex Technology: The
billets manufactured are re-heated at a temp. of
1200°C in the re-heating furnace and are rolled
into specific sections of finished material in the
Rolling Mill Unit. In the case of manufacturing TMT
Re-bars, from the finishing stand of the rolling Mill,
the Re-Bars are guided through a specially designed
proprietary Thermex pipes to obtain special
property 'Thermex Process' as explained below:
Quenching: The hot rolled bar from the finished
mill stand enters into the 'Thermex System' and is
rapidly quenched by a special water spray system.
This rapid quenching hardens the surface of the
TMT Re-bars to a depth optimized for each section,
forming a Martensitic rim while the core remains
hot & Austenitic.
Self Tempering: After Re-bars leave the quenching
box, the core remains hot compared to the surface
allowing heat to flow from the core to the surface
causing Tempering of the outer Martensite layer thus
forming a structure called 'Tempered Martensite'.
Atmospheric Cooling: This takes place on the
cooling bed, where the Austenitic core is
transformed into ductile Ferrite-Perlite structure.
Thus the final structure consists of stronger outer
layer (Tempered Martensite) with ductile core
(Ferrite-Pearlite). This process increases the tensile
strength of the material while keeping high ductility
and weldability. This whole process is a patented
technology from HSE, Germany under the brand
name of 'Thermex'.
Production Process
Rolling Mill
Thermex Plant

13. Schematic Diagram of QC
Quality Check flow chart
Hold Point Activity
1. Chemical analysis of iron ore,
coal, dolomite
2. Final chemical analysis of
sponge iron
3. Chemical analysis of sponge iron,
ferro alloys & other elements
4. Refining and deslagging
5. Chemical analysis and visual
inspection of billets
6. Final chemical analysis of billets
7. Re-heating furnace temperature
check
8. Splitting tendency check
9a. Incoming material temperature
check
9b. Water temperature and pressure
check
9c. Outgoing material temperature
check
9d. Equalising temperature check
10. Final physical and chemical
analysis of finished product
Sponge Iron
Ferro
Alloys Sponge
& Other Iron
Elements
HOLD PT(2)
HOLD PT(3)
HOLD PT(4)
HOLD PT(5)
HOLD PT(6)
HOLD PT(7)
HOLD PT(8)
HOLD PT(9A)
HOLD PT(9B)
HOLD PT(9C)
HOLD PT(9D)
HOLD PT(10)
Irone Ore Coal Dolomite
HOLD PT (1)
EAF
BILLET CASTER
COOLING BED
BILLET YARD
REHEATING FURNACE
Roughing Mill
Intermediate Mill
Finishing Mill
THERMEX PLANT
COOLING BED
FINAL PRODUCT
LAB
LADLE

14. 16
Inspection Process
Purpose: To conduct inspection, testing, identification
and traceability of materials and products in various
stages of production in accordance with the applicable
IS specifications and customer requirements.
Scope: The process covers inspection, testing,
identification and traceability of the product from
receipt stage, in process inspection and final inspection
till desptach.
Procedure
Direct Reduced Iron Unit (D.R.I.): The sized iron-ore
is tested for its Fe content and coal for its ash content
and is then charged to D.R.I plant. The finished product
of DRI plant i.e. sponge iron is then tested for its Fe
content and chemical composition and is identified by
day wise production.
The conforming material is taken to SMS plant for
charging and in case of non-conformation, material is
sent to rejection yard.
Steel Melting Shop (SMS): In the SMS plant the material
is melted at about 18,000°C in an Electric Arc Furnace.
The slag is removed automatically in the Arc furnace
to achieve precision control of chemistry of
the molten metal. The hot molten metal is checked for
its chemical composition. Depending upon the
composition required, various ferro alloys are added to
it. Then the molten steel with requisite chemical
composition from Electric Arc Furnace is sent to the
continuous casting unit for casting billet.
Continuous Casting Machine (CCM): The billets thus
produced are first visually inspected for the surface
condition and then tested for its chemical composition.
If any surface discontinuity is observed in the material
it is then sent to SMS unit for recycling. The tested billet
is then sent to the Rolling Mill raw material yard with
a proper batch number.
Rolling Mill: The billets are then taken for production
in the Rolling Mill. During the production process,
inspection is done at various stages. The non-
conforming products are identified and segregated
properly for recycling. The finished product is then
subjected to final inspection (visual inspection &
physical property) and a Lot Number is allotted to it
before being stored in the finished product yard.
The finished product is properly tagged which carries
the following information:
I. Name of the Company II. Lot No.
III. Size of the product IV. Grade
Control Panel - Universal Testing Machine Control Panel - Electric ARC Furnace

15. 26
Responsibility Matrix
Sl. No. ACTIVITY MD GM MR WM MKT PUR PROD QA STORE MNT
1. Quality System DR DR DR DR CR CR CR DR CR CR
2. Control of Documents DR DR DR DR CR CR CR CR CR CR
3. Control of Records DR DR DR DR DR DR DR DR DR CR
4. Management Responsibility DR DR DR DR CR CR CR CR CR CR
5. Resource Management DR DR DR CR CR CR - - - -
6. Complete Awareness Training DR DR DR DR CR CR CR DR CR CR
7. Customer Related Processes DR DR CR CR DR - CR CR - -
8. Purchase DR CR - CR CR DR CR CR CR -
9. Production CR DR - DR - - DR CR CR -
10. Maintenance - CR - CR - CR CR CR - DR
11. Identification & Traceability - CR - DR - - DR DR DR -
12. Preservation of Products - CR - - - - DR DR CR -
13. Control of Monitoring - DR - DR - DR DR DR CR -
& Measuring Devices
14. Monitoring & Measuring - - - - - CR DR DR CR -
15. Internal Audit CR CR DR CR CR CR CR CR CR CR
16. Control of Non- DR DR CR DR DR DR DR DR CR CR
Conforming Products
17. Data Analysis CR CR - - - DR DR DR CR -
18. Corrective Action CR CR CR CR - DR DR DR CR -
19. Preventive Action DR DR DR DR CR DR DR DR CR -

16. Joint Inspection Process
During any client visit for approval of our brand or any third party inspection of material before despatch, the
testing of physical and chemical properties of any ready lot is done again and witnessed by the client/third party
inspector. During this inspection process a joint inspection report of finish product testing is prepared and signed
by both the parties.
The following Third Party inspection Agency doing inspection of material at our plants:
1. Lloyds Register Asia. (LRA) 2. Bureau Veritas (I) Pvt. Ltd. 3. Rites Ltd.
4. Det Norske Veritas As (DNV) 5. TUV India Pvt. Ltd. 6. SGS India Pvt. Ltd
Activities:
Policy: Inspection and testing shall be carried out at different stages to verify that the specified requirements for
the products are met.
Scope: These procedures cover the inspection and testing of purchased products, semi-finished products and
finished goods, right from the raw material to the finished product stage.
Responsibility: Quality Assurance Manager is responsible for implementation of these procedures.
Scope & Responsibility of Quality
Management Department
Type of Inspection & Testing Responsibility Reference Document
Raw material inspection & testing Quality control manager Receiving inspection report
In-process inspection Lab/inspection in-charge In-process inspection report
Final inspection Quality Control Manager Final inspection report
Joint inspection Quality Control & third party Joint inspection report
inspection authority or
client representative

17. 28
Product Realisation Process and Interaction
CustomerRequirement
Management Responsibility
Resource Management
Marketing
Manufacturing
Quality Assurance Purchase Store
Control of document Control of
& record NC product
Corrective & Analysis
Preventive action of Data
ProductrequirementRequirementbasedonpurchaseorder(ifany)
CustomerSatisfaction
GeneralfeedbackreportProductfeedbackreporCustomercomplaintCustomervisitreport

18. Control of Non-conforming Product
Products that do not conform to specified requirements are identified and controlled to prevent unintended use
or delivery. The control and related responsibility and authority for dealing with non-conforming product are
described in documented procedure QP/SSIL/8.3/00.
1. Identified
nonconforming
products
2. Identified non-
conformity and
action
Disposition
action taken
Summary report
for corrective &
preventive action
taken
Key Tasks/
(Responsibility)
a) Inspection & Identification of non-conforming
products (inspection/lab in-charge)
b) Review and Disposition of non-conforming
products (Q.C. Manager)
a) Take corrective action against the Identified
nonconformity
b) Take preventive action against the non-
conformity, compiling and presentation of
summary report for management review meeting
(Q.A. Manager)
Process Map - Quality Management Process
INPUTS OUTPUTS