Growth through Sustainability

QUALITY

01

Vision : 02

Quality Policy : 03

Corporate Social Responsibility Policy : 03

Occupational Health & Safety Policy : 03

Total Quality Management : 04 - 06

Certificates & Licenses : 07

Integrated Steel Plant : 08

DRI Plant - Flow Chart : 09

Electric ARC Furnace - Flow Chart : 10

Rolling Mill - Flow Chart : 11

Manufacturing Process : 12 - 14

Quality Check - Flow Chart : 15

Inspection Process : 16

Guidelines : 17 - 20

Quality Assurance : 21 - 25

Responsibility Matrix : 26

Scope & Responsibility of QMD : 27

Product Realisation : 28

Control of Non-conforming Product : 29

Inspection : 30

Lab and Test Equipments : 31

Testing Codes & Standards : 32

02

Total Quality Management VisionCustomer Satisfaction

=

Organizational Performance

=

Manufacturing Excellence

=

Employee Contentment

=

Social Responsibility

03

Quality PolicyShyam Steel Industries Ltd is committed to:

= Delivering the required products at the right place at the right time at the right cost from our Integrated Steel

Plant(original producer) form the very backbone of our Principles of Manufacturing.

= We view improvement as a continuous process. We are constantly aspiring to achieve betterment

of our core processes, be it manufacturing, quality control, sales or delivery. There is a joint effort

to achieve Manufacturing Excellence.

Corporate Social Responsibility PolicyAs a Corporate Organisation we believe that it is our primary purpose to give back to society. Giving and sharing

what we have received is embedded deeply in us. We have actively pursued to raise the quality of life of the

people around us. We hold hands in our joint effort to create better tomorrows.

Occupational Health & Safety PolicyAt our world class Integrated Steel Plant we treat our worker's well being as a mandate and not as an option.

Ensuring the highest standards of safety is imperative. We follow the occupational health and safety policy certified

under ISO 18001 : 2007.

We aim to:

= Create an environment which is safe and secure for everyone in its vicinity, be it a worker, contactor, visitor

and even the local community. All identifiable OHSAS risks and hazards are treated with the gravest concern.

= To constantly endeavour towards the highest level of health and safety such that injuries, waste and emissions

are reduced to the bare minimum.

= Train all employees to work safely and responsibly thus preventing injury to themselves and others.

= Ensure that optimum conditions exist for the proper execution of all the stipulated health and safety norms.

Following and implementing the OHSAS responsibilities is the prerogative of everyone, at all levels of

management and employees.

S. S. Beriwal

Chairman and Managing Director

04

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.

ManagementResponsibility

PLAN

DO ACT

CHECK

ResourceManagement

Measurement Analysisand Improvement

Product Realization

The P-D-C-A Cycle

05

Total Quality ManagementTQM 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

ProcessImprovement

TotalInvolvement

Customer Focus

Obj

ectiv

e

Prin

cipl

es

Leadership Education and Training Supportive Structure

Communications Reward and Recognition Measurement

Elem

ents

Electric ARC Furnace

06

Total Quality ManagementTQM 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 8402Management 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 ManagementQuality 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

07

Certificates & LicensesCertificates1. 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 Licenses1. 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

Universal Testing Machine

08

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

09

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)

Dol

omite

Ore

Siz

e

(5-1

8mm

)

Kiln (reduction)

Cooler

Product separation bin

Lumps

(5-20 mm)

Sponge Iron(stored with heat

No. marking)

Char(unburned coal)

Sponge IronChar

(unburned coal)

Fines

(0-5 mm)

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 additionof Cu (Copper) and

Cr (Chromium)

11

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

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 (8500C -10,500C). 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 ArcFurnace 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 1800C.

Production Process

DRI Plant EAF

13

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:

EAF - Electrodes Concast

14

3) Continuous Billet Casting: Molten steel fromEAF 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: Thebillets manufactured are re-heated at a temp. of

1200C 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

15

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

FerroAlloys Sponge

& Other IronElements

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

16

Inspection ProcessPurpose: To conduct inspection, testing, identificationand 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.

ProcedureDirect 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 18,000C 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

17

MISCELLANEOUS TERMS:

Steel Melting Scrap: Steel waste/scrap not usable as such in its existing form which are further re-meltedto produce liquid steel to produce various products. Depending on their form/type, they are classified asHeavy Melting Scrap, Light Melting Scrap, Turnings/borings etc.

Re-rollable Scrap: Seconds & defective products, cuttings/end cuttings, used steel products like used railsetc which could be directly used for re-rolling (without resorting to re-melting) into finished products forspecified applications. These are substitutes of steel billets /pencil ingots. Ship breaking generates substantialquantity of re-rollable steel scrap.

Integrated Steel Plants: Steel plants using iron ore as the basic raw material for production of crude steelwhich is further rolled into finished shapes in-house. Conventionally, these plants have captive coke ovensalso and the sensible heat of the outgoing gases from iron/coke making are utilised as fuel for variousapplications. It therefore, includes units with in-house coke making (optional), iron making followed byproduction of liquid steel & crude steel and finished steel. So all ISPs adopting BF- BOF route and Majorproducers adopting Corex-BOF or DRI-EAFor MBF-EOF technology would technically, fall under thiscategory.

Mini Steel Plants: Conventionally, EAF/IF based steel plants with/ without captive rolling mills were coveredunder this category. However, now all steel plants (based on any technology) of capacity upto 5 lakh tpaare covered under this category.

Primary Steel Producers: Steel (crude and/or finished steel) producers using iron ore as the basic rawmaterial/input. It therefore, includes in-house iron making followed by production of liquid steel & crudesteel with/without in-house rolling. So, all ISPs adopting BF- BOF route and Major producers adoptingCorex - BOF or DRI-EAF or MBF-EOF technology would fall under this category.

Hot Rolling: Rolling of steel at above the recrystallisation temperature of steel (normally above 1000 C) toproduce Hot Rolled Long products/Flat Products from semis. Ingots are also hot rolled to get semis. Attimes blloms are also hot rolled to produce billets. Rolling Mills used for hot rolling are known as HotRolling Mills.

Cold Rolling: Rolling of steel (normally flat products) below the recrystallisation temperature of steel(normally at room temperature) to produce cold rolled sheets /strips /coils. Mills used for the purpose arecalled Cold Rolling Mills.

2Hi/4 Hi/6 Hi/20 Hi Mills: Rolling Mills are classified as 2-High / 2 Hi, 4 Hi and so on depending onNumber of Rolls used in the arrangement/configuration of rolls in single stand. For example, a 2 Hi millconsist of 2 rolls one above the other known as upper roll and the lower roll. In a 4 Hi mill, there are 4rolls in a stand2 upper rolls one above the other and 2 lower rolls one above the other.

Glossary of Terms/ Definitions Commonly used in Iron & Steel Industry

18

Integrated Steel Plant Vs Ordinary Re Roller

Integrated Steel Plant Ordinary Re-Rolle

Manufacturing flow chart process: Iron Ore Manufacturing flow chart process: Ingot RM DRI SMS CCM (Billet Plant) RM TMT TMT Route TMT Re-bar Ingot produces from Route TMT Re-bar different type of steel scrap SMS Ingot

Integrated Steel Plant conforms the consistency Ordinary Re-Roller cannot conform the in quality product consistency in quality product

Chemical properties of billet top, middle & bottom Chemical properties of ingot top, middle & portion all are same. Shape of billet is square bottom portion are different types. Shape of

ingot is taper.

Continuous casting billet is a very minor casting Ingot is another harmful defect such as centerdefect in respect of ingot piping, blow hole, cracks & inclusions etc.

This has a very bad effect in rolling product

Achievement of proper levels of sulphur & Major Re-rollers/Ingot producers are unable to phosphorus is a process of capability inherent meet even these relaxed standard consistently to the iron ore based integrated steel making route. As per Indian Standard (IS 1786) calls for sulphur & phosphorus content of 0.060% max. each for the Fe 415 grade with further provision that S&P added together would not exceed 0.110%.

Complete automation TMT route can produce Re-roller neither maintains adequate TMT route the desired yield strength with steel of relatively and chemical composition of material nor lower carbon equivalent by adjusting the on line maintains a specific range since they are using Q& T parameters. IS :1786 limits the carbon an Ingot. content to 0.25% max. & CE to 0.42% max. forguaranteed weldability. The average carbon content maintained by Shyam Steel Industries Limited is 0.19% with a standard deviation of 0.03% across all sections.

Good Thermex TMT Re-bars ensure the Re-bars Major Re-rollers producing TMT Re-bars do not with a uniform and concentric hardened tempered ensure that the Re-bars have a uniform and hard Martensite periphery and the softer Ferrite - periphery signifying the quenching has not taken Pearlite core. place all round the periphery. Rolling mill production

system is either manual or semi automatic & millpersonnel are not fully trained in quenching &tempering technology.

19

Induction Furnace VS Electric Arc Furnace

Sl No. Characteristic Arc Furnace Induction Furnace

1 Operating Principle

The arc forms between the charged Induction Furnace heating is material and the electrode by short- accomplished through induction i.e.circuit between the electrodes and heating an electrically conducting raw materials which causes high- object (usually a metal) by Electrotemperature electric arc to melt raw magnetic Induction where eddy materials current is generated within the

metal and resistance leads to JouleHeating of the metal. An InductionFurnace uses induction to heatmetal to its melting point.

Slag is removed automatically Slag is removed manually

Precision control of chemistry of Control of chemistry of the molten 2 Refining Capability the molten metal metal is not good i.e. lack of

refining capacity

S & P removal capacity is very good Removal of S & P is limited

3 Operating High operating temperature Operating temperature is lowerTemperature than Arc Furnace

4 Dissolved Gas Low content of dissolved gases in Content of dissolved gas in molten molten metal. metal is more than Arc Furnace

5 Reduction in Large reduction in specific energy Large reduction in specific energy Specific Energy (energy per unit weight) required to (energy per unit weight) to produce

produce the steel the steel is not possible in InductionFurnace

6 Starting or stopping Arc Furnace can rapidly start and stop, Induction Furnace cannot startthe Furnace allowing the steel mill to vary or stop rapidly

production according to demand

7 Life of Refractory Life of Refractory lining is more Life of Refractory lining is comparativelylining than Induction Furnace lower than Arc Furnace

8 Variety of Steels Possibility of producing variety Variety of steels cannot beof steels produced

Power Cables Electrodes

Copper induction coils

Refractory material

Molten metal(arrows indicatemixing action)

Cover

Oxygen inlet

Tapping spoutfor molten iron

Iron ore

Door forremoving slag

Hatch for iron ore,lime and other material

20

M.S. Billet vs M.S. Ingot

Ingot Billet

In Ingot casting, the liquid steel flows through a In continuous casting technology liquid steel refractory channel & fills up cast iron mould under flows from furnace to caster through a copper static condition from one side. This process has mould. The water in the mould gets cooled and certain deficiencies. Like:- Refractory particles oscillates at a predetermined rate. The oscillation,chip-off from the channel and get mixed with cooling and pausing is done in such a controlled liquid steel thereby causing undesirable inclusions condition that the liquid steel solidifiesin Ingot leading to rolling defect into equiaxed crystals

The liquid steel during the solidification process The gas in liquid steel escapes during solidificationreleases gas which gets entrapped in the steel and owing to continuous casting technology form blowholes and cavities in Ingot

Owing to the process of solidification segregation In billet owing to continuous casting of chemical alloys takes place. The chemical chemical alloys are uniformly spread properties vary at different portions of Ingot

In Ingot very harmful defects such as center piping, In continuous casting, no centre piping blow hole, cracks & inclusions etc. are found blow hole, crack or inclusion is formed

The surface of Ingot develop scabs and laps due to The surface of billet is clear with no scabs and pouring defects on account of bad mould surface laps due to smooth copper mould surface

TMT Re-bars rolling from Ingots suffer from TMT Re-bars produced from continuous casting deficiency in tensile properties and there is billets show high tensile strength and elongation inconsistency in tensile strength and elongation and there is remarkable consistency of properties

Ingots Billets

21

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s

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etSu

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ish

&V

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l ins

pect

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As

per

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/283

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nal I

nspe

ctio

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epor

tdi

men

sion

of

mea

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men

t of

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(Doc

. No.

QS/

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00)

norm

s

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ared

by

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ed b

yA

ppro

ved

by

GM

- Q

.A.

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agin

g D

irec

tor

Prof

esso

r

S. D

asgu

pta

P. B

eriw

ala

Dr.

T.K

. Pal

SSIL

SSIL

JU, K

olka

ta

23

Qua

lity

Ass

uran

ce P

lan

for

Ther

mo

Mec

hani

cally

Tre

ated

(TM

T) R

ebar

s

Sl.

Type

of P

rodu

cts

Cha

ract

eris

tics

Type

of I

nspe

ctio

nA

ccep

tanc

eFo

rmat

of

No.

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ratio

nch

ecke

dTe

stin

gno

rms

Rec

ord

1.R

aw m

ater

ial-

Surf

ace

finis

h /

Vis

ual /

Rev

iew

IS

: 28

30D

oc. N

o. Q

S/Q

A/B

3/00

bille

tC

hem

ical

com

posi

tion

of B

illet

Cer

tific

ate

IS :

1786

2A.

TMT

Reb

arSu

rfac

eV

isua

l /

IS :

1786

Fi

nish

/Sur

face

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oc. N

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3/00

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ract

eris

tics

&

2B.

Do

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dard

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ght p

er m

eter

leng

th b

yIS

: 17

86

Doc

. No

: QS/

QA

/T4/

00w

eigh

tel

ectr

onic

bal

ance

2C.

Do

Mat

eria

l C

hem

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Ana

lyst

s IS

: 17

86D

oc. N

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S/Q

A/T

3/00

com

posi

tion

%C

, %S

& %

P an

d ot

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for

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CR

E)

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oM

echa

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l pro

perti

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nsile

test

ing

0.2%

P.S

. / Y

.S,

IS :

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Doc

. No

: QS/

QA

/T3/

00(N

orm

al &

. D g

arde

UTS

, % E

long

and

% T

otal

TM

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onga

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at M

axim

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enda

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B

end

test

& R

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: 17

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oc. N

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S/Q

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3/00

Reb

enda

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entif

icat

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&V

isua

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undl

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bar

mus

tD

oc. N

o : Q

S/Q

A/T

3/00

Mar

king

have

met

al ta

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ting

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rade

r, si

ze,

spec

ifica

tion

No.

, Tr

ade

mar

k.

Prep

ared

by

Issu

ed b

yA

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ved

by

GM

- Q

.A.

Man

agin

g D

irec

tor

Prof

esso

r

S. D

asgu

pta

P. B

eriw

ala

Dr.

T.K

. Pal

SSIL

SSIL

JU, K

olka

ta

24

Qua

lity

Ass

uran

ce P

lan

for

Stru

ctur

al S

ectio

n (A

ngle

, Che

nnel

& Jo

ist)

Sl.

Type

of P

rodu

cts

Cha

ract

eris

tics

Type

of I

nspe

ctio

nA

ccep

tanc

eFo

rmat

of

No.

Ope

ratio

nch

ecke

dTe

stin

gno

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ord

1.

Raw

mat

eria

l-Su

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ish/

Vis

ual /

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iew

IS

: 28

30D

oc. N

o.: Q

S/Q

A/B

3/00

bille

tC

hem

ical

of B

illet

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tific

ate

IS :

2062

com

posi

tion

2A.

Ang

les,

Cha

nnel

, Su

rfac

e Fi

nish

/ V

isua

l / M

easu

rem

ent

IS :

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, IS

: 185

2D

oc. N

o : Q

S/Q

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1/00

Jois

tD

imen

sion

2B.

Do

Stan

dard

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ght p

er m

eter

leng

th b

yIS

: 80

8

wei

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el

ectr

onic

bal

ance

2C.

Do

Mat

eria

l com

posi

tion

Che

mic

al A

naly

sts

IS :

2062

Doc

. No

: QS/

QA

/G1/

00

2DD

oM

echa

nica

lTe

nsile

test

ing

Y

.S, U

TS,

IS :

2062

Doc

. No

: QS/

QA

/G1/

00

prop

ertie

s%

Elo

ng &

Ben

ding

2ED

oId

entif

icat

ion

&V

isua

lEa

ch b

undl

e of

item

Doc

. No

: QS/

QA

/G1/

00

Mar

king

mus

t hav

e m

etal

tag

indi

catin

g Lo

t no,

grad

er, s

ize,

spec

ifica

tion

No.

,

Man

ufac

ture

r N

ame.

Prep

ared

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Issu

ed b

yA

ppro

ved

by

GM

- Q

.A.

Man

agin

g D

irec

tor

Prof

esso

r

S. D

asgu

pta

P. B

eriw

ala

Dr.

T.K

. Pal

SSIL

SSIL

JU, K

olka

ta

25

Qua

lity

Ass

uran

ce P

lan

for

Stru

ctur

al S

ectio

n (R

ound

, Squ

are

bar

and

Flat

)

Sl.

Type

of P

rodu

cts

Cha

ract

eris

tics

Type

of I

nspe

ctio

nA

ccep

tanc

eFo

rmat

of

No.

Ope

ratio

nch

ecke

dTe

stin

gno

rms

Rec

ord

1.

Raw

mat

eria

l-Su

rfac

e fin

ish/

Vis

ual /

Rev

iew

IS

: 28

30D

oc. N

o.: Q

S/Q

A/B

3/00

bille

tC

hem

ical

of B

illet

Cer

tific

ate

IS :

2062

com

posi

tion

2A.

Rou

nd, S

quar

e

Surf

ace

Fini

sh/

Vis

ual /

Mea

sure

men

tIS

: 20

62, I

S : 1

148

Doc

. No

: QS/

QA

/G1/

00

bar

and

Flat

Dim

ensi

on

2B.

Do

Stan

dard

Wei

ght p

er m

eter

leng

th b

yIS

: 17

30, I

S : 1

732

wei

ght

el

ectr

onic

bal

ance

2C.

Do

Mat

eria

l com

posi

tion

Che

mic

al A

naly

sts

IS :

2062

Doc

. No

: QS/

QA

/G1/

00

2DD

oM

echa

nica

l pro

perti

esTe

nsile

test

ing

Y

.S, U

TS,

IS :

2062

Doc

. No

: QS/

QA

/G1/

00

% E

long

& B

endi

ng

2ED

oId

entif

icat

ion

&V

isua

lEa

ch b

undl

e of

item

Doc

. No

: QS/

QA

/G1/

00

Mar

king

mus

t hav

e m

etal

tag

indi

catin

g Lo

t no,

grad

er, s

ize,

spec

ifica

tion

No.

,

Man

ufac

ture

r N

ame.

Prep

ared

by

Issu

ed b

yA

ppro

ved

by

GM

- Q

.A.

Man

agin

g D

irec

tor

Prof

esso

r

S. D

asgu

pta

P. B

eriw

ala

Dr.

T.K

. Pal

SSIL

SSIL

JU, K

olka

ta

26

Responsibility MatrixShyam Steel Industries Ltd Quality System Manual IOCL NO. # 5.5

DOC. NO. #QSM/ SSIL /5.5/00

Title: Management Responsibility Authority & Communication Page: A5

Legend DR - Direct ResponsibilityCR - Contributory Responsibility

Approved by : CMD Issued by : MR Issue : # 01Issue Date : 15.10.05

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 -

27

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

28

Product Realisation Process and Interaction

Cus

tom

er R

equi

rem

ent

Management Responsibility

Resource Management

Marketing

Manufacturing

Quality Assurance Purchase Store

Control of document Control of

& record NC product

Corrective & Analysis

Preventive action of Data

Prod

uct r

equi

rem

ent

Req

uire

men

t bas

ed o

n pu

rcha

se o

rder

(if a

ny)

Custom

er Satisfaction

General feedback report

Product feedback reporC

ustomer com

plaintC

ustomer visit report

29

Control of Non-conforming ProductProducts 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

30

Shyam Steel Industries LimitedAngadpur, Durgapur, West Bengal

Inspection Check list for an Integrated Steel Plant

1. Inspection of manufacturing Process flow chart from basic raw material to finish product (DRI EAF

CCM RM TMT Plant) including technical specification.

2. Checking of approved QAP & inspection of Quality Control Process flow chart from raw material to finish

product.

3. Inspection of Steel Billets and their certification from Bureau of Indian Standard.

4. Inspection of finish product such as TMT Re-bars and their certification from Bureau of Indian Standard.

5. Inspection of Identification mark at every stage of Quality Control and stockyard.

6. Inspection of Laboratory and testing facilities available in Lab. Calibration certificates verification of testing

equipments.

7. Checking of certificates, Licenses and quality control documents.

8. Verification of supply of material at nationally important infrastructural projects.

9. Details of new product development and development reports.

10. Witnessing of sample testing in the Laboratory.

11. Verification of quality assurance system documents,

12. Sign off all inspection reports.

Prepared by Issued by Approved by

GM- Q.A. Chairman cum M.D. ProfessorS. Dasgupta S. S. Beriwala Dr. T. K. Pal

SSIL SSIL Metallurgical Dept.

J. U. Kolkata

31

Lab and Test EquipmentsSl.No. Name of Equipment Make Range/L.C Idft. no. Status of

Calibration no.

1. Universal testing Krystal Elmec 1000.0 KN, 0.2 KN, UT/01 Yes

Machine 0.5 KN, 1.0 KN & 2 KN

2. Microscope Apollo 10x, 15x MS/01 Not Required

3. Spectrometer Spectro Analysis Module for Spectro/01 Yes

Analytical Fe with Low Alloy, Cast

Instrument Iron, Stainless Steel &

Gmbh & Co. Kg Manganese Steel

4. Impact type portable Dietmar System, Scale - HV, HB, PH/01 Yes

hardness tester Khedekar Sadan, HRB, HRC, HSD

Killa Miraj

5. Double pan balance Rohtar 0-5000 gm./1 gm. DPB/01 Yes

6. A set of weight range A.Bhatta & Co 0.030-100 gm./0.03 gm. W/01 Yes

7. Mandrel for bend & Blue Star 6-32 mm SSIL Not Required

rebend test

8. Strohlein apparatus Banner & Co. 1.5c.c burr at SP Yes

i) Tube furnace 0-1350c

ii) Auto transformer

9. Muffle furnace with A.Bhatta & Co 0-1200c MF/01 Yes

temp. control box.

Size: (1200x1200x2700) mm

10. Hot Plate (Size:275mmx125mm) A.Bhatti & co HP/01 Not Required

11. Chain-o-matic balance Kercy & co 200gm/0.001 CB/01 Yes

12. Fortein barometer Banner & Co. Max.635mm of hg. FB/01 Yes

13. Vernier caliper Mitutoyo 0-200mm/0.02mm VC/01 Yes

14. Vernier caliper Mitutoyo 0-300mm/0.02mm VC/02 Yes

15. Outside micrometer Mitutoyo 0-25mm/0.01mm M/01 Yes

16. Steel scale Kristeel 0-1000mm/0.5mm SC/01 Yes

17. Steel scale Kristeel 0-300mm/0.5mm SC/02 Yes

18. Steel tape Freemans 0-3000mm/1mm ST/01 Yes

19. Radius gauge Mitutoyo 0-7mm/0.25mm RG/01 Yes

20. Spring caliper Kristeel 150mm SPC/01 Not Required

21. Sample polishing machine A.Bhatta & Co PC/01 Not Required

32

Manufacturing and Testing Codes & Standards

Details of different Codes and Standards of rolling product for various

requirements are as follows:

A. Raw Material

IS 2830/1992 : Carbon steel cast billet, ingots, blooms and slabs for rerolling into steel for general

structural purpose.

IS 2831/2001 : Carbon steel cast billet, ingots, blooms and slabs for rerolling into low Tensile Structural

steel for general structural purpose.

IS 10812/1992 : Specification for Sponge iron.

B. TMT Re-Bars / HYSD Bars

IS 1786 / 2008 (Fe 415 / Fe 415D / Fe 500 / Fe 500D /Fe 550 / Fe 550D / Fe 600):

Specifications for High Strength Deformed Steel Bars (TMT Bars) & Wires for concrete re-enforcements.

C. Angle, Channel, Flat, Bar & Structural Steel Section.

IS 2062 / 2006 : Hot Rolled Low, Medium and High Tensile Structural Steel.

D. Door, Window & Ventilator Section

IS 7452 / 90 : Specification for hot rolled steel sections for doors, windows and ventilations.

E. Dimension and Testing Codes & Standards

IS 228 / 87 : Method for chemical analysis of steels.

IS 808 /1989 : Specification for Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle

Sections.

IS 1599 / 85 : Method for Bend Test.

IS 1608 / 2005 : Specification for Mechanical testing of metals.

IS 1730 / 89 : Steel Plates, Sheets, Strips and flats for Structural and general Engineering purpose.

IS 1731 / 71 : Dimensions for steel flats for structural & General Engineering purpose.

IS 1732 / 89 : Dimensions for round and square steel bars for Structural purpose.

IS 1852 / 85 : Specification for Rolling & cutting tolerances for hot-rolled steel products.

Shyam Steel Industries LtdShyam Towers, EN 32, Sector V, Salt Lake, Kolkata 700091

Tel +91 33 4007 4007 Fax +91 33 4007 4010

www.shyamsteel.com

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