ROOT CAUSE OF MILL DEFECTS AND ITS REMEDIES

GUIDED BY:Mr. I Mukherjee (AGM) Mr. S.K. Malik (Ast. Mgr) Mr. Rajeev Ganer (Ast.
Mgr)
Presented By:
Soumyo Broto Das (4687) U.S. N Raju (4691) Sushil Kumar Patel (4688) Nitesh Chan
d (4692)

6th Batch
Group R2

What is Quality ?

Quality in business, engineering and manufacturing has a interpretation as the n

on-inferiority or superiority of something. Quality is a perceptual, conditional
and somewhat subjective attribute and may be understood differently by differen
t people. Quality may be defined as the products fitness for consumption/use.

Definition of Quality!
Definitions The common element of the business definitions is that the quality
of a product or service refers to the perception of the degree to which the prod
uct or service meets the customer's expectations. Quality has no specific meanin
g unless related to a specific function and/or object. Quality is a perceptual,
conditional and somewhat subjective attribute.

Quality from Customer point of view

Customer may focus on the specification quality of a product/service, or how it
compares to competitors in the marketplace.

Quality from Manufacturer point of view

Manufacturer might measure the conformance quality, or degree to which the produ
ct/service was produced correctly.
Quality Mantra Right specifications, Right Time, Right Price

Customers Needs
Stated Implied Design as per customers requirements
Manufacturing Supply
On right Time
Of right specifications
At right Price
EVERY TIME - FIRST TIME

Definition of Customer Customer is one who uses our product or services

Types of Customer 1.Internal Customer Next User 1.Intermediate Customer Next dep
t/Other plant/sister concern 1.External Customer End User
To satisfy all these customers is our first & foremost objective

Packing & Dispatch

CUSTOMER
Quality Control
Marketing
Production
Quality Loop
Technical Support
Store
Marketing
Purchase
Design /Engineering

Customer Process Route.

CUSTOMER
Drawing
Forging
Cold Forging
Machining
Heat Treatment

JNIL Process Chart

PINCH ROLL
GCPR-1 GARRET COILER-1
GCPR-2 GARRET COILER-2
SLAT CONVEYOR TRANSFER DEVICE SLAT CONVEYOR CAPSTAN SHIPING YARD

Defects Undesirable By Customer

Fins Laps Roughness Seams Dent Scratches Stick Scales Fire Cracks Transfer Marks
Roll Marks Surface Decarburation
Dimensional Problem
Forging Problem

Upset Problem

Poor Surface Finish

Deterioration in Mechanical Properties

FINS
Fins are narrow beads running longitudinally. Occurrence : Several fins uniforml
y distributed at the periphery of the wire rod can be caused if the finishing pa
ss is overfilled because of improper roll adjustment. When material is rolled in
multi stand continuous mills, fins can not be avoided at the ends of the coil b
ecause of the tension effect. Root Cause of Fins Over filling because of imprope
r roll adjustment.

Detection Of Fins Fins can easily be detected by naked eyes generally.

LAPS

This type of defect occurs when a corner or fin is folded over and rolled but no
t welded into the metal. They appear across the surface of the metal. Root Cause
Pass overfilling is the most frequent cause of laps, when material which is for
ced out into the roll gap folds over and is rolled into the rod surface during s
ubsequent passes. Passes are overfilled when too large reduction is attempted or
the wrong pass design is used.
Detection Of Laps
Generally Laps can easily be detected by naked eyes. Laps can u
sually be distinguished from cracks by the typical configuration and arrangement
of the defect, such as parallel double lines or discontinuities in the material
distributed uniformly over the section and following the circumference.

ROUGHNESS

Continuously recurring, irregular depressions and elevations on the surface of w

ire rod are known as roughness. Root Cause A rough wire rod surface is usually c
aused by severe roll groove wear, particularly in the last two forming stands. S
urface roughness can also caused by corrosion if the rod stored for lengthy peri
ods in a damp or corrosive atmosphere.

Detection Of Roughness
Generally Roughness can easily be detected by naked eyes. Further roughness can al
so be detected under microscopic test. Roughness can also felt and observed, if n
aked hand is gently rubbed over the surface of the wire rod.

SCALE

Scale is the oxide layer on the surface of wire rod. This oxide layer of varying
thickness and colouring may cling loosely or adhere firmly. It can have an adve
rse effect if its condition or constitution is unsuitable for the further proces
sing of the rod and if it adheres so tightly to the base material that it is dif
ficult to remove. The constitution and thickness of the oxide layer (layer of sc
ale) depend on temperature and the rate of cooling.
Root Cause

Detection Of Scale
Thickness and constitution of the scale and thus the suitability of the material
for further processing can be established by pickling and bend tests, by weighi
ng before and after descaling and by microexamination.

SCRATCHES
Scratches are furrow-like depressions which always run longitudinally. The form
and the size of the scratches vary considerably according to the source of the d
efect. Scratches are mechanical marks occurred during Rolling. Root Cause
Scratc
hes are caused by scoring of the stock by sharp or pointed objects. The defect m
ay, for instance, be caused by the uneven surface of guide parts on which scale
or particles of the rolled product have built up.

Detection Of Scratches
Scratches ca be detected with the naked eyes or with low magnification, even in
the scaled condition, though more easily in the descaled state. Unlike laps, scr
atches seldom opens up during upsetting test.

ROLL MARKS
Roll marks are embossed elevations or depressions usually recurring periodically a
nd varying greatly in shape and size
Root Cause
Roll marks occurs due to depressions of various kinds in the rolls themselves or
in the pinch rolls.
Detection Of Roughness
The defects can usually be detected with naked eyes or with a low magnification
on the scaled or descaled specimen.

Rolled in matter in guide roller Roll mark defects

Mark from upper roller
Mark from lower roller

FIRE CRACK TRANSFER MARKS

Fire Crack transfer marks are patterns of elevations that recur periodically and
run at right angles to the direction of rolling.
Root Cause
During hot rolling, surface of the roll is continuously heating and quenching &
because of this cracks occurs on surface of hot metal. Detection Because of thei
r characteristic form, fire crack transfer marks can easily be detected with the
naked eye or with a low magnification.

SEAMS
These are the discontinuous scratches occurred due to non metallic inclusion emb
edded in steel.
Root Cause

During the production processes, the stock comes into contact with metallic and
non-metallic materials. Parts of the surface regions of the stock. Sometimes, me
tallic foreign bodies can become welded to the stock. These defects may also be
caused by parts of guides which come loose or are broken or torn off.
Detection
Seams can be detected with naked eye or with a low magnification. Micro-examinat
ion or chemical analysis of the foreign body will indicated the origin of the de
fect.

SURFACE DECARBURATION

Surface Decarburisation is a loss of carbon, on furnace due to interaction with

the gases in the reheating furnace. Decarburization is the decrease of the carbo
n content of (the surface of) a steel due to interactions with the environment a
t elevated temperatures. Carbon has a large influence on the mechanical properti
es of the steel. The decreasing carbon content causes a degradation of these pro
perties, as the hardness as well as the strength decrease.

SURFACE DECARBURATION
Root Cause
If the steel is heated for too long period at a high temperature or if there is
only a slight reaction between the furnace atmosphere and the iron itself but a
distinct reaction with carbon, there is a loss of carbon in the surface region o
f the rolled product. Slight reaction between the oxidizing furnace atmosphere.
Detection This defect can be observed under microscope.