c




c


c

c

      !  ! "   #  $ %
"%& !& '
(() ' % *

  !'+
From 8th November 2003 to 21st November 2003
Duration: Fourteen days.

 º!, +
Salem Steel Plant (SAIL)
Salem ± 636013
Tamil Nadu
India.
Phone: 0427 ± 2482490

 %! - +

Salem steel Plant, Steel Authority of India Limited (A Government of India
Enterprise)

  +
Trainee in Quality Assurance Engineer

c

. c/º
+

I did my Bachelor of Mechanical Engineering from Coimbatore Institute of

Technology (CIT), Coimbatore, an autonomous institution affiliated to Anna University in
first class. Salem steel Plant one of the group companies of SAIL, India, it was my First
 industry in my career. It is producing Sheet Metals. The company has various departments
like Human Resource, Engineering, Production Planning, Purchase, Manufacturing, Quality
Assurance, Finance and Marketing. I started my work as a Quality Assurance engineer. The
company has a huge range of technical book collection which have all the details of various
manufacturing system used in the steel manufacturing process.

c

+.0c12345
/

The principal objectives at Salem Steel Plant were,

 To ensure that the final product produced has no defects.

 To ensure the quality of the component after every operation.
 Responsible for calibration of measuring instruments as per the time frame.
 To document and analyse all the inspection data obtained.
 To train the quality inspection operator in using the instruments for
measuring.
 To coordinate with the customers in his inspection.

c


+6 
2345
/
 6c3 4
34
6c3 4

The nature of my work area in the Quality Assurance department of the company were,

 Initially I learned in detail about the processes in manufacturing line & details of the
machines used for production.
 My job was to ensure the quality of the manufactured product at every stage of
production.
 My job was to review and authorize the Quality control charts for the process on daily
basis.
  My responsibility was to analyse the causes for rejection of the components produced.
Take corrective actions for the causes identified.
 My duty was to ensure that the machine operators are aware of the quality issues.
 My job was to use Quality instruments like Roundness tester, Surface roughness tester,
Coordinate Measuring Machine (CMM) etc., to measure the components.
 My duty was to get trained in the Quality inspection operators in measuring the
components and then to report the management of day-to-day activity.

c

)+
º   ,
c
6º6,º6º34+


 3 ! !
 



 
 






6
 1  7&' 1  &  1  2   1 

6
3 ! 7   7 3 ! 3    3# ! 2  
3 ! 3 ! 3 ! 3 !




   
 !   !  &  & 
 !     ! 3 !
8%' 9 
3 !



   


  
c

:+º
,
º
1.46c3 4+

ð A thorough overview about Salem Steel Plant.

ð Terms and conditions of the company.
ð Introduction to the higher officials in the company.
ð The basic understanding about the products manufactured in the company.
ð Îob responsibility of various departments.
ð Company quality policy and dedications.
ð Quality system in general.
ð Understanding all the operational processes and applications of the products.

c
)
 ,5
/, c c14

During the period of my work as trainee in Quality Assurance engineer, I was initially
with the production engineers to get familiar with the manufacturing operations and the issues in
the various operations affecting the quality. Since we manufacture higher grade Metal sheets, the
quantity of metal sheets produced will be always in mass production. So every time we will be
getting new thickness of the sheet metal that had to be produced. I was mainly engaged in
studying the thickness and quality of output obtained and prepares a Quality plan for the
inspection of components. In case of difficulty in measuring certain dimensions, I used to get
advice from our Managers about the alternate methods to measure those dimensions that meet
their requirements.

c
)+c6c , ,2345
/
At Salem Steel Plant as a Trainee in Quality Assurance engineer, I was dealing with all
the rolled sheet Metals. I was responsible for the performing inspection activity and delivering
the components in the committed time. I was also responsible for the correctness of the measured
values and answerable to my manager in case the values measured in-house does not match with
those measured at our customers end.
The various specialized quality measuring equipments that I am responsible of and also train
operators in its usage are as follows:
 Roundness Tester (Talyrond)
 Surtronic
 CMM


c
)
+ ,c 2º
º/5,º /,,
Since I have learned about Quality Assurance, I had a general view of how quality
system works. In Salem Steel Plant I made use of my Knowledge in using the specialized quality
equipments. Since, the components manufactured ranged, the method of measurement varied for
every dimension. I also used First principle method to measure most of the dimensions. Only
those dimensions which consumed more time to measure using first principle method were
measured using specialized equipments.

c
))+ / ,,3
There were a lot of tasks performed at Salem Steel Plant as I mentioned earlier. When I
joined the company, they had only Surtronic which is used to measure profiles in the
components. All the dimensions were measured using height gauge, Vernier caliper, Screw
gauge, slip gauges etc., For those dimensions that they found difficult to measure, they took the
components to other metrology labs for measuring. This cost a lot and also the measurement time
was very huge. So, company decided to buy Talyrond and CMM. I was asked to take
responsibility of getting the equipments fixed. The equipment suppliers installed the equipments
and gave training in the use of the equipments. I was very easy for me to understand the
procedure of measurement. I created programs for measuring the components so that it will be
easy for others to just run the programs to measure the dimensions. This also helped to eliminate
the errors in measurement while measured by the operator. This task saved a lot of time in
measurement and also gave the flexibility to measure the components as per our requirements.
The other important task that I performed was preparation of Quality control charts.
Since, quality control charts are the base document used to ensure the product quality I took
immense care in preparing them. For measuring certain dimensions, there is more than one
method. I measured using all those methods to know which method is more efficient, easy to
measure, reliable and identified the method that has a good repeatability. Then the quality plans
were sent to the customers for their approval and their comments. Then the customers sent the
quality plans approved. This was used as our base document for inspection. This was one of my
major tasks because we have a variety of components.

c
):+5
/º1
3
I was working with planning and production engineers. Whenever a problem arises I
had a brain storming with other engineers and gathered ideas. I also discussed about the quality
issues with the machine operators because they have a good knowledge about their machine and
process. This gave me an opportunity to nurture me well in the team. All the engineers have
meeting about the issues every day. We will take responsibility to solve certain issues.

c
:33
4

The position of Trainee in Quality Assurance Engineer at Salem Steel Plant gave me a
lot of experience in handling the Quality instruments for measuring a variety of components,
calibrating the quality instruments, understanding of processes in the manufacturing line, setting
quality standards based on requirements, dealing with our customers etc., Working with erudite
professionals and other engineers provided me to gain a wide knowledge in the field of
Engineering. My communication with the senior officials gave me the best industrial exposure. I
was very much satisfied with my work duties and tried to learn as much as possible and always
delivered outputs to my level best.