End of co-op presentation

1. Co-op Experience – Spring/Summer 2015
David Pearson
18 September 2015

2. 2
About Me
• School: Drexel University - Materials Science and
Engineering
• Position: Metallurgical Engineering Co-op, Quality
Department
• Future plans: United States Army Reserve, Grad. School

3. Projects
3
Gray Red
• Load bank quality audit
• Handheld scanners implementation
• Scale color analysis
• Cut-to-length flatness analysis (light-gauge carbon
coils)
• Thermal image data collection

4. Load Bank Quality Audit
Problem:
•Nonconforming material being sent to load bank (LB) and
shipped to customers
– Losing customers for poor quality (Trinity)
– Change of company culture and mindset over time
– Quality issues on LB: cut corners, test knotches, improper
skidding, out-of-flatness, grease/rust/debris, fins, camber,
surface defects
Goals:
• Restore company culture: zero tolerance policy for shipping
defective material
•Remove all defective material from LB
•Ensure that all material coming to load bank is of good quality
4

5. Load Bank Quality Audit
Early June, 2015 – scanned LB1 and LB2 for quality violations
• Identified over 60 transfers with plates having cut corners, test
knotches, improper skidding, out-of-flatness, grease/rust/debris,
fins, camber, surface defects
•Placed each affected piece on ‘hold’
•Communicated with supervisors to have pieces transferred from
LB and corrected
September 10, 2015
All nonconforming material previously on LB:
1. Removed from load bank and sent to correction operation
2. Already corrected & returned to load bank (released)
5

6. Handheld Scanners Implementation
• Problem: no locations assigned to transfers going to the load
bank – time spent looking for transfers  increased delinquency
– Material lost
– Plates rejected
• Goals:
– Continue where previous intern left off
– Train load bank personnel how to use the handheld scanners
– Track progress of amount of scanned material going to the
load bank
– Ensure that all load bank personnel are using the scanners
regularly before the inventory audit
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7. Handheld Scanners Implementation
• For a month, trained material movers and crane operators how
to use handheld scanners to assign locations to transfers going
to the load bank
• Current status: all shipping personnel trained and regularly
using handheld scanners
– No way of knowing the workers who do not scan material,
only the workers who do scan material
• Future: tie handheld location updates / ‘scanned’ or ‘not
scanned’ / ‘scanned by’ into Access to determine who is and is
not scanning transfers going to LB
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8. Handheld Scanners Implementation
8

9. Handheld Scanners Implementation
•Future:
– handheld location updates
– ‘scanned’ or ‘not scanned’
– ‘scanned by’
reported into Access to determine who is and is not scanning
transfers going to LB
9

10. 10
Scale Color Analysis
Problems
1. Plate-to-plate color variation not appealing to
customer
2. Red scale harder to remove by customer than
grey scale (Meritor complaint)
3. Some plates have both red and grey scale
traces
• Customer more willing to accept material
with uniform surface appearance

11. 11
Scale Color Analysis
Red vs. Grey Scale

12. 12
Scale Color Analysis
Goals
1. Continue analyzing scale color data where
Jen (previous Intern) left off – quantify color
2. Research instrumentation to determine color
rather than assigning a ‘Yes’ for Red and ‘No’
for Grey

13. Scale Color Measurement
13
PCE Instruments:
NR20XE Spectrophotometer

14. 14
Scale Color Analysis Results
• Analyzed over 25
variables
• Correlation b/w redness
and Si content / finish
surface temperature at
Steckel mill relatively
strong
• As %Si and surface
temperature increase,
amount of red scale
increases

15. 15
Scale Color Analysis
Proposed mechanism (research-supported)
• Si-containing steels form Fayalite (Fe2SiO4)
upon heating
• Fayalite penetrates surface to form a
mechanical key = difficult to remove
• Fayalite oxidizes and turns red
• Result: difficult-to-remove red scale
“Mechanism of Red Scale Defect Formation in Si-Added Hot-rolled Steel
Sheets” – Tomoki Fukagawa, Hikaru Okada, Yasuhiro Maehara - 1994

16. CTL Flatness Improvements
(Light Gauge Carbon)
– Problem:
• Flatness issues at cut-to-length (CTL)
line
– Money wasted sending carbon
grades to be levelled (high NSEP)
– High claim rate from customers
due to flatness (Fisher Tank)
– Goals:
• Monitor flatness of carbon coils for
different gauges and MPS
– Focus on 0.1875” and 0.25”
• Determine which variables have
greatest effect on flatness
16

17. Corrective Actions
• Side shear the light gauge carbon coils
– Mill started to provide wider coils to be sheared at CTL
• Work on improved settings at the CTL
– More aggressive sheet leveler settings
• Monitor coil quality from the mill (‘displacement’ measurement)
Copyright © ArcelorMittal 06/20/16 17

18. CTL Flatness Data Analysis
18
Before 5/4/2015
Qty Qty
ME CE Total ME CE
Level Good Level Good Level Good Level Good
0.1875 1041 493 142 498 2174 0.1875 67.9% 32.1% 22.2% 77.8%
6 mil 25 69 94 6 mil 26.6% 73.4%
0.25 861 2635 125 1399 5020 0.25 24.6% 75.4% 8.2% 91.8%
7 mil 134 270 404 7 mil 33.2% 66.8%
0.312 145 1285 1 254 1685 0.312 10.1% 89.9% 0.4% 99.6%
9 mil 58 58 9 mil 0.0% 100.0%
0.375 57 263 320 0.375 0.0% 100.0% 0.0% 100.0%
Total 2206 4867 268 2414 9755 Total 31.2% 68.8% 10.0% 90.0%

19. CTL Flatness Data Analysis
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After
Qty Qty
ME CE Total ME CE
Level Good Level Good Level Good Level Good
0.1875 346 626 210 974 2156 0.1875 35.60% 64.40% 17.74% 82.26%
0.25 166 923 48 1373 2510 0.25 15.24% 84.76% 3.38% 96.62%
7 mil 2 198 200 7 mil 1.00% 99.00%
0.312 42 493 164 699 0.312 7.85% 92.15% 0.00% 100.00%
0.375 1 457 26 484 0.375 0.22% 99.78% 0.00% 100.00%
Total 557 2697 258 2537 6049 Total 17.12% 82.88% 9.23% 90.77%
5/4/2015

20. Effect of Sideshearing – 0.1875”
• For 0.1875” gauge: 32% to 64%
20

21. Coil Quality Measurement
• Analyzed over 300 carbon coils
21

22. Effect of changing CTL Settings– 0.1875” (least
to most aggressive settings)
22*Note: date 7/6/15 to 7/18/15  2 weeks of more aggressive settings at CTL
0.1875"
121 + 91-120 0-90
256 15 20
33% 15% 54%
526 83 17
67% 85% 46%
Sht. Lev. Entry Settings
Out-of-flat
Flat

23. Effect of changing CTL Settings– 0.1875”
23*Note: date 7/6/15 to 7/18/15  2 weeks of more aggressive settings at CTL
• For 0.1875” gauge – 65% to 85%

24. Flatness Data Analysis (Minitab)
Y variable:
–Flatness (Y or N)
• Y – flat
• N – out-of-flat
24
X variables:
–Entry/exit settings of
• Straightener
• Plate Leveler
• Sheet Leveler
–Backup rolls
–Wrap displacement
(coil quality)

25. Thermal Image Data Collection
Problem
•Mill rejections for cold ends, mixed-gauge, rolled-in scale
Goals
•Run trials to determine if an IR camera can be a useful tool to
have permanently at the mill
– Ability to detect non-uniformities in temperature and scale on
the surface of plates being milled
25

26. Thermal Image Data Collection
Description:
•Took images and videos with FLIR T640 IR camera of:
1. Slabs coming out of the furnace and going into Roughing
Mill
• Quantified amount of scale remaining on slabs after descale
1. Plates coming out of Roughing Mill and going into Steckel
Mill
• Characterized non-uniformities in temperature on plate surface
• Cold streaks, cold ends, water on plates
•Stood on catwalk and on platform near heat deflectors
26

27. Thermal Image Data Collection
27
FLIR T640 IR Camera

28. Thermal Image Data Collection
• Observed over 100 slabs from furnace to Roughing Mill for
amount of scale remaining after descale box
– Found that nearly 70% of slabs still had scale heading into
RM
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29. Thermal Image Data Collection
• Observed over 200 plates from Roughing Mill to Steckel Mill
• Characterized plates by non-uniformities in temperature
– Cold ends, cold streaks
29

30. Thermal Image Data Collection (Video)
30

31. Ideas for Future Work
• Use data captured with IR camera and correlate:
– Scale going into the mill with rolled-in scale rejections
– Non-uniformities in plate temperature with rejections for cold
ends or mixed gauge
• Consider if it would be beneficial to have camera mounted
permanently at mill – operators could stop if they notice cold
ends, etc.
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32. Questions?
32