Improvements never stop at Quad. The success of Version 10.4 brought upon new changes and further enhancements than ever before predominantly for QMOS’s QC functionalities.
In previous versions of QMOS, there is no distinction between a QC Hold Code and other manual Hold Codes at the heat level. Meaning, if a melt heat was placed on ‘Hold’ for chemistry reasons, the heat’s disposition could be changed to ‘Prime’ while the billets remained on ‘Hold’. To resolve this, the user would have to manually change the disposition of the Billets and this was deemed as an unnecessary step. Furthermore, since distinctions between the QC Hold Codes and other manual Hold Codes at the Billet level were not in place, operators could have changed the disposition of the melt heat to ‘Prime’ without the QC departments knowledge and approval.
Version 10.5 has remedied these deficiencies by clearly making a distinction between manual Hold Codes input by operators and QMOS generated Hold Codes that are automatically assigned. If the chemistry of a given melt heat fails, QMOS automatically places all billets of that melt heat on ‘Hold’ as well. Subsequently, if the user wants to Force Pass the failure they are permitted to do so. However, the Billets of a melt heat on ‘Hold’ for chemistry failure cannot be assigned to a Rolling Mill work order without a supervisor Force Passing that Heat. Hence, the option of manually removing the Hold Code from billet inventory without QC department’s knowledge is no longer an issue.
Supervisory Force Pass of a Heat having failed because of chemistry, allows the Billets of that melt heat to be assigned to any Rolling Mill order based on the filters specified on the Assign screen. The Heat number is distinctively displayed, making it easier for anyone to identifying the Force Pass.
Another functionality which is unique to version 10.5 is the ability to see Physical and Mechanical test results against a previously rolled heat. Warning flags are given indicating that some billets of the selected melt heat have been rolled and there are results recorded against them. Furthermore, the billets rolled against the mill heat along with their respective test results are immediately available for review. Allowing the user to see previously recorded test results against the melt heat at the time of assignment provides the user with tools for better judgment, analysis and decision making. Operators can forecast whether the Physical and Mechanical properties of the finished good they are trying to meet will be satisfied or not.
Finally, another design unique to version 10.5 is calculation and evaluation of specifications at the melt heat level. As opposed to previous versions, where a specification is defined at the order level, the new version gives the ability to define the specifications at an individual melt heat level depending on the chemistry composition of their scrap content. Some mills have different specifications for their chemistry elements based on the Chromium content of their first furnace sample. QMOS has allowed for on-the-fly calculation of the specifications upon receiving the very first furnace sample. The user also has the ability to use the latter sample to drive this calculation.