The "SOP Manual for Rolled Steel Shape Manufacturing" generates substantial returns in the steel manufacturing industry. Firstly, it establishes standardized operating procedures for various stages of production, such as rolling, shaping, quality control, and safety protocols. This ensures consistency, efficiency, and high-quality output in the manufacturing process.

Employee training becomes a key benefit, as the SOP manual equips workers with the necessary skills, knowledge, and safety practices, fostering a skilled and competent workforce. This enhances overall productivity and reduces the risk of accidents.

The manual contributes to risk management by addressing safety measures, equipment handling guidelines, and compliance with industry regulations. It also aids in quality assurance, minimizing errors and deviations in the production of rolled steel shapes.

Ultimately, the "SOP Manual for Rolled Steel Shape Manufacturing" yields returns in the form of improved operational efficiency, employee competency, safety compliance, and consistent high-quality steel products, positioning the manufacturing facility for success in a competitive market.

CLICK HERE to download the List of SOPs Document in PDF format. Please share this document with your clients, colleagues and senior officers.

Top 50 Standard Operating Procedures (SOPs) for Rolled Steel Shape Manufacturing

SOP-125-001: Standard Operating Procedure for Equipment Inspection and Maintenance
SOP-125-002: Standard Operating Procedure for Raw Material Handling
SOP-125-003: Standard Operating Procedure for Steel Cutting and Shearing
SOP-125-004: Standard Operating Procedure for Steel Bending and Forming
SOP-125-005: Standard Operating Procedure for Welding and Fabrication
SOP-125-006: Standard Operating Procedure for Heat Treatment of Steel
SOP-125-007: Standard Operating Procedure for Dimensional Inspection
SOP-125-008: Standard Operating Procedure for Surface Treatment and Coating
SOP-125-009: Standard Operating Procedure for Quality Control in Manufacturing
SOP-125-010: Standard Operating Procedure for Material Traceability

SOP-125-011: Standard Operating Procedure for Roll Forming Operations
SOP-125-012: Standard Operating Procedure for Straightening and Cutting
SOP-125-013: Standard Operating Procedure for End Forming and Hole Punching
SOP-125-014: Standard Operating Procedure for Non-Destructive Testing
SOP-125-015: Standard Operating Procedure for Packaging and Shipment
SOP-125-016: Standard Operating Procedure for Inventory Management
SOP-125-017: Standard Operating Procedure for Machine Setup and Calibration
SOP-125-018: Standard Operating Procedure for Operator Training and Certification
SOP-125-019: Standard Operating Procedure for Emergency Response and Evacuation
SOP-125-020: Standard Operating Procedure for Environmental Management

SOP-125-021: Standard Operating Procedure for Hazardous Material Handling
SOP-125-022: Standard Operating Procedure for Tooling Maintenance
SOP-125-023: Standard Operating Procedure for Noise Control Measures
SOP-125-024: Standard Operating Procedure for Energy Conservation
SOP-125-025: Standard Operating Procedure for Production Scheduling
SOP-125-026: Standard Operating Procedure for Scrap and Waste Management
SOP-125-027: Standard Operating Procedure for Equipment Calibration
SOP-125-028: Standard Operating Procedure for Material Inspection and Acceptance
SOP-125-029: Standard Operating Procedure for Safety Data Sheet Management
SOP-125-030: Standard Operating Procedure for Welding Procedure Qualification

SOP-125-031: Standard Operating Procedure for Hydraulic Press Operation
SOP-125-032: Standard Operating Procedure for CNC Machining
SOP-125-033: Standard Operating Procedure for Robotic Automation in Manufacturing
SOP-125-034: Standard Operating Procedure for Lubrication and Maintenance
SOP-125-035: Standard Operating Procedure for Employee Health and Safety
SOP-125-036: Standard Operating Procedure for Equipment Troubleshooting
SOP-125-037: Standard Operating Procedure for Waste Water Management
SOP-125-038: Standard Operating Procedure for Fire Prevention and Control
SOP-125-039: Standard Operating Procedure for Material Handling Equipment
SOP-125-040: Standard Operating Procedure for Production Reporting

    

SOP ToolBox: If you are reading these lines, I am sure you are looking for Standard Operating Procedure guidelines or SOPs itself. In both the cases, searching in internet will not be yielding any great help. Because no company shares their SOP Development Process and certainly don’t share their SOP Documents. The best way to develop an SOP is creating one for yourself. At Fhyzics, we write SOPs day-in and day-out for companies across the globe including some of the Fortune 500 organisations. Our charge ranges from USD 5000 to USD 50000 depending upon the number of processes to be covered. Certainly, this is not affordable to small and mid-size organisations. Hence, we decided to create this SOP ToolBox to disseminate our 8-Step SOP Development Life-Cycle and best practices at an unbelievably low price.

I always say, writing an SOP is somewhere between art and science. So far you may be clueless on where to start and how to progress on an SOP? This will not be the case after you diligently go through this SOP ToolBox. We have summarised all our secrets here to get you started and to deliver a stunning SOP to your management.

Different Forms of Rolled Steel:

• Angle sections
• Channel sections
• T- sections
• I-sections
• Round bars
• Square bars
• Flat bars
• Corrugated sheets
• Expanded metal
• Plates
• Ribbed bars (HYSD)
• Ribbed bars (mild steel)
• Thermo-mechanically treated bars
• Welded wire fabrics

Industry’s Subsector:

• Bars, concrete reinforcing (rebar), made from purchased steel in steel rolling mills
• Bars, steel, made from purchased steel in cold rolling mills
• Cold rolling steel shapes (e.g., bar, plate, rod, sheet, strip) made from purchased steel
• Concrete reinforcing bar (rebar), made from purchased steel in cold rolling mills
• Concrete reinforcing bar (rebar), made from purchased steel in steel rolling mills
• Corrugating iron or steel in cold rolling mills made from purchased iron or steel
• Ferrous metal powder, paste, and flake made from purchased iron or steel
• Flakes made from purchased iron or steel
• Flat bright steel strip made in cold rolling mills made from purchased steel
• Hot-rolling purchased steel
• Metal powder and flake made from purchased iron or steel
• Nut rods, iron or steel, made in cold rolling mills
• Paste made from purchased iron or steel
• Powder made from purchased iron or steel
• Razor blade strip steel made in cold rolling mills
• Wire, flat, rolled strip, made in cold rolling mills

Production Process:
According to the requirement the designing process is been done and then, the steels are undergone for heating at a high temperature of around 1100 degrees Celsius. The heating process is done until, the steel reaches recrystallization point. Now, the heated material is allowed for rolling process through a variable number of stands, were it rolls the steel according to the required shape. These stands, contain high and various design flexibility, therefore the shape of the stands determines the shape of the steel. Now, the steel is allowed for cleansing process, in order to remove the mill scale and then, the steels are undergone for cooling treatment to correct the crystallization state of the steel. Finally, coating is applied in the steel in order to prevent from the corrosion and inspection is been done to check the quality of the product.

Steps involved in production process:

• Raw Materials Preparation
• Designing
• Heating
• Rolling process
• Cleansing
• Quality control and Packaging

Machines used in this industry:

• Blast furnace
• Reheating Furnace
• Heat-treatment furnaces
• DC electric arc furnace
• Stepping cylinder
• Steel Melting
• Rolling Mills
• Sinter Plant & Pallet Plant
• Continuous Casting Machine
• Long Product Cooling Bed
• Rolling Mill Gear Boxes
• Shears
• Interstands
• Scratch Free Roll Systems
• Furnaces Auxiliary Equipment
• Automatic Cold Rolling Mills

International Standard Regarding this Industry:

• ISO 24314:2006(en)|International Organization for Standardization- https://www.iso.org/obp/ui/#iso:std:iso:24314:ed-1:v1:en
• ISO 77.140.60| International Organization for Standardization- https://www.iso.org/ics/77.140.60/x/
• Steel Standards| ASTM International- https://www.astm.org/Standards/steel-standards.html
• Ministry of Steel| Government of India- https://steel.gov.in/standardization-quality-control-iron-steel

Here is the list of world leaders in this Industry:

• ArcelorMittal| Luxembourg| https://corporate.arcelormittal.com/
• Baowu| Shanghai, China| http://www.baowugroup.com/en/
• Hesteel Group| Shijiazhuang, China|http://www.hbisco.com/site/en/index.html
• POSCO| Pohang-si, South Korea|http://www.posco.com/
• Shagang Group| Suzhou, China|http://www.sha-steel.com/eng/
• Ansteel Group|Anshan, China| http://en.ansteel.cn/
• JFE Steel|Tokyo, Japan| https://www.jfe-steel.co.jp/en/
• Shougang Group| Beijing, China|https://www.shougang.com.cn/en/
• Tata Steel Ltd| Mumbai, India|https://www.tatasteel.com/ 
• Hyundai Steel|Seoul, South Korea| http://www.hyundai-steel.com/ 

Journals and Magazine Related to this Industries:

• Steel & Metallurgy- https://www.steelmetallurgy.com/ 
• Steel 360-https://www.steel-360.com/ 
• Steel Times International- https://www.steeltimesint.com/ 
• Steel Tech-http://www.steeltech-india.com/ 
• Modern Metals Magazine- https://www.modernmetals.com/
• Journal of Iron and Steel Research International| Springer- https://www.springer.com/journal/42243 

Research By : Udhay Sankar

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