POSCO-VST 2011 New Employees training

Concept of STS cold rolling operation and process

Table of contents
1. Overlook manufacturing process for STS 2. Introduce and describe each operation 3. Introduce our factory - material flow, etc 4. Introduce whole process of order and material 5. Some introduces

1. Overlook manufacturing process for STS Manufacturing overview (total)

Make iron Make steel
Make cast

Rolling

General process of iron and steel

Hot rolling
Slab

Iron ore

Raw coal

Continuos casting

1. Make iron . With raw stuffs, make iron by using furnace 2. Make steel . With iron, make steel

plate
limestone Make steel Bloom Steel frame Billet

Cold rolling
sinter COKE

Ladle

Electric rolling
pure

3. Rolling . With slab, bloom, billet, make coils or plates

Bloom Billet Topedo Car furnace Steel converter

wire

1. Overlook manufacturing process for STS Manufacturing overview (total) Make steel, Hot rolling

1. Overlook manufacturing process for STS Manufacturing overview (STS) - General

SCRAP
?

EAF (Electric Arc Furnace) AOD(Argon Oxygen Decarburization) VOD(Vacuum Oxygen Decarburization)

Alloys EAF AOD

?

Hot rolling
Heater

Fe-Ni

Make Steel Fe-Cr

Alloys

C/C#1

Wire BLOOM
SLAB

Black coil

General process of STS making

1. Make Steel . With raw stuffs, make steel by using electric furnace 2. Annealing and Pickling . With hot coil, make white coil 3. Cold Rolling . With white coil, make CR, Sheet, Skelp.

Cooling Rolling White coil

VOD CPL

Ann & Pick

APL BAF CGL

STS HR COIL

STS Cold Rolling

TLL
Cold Rolling

STS CR COIL

C-APL CPL ZRM/CRM BAL SPM

SHL

STL
5

1. Overlook manufacturing process for STS About STS

1. Definition : Contains Cr (Chrome) over 12%, very thin and compact Cr2O3 film on surface. No stain. Compare surface
STS Steel Cr2O3 film Fe-Oxide Carbon Steel

2. Types of STS
Chemical Steel type Marten site Fe-Cr S T S Manufacturing

(400)

Ferrite (Knife, Operation equip, Spring, Building, Sink, House equip) Austenite

STS Hot STS Cold STS Wire Rods STS Plate

Fe-Cr-Ni

Duplex precipitation hardening (Bolt, Chemical equip, PIPE)

(300)

1. Overlook manufacturing process for STS Product types - Fe-Cr-Ni(300) Fe-Cr304 18Cr8Ni General
329J3L 22Cr-6Ni-3Mo Sea Equip

304J1 17Cr-8Ni-2Cu Sink, Thermos

316L 18Cr-12Ni2Mo Indus equip 1

321 18Cr-9Ni-0.3Ti Indus equip 2

XM15J1 19Cr-13Ni-4Si Vehicle

304N1 19Cr-8Ni0.13N Street light

301(L) 17Cr-7Ni Train

305EG 16Cr-14Ni Electron Gun

1. Overlook manufacturing process for STS Product types - Fe-Cr(400) Fe410L 11Cr-0.02C Container 430 16Cr Tableware

420J2 13Cr-0.3C Scissors, etc

410B 12Cr-0.2Cu Disk Brake

409L 11Cr-0.3Ti Vehicle

430J1L 19Cr-0.5CuNb Laundry

436L 18Cr-1Mo-Ti Vehicle

444 18Cr-2Mo-Nb Water storage

446M 26Cr-2Mo-Nb Roof

1. Overlook manufacturing process for STS

ASEM Center Roofing System

1. Overlook manufacturing process for STS

Pyung yang Gym in North Korea

10

1. Overlook manufacturing process for STS

Duplex : Potable water tank

Potable Water : Concrete Stainless

11

1. Overlook manufacturing process for STS

Home Appliances

12

1. Overlook manufacturing process for STS

IT Electrical Appliances

13

1. Overlook manufacturing process for STS

Paco Rabban Fashion in Paris

14

1. Overlook manufacturing process for STS

15

2. Introduce and describe each operation Manufacturing

Melt Refine
EAF (Electric Arc Furnace) AOD(Argon Oxygen Decarburization) VOD(Vacuum Oxygen Decarburization)

Continuous cast

STS Make Steel

Scrap Fe-Cr Fe-Ni Alloys

EAF

Refine AOD Furnac e

Raw

Electric

VOD

Caster

H O T S T Hot Rolling S Ann&Pick A N N P I C K

VSB Heater

Cooling R1 R2 R3R4 Roller

CPL

H-APL

CGL BAF

16

2. Introduce and describe each operation Manufacturing

Recoilin g
CPL

STS Cold Rolling - Wide

CRM VBA(BAL) SPM ZRM APL TLL CTL (SHL)

Rolling

Ann

Skin pass

STL

Recoilin g

STS Cold Rolling - Precision

PTL PZM(ZR M) SPM PBA(BAL)

PDG

Rolling

Ann

Skin pass
PSL

17

2. Introduce and describe each operation Our factory (VST)

ZRM Wide V S T Precision VBA SPM CTL SL TLL DG STS Hot STS Cold

Production : 304, 304L, 409L, 430, 420N1

2nd
CAPL

1st

#1 ZRM Hot Coil Material Yard

#2 ZRM CBL

TLL STL

SPM Product Yard

18

2. Introduce and describe each operation Characteristics of STS equipment

CPL (COIL Preparations Line)
Characteristics - Side trimming according to customer - Leader Strip - Recoiling

BAF (Batch Annealing Furnace)

Characteristics - Batch Annealing

H-APL (Hot Annealing & Pickling)

Characteristics - Annealing and surface SCALE removing

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2. Introduce and describe each operation

CGL(Coil Grinding Line) - Also in PDG : de-greasing line
De-greasing

Characteristics - Surface defect removing

ZRM / CRM (Cold rolling) - Also in PZM : precision line

Characteristcs - Rolling STS coil according to customers request 20

2. Introduce and describe each operation

C-APL / BAL (Annealing and pickling) - Also PBA in precision line
Annealing De-greasing Pickling Annealing Characteristics - Annealing and pickling

SPM (Skin pass) - Also in precision line

Characteristics - Surface brighten 21

2. Introduce and describe each operation

TLL / C-CPL (Leveling)

Leveling Characteristics - TLL : Leveling - C-CPL : Surface defect removing

Grinding

SHL / STL (Recoiling) - Also in precision line

Sheet Characteristics - SHL : Cut and pile - STL : Slit and cut

Coil, Skelp

22

2. Introduce and describe each operation

BRIGHT ANNEALING LINE HI SENDZIMIR MILL SKIN PASS MILL

CR COIL CR SHEET SHEARING LINE Precision SENDZIMIR MILL Precision BRIGHT ANNEALING LINE

CR HOOP SLITTING LINE

CR COIL

SHEARING LINE CR SHEET SKIN PASS MILL TENSION LEVELLING LINE De-greasing line SLITTING LINE 23

2. Introduce and describe each operation

ZRM Layout
Fume Duct Mill Housing -Ray Measuring Roll SCP Wiper Deflector Roll LH Tension Reel -Ray Measuring Roll SCP Wiper Deflector Roll RH Tension Reel Feed Leveler Pay Off Reel

BAL Layout
Top Roll Box Entry Looper

Exit Looper

T/R

POR

24

2. Introduce and describe each operation

SPM Layout
NO1,2 PAPER WINDER SKIN PASS MILL NO1,2 PAPER UNWINDER

Entry BRUSH ROLL

Delivery BRUSH ROLL

SHAPEMETER ROLL PAY OFF REEL TENSION REEL

TLL Layout
Shear POR Check Trimmer Leveller Dryer Shear TR

Welder

Entry Bridle roll

Deliver Bridle roll

25

2. Introduce and describe each operation

STL Layout
Shear POR Vinyl Coater Slitter Tension Pad Check

TR

Deflector Roll #1 Looper #2 Looper

SHL Layout
Shear POR Trimmer Wringer Roll Vinyl coater Flying Shear Conveyor belt

#1 Looper

#2 Looper

Heavy Leveller

Light Leveller #3 Looper

Reject piler

#1 piler

#2 piler

26

2. Introduce and describe each operation Flow with POSCO

Making STS Steel Hot rolling CPL STS Ann & Pick H-APL (CGL) POSCO Make Steel Make Cast VST Receive CBL BAF H.Coil VBA SPM ZRM *Leader Strip Precision

HOT

Rolling *ZRM/CRM F/H Ann *C-APL/BAL 2D CTL SPM TLL, STL C-CPL 2B Shipping SHEET

STS Cold rolling

STL

COIL/Skelp

27

3. Introduce our factory - material flow, etc Material/Product Flow in VST Factory Focus on CRP [PORT]
Vehicle

1
POSCO/Other Purchased Material Ship

[Factory]
PDA
Product Yard
3-4

Material yard

3-1

Vehicle Ship Invoice

Production Lines
E D E D B

4 Customer

3-0

3-3

Label ZRM,VBA, Conveyor SL, E D E D

3-2

3-0

Conveyor Y X

Marketing CRC

28

3. Introduce our factory - material flow, etc Material/Product Flow in VST Factory Focus on Shipping Control
1
POSCO/Other Purchased Material Ship Vehicle

[PORT]
2

[Factory]
PDA
Product Yard Ship
3

Invoice Label

Production Lines
E F J 1 A B
3 Label

Material 3-1 yard

4 Customer
Y

Carry-In

MES

Ship/Trans Order

Conveyor

Lines

Conveyor

Return

Marketing

2, 4 : Shipping Control, 3 : Yard

29

3. Introduce our factory - material flow, etc Flow and layer Supplie r
Produce
Shipping

Departure

Customer

Order Location, Work order, Supply

Delivery

Order

Grab

Cabin

Warehousing Shipping

Production

E M

Inspection
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3. Introduce our factory - material flow, etc Quality is important

Quality design (Spec, ) Customer MENU toast Bread Order How to cook bread toast Wheat flour : 1/2 Sugar:1Kg Water : 1 Temperature : 100 C Manual

Price, quantity, type (toast,)

Mix

Manufacturing

Customer Money

Bake

SPEC check Good : ok Bad : no ok

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3. Introduce our factory - material flow, etc Our factory and its codes
Seq
1 2 3 4 5 6 7 8 9 10 11 12 13 14 #1ZRM-1st #1ZRM-2nd Cold Rolling #2ZRM-1st #2ZRM-2nd #1VBA-1st #1VBA-2nd #2VBA-1st #2VBA-2nd SPM CTL STL H-STL H-CTL Skin Pass Sheet Slit Slit - Hot Sheet Hot Brighten Annealing 9D 9E 9G 9H 9K 9L 9N 9R 9S 9U 9W 3 4 5 6 7 8 9 10 11 12 13 14 #1PZM-3rd #1PBA-1st #1PBA-2nd #1PBA-3rd SPM PTL PDG #1PSL #1PSL-1st Slit #1PSL-2nd #1PSL-3rd #2PSL Slit - high RH RJ RT Skin Pass Tension Leveler De-greasing Brighten Annealing PC QA QB QC RA RB RE RF RG

Factory : Wide

Code
9A 9B

Seq
1 2 #1PZM-1st

Factory : Precision

Code
PA

#1PZM-2nd

Cold Rolling

PB

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3. Introduce our factory - material flow, etc Business process - Material

System process Business process
2.Skip

Work orders

Monitoring

Actuals
9.Surface Judgment

2.Request Work order 3.Change Seq 3.Reject 4.Spilt in Entry 10.Product Actuals (Abnormal case)

Purchased Material

Yard Input 1. our coil

5.Pause Actuals

8.Balanced WGT

6.Sampling 7.Sample Label 13.Packing Actuals 12.Prod Label

14.Return 11.Packing order

Warehouse
Warehousing Final Judge

Packing Area
*Warehousing Standby *Packing Standby

*Final Judgment Standby

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3. Introduce our factory - material flow, etc Business process - Product

STS Clod Rolling Production

Shipping Control Progress Code

Carry In Shipping Return Storage

STS Coil Packing Line

MT-1

Transfer

Shipping

Customer

Y
Warehousing Done Standby Delivery

3 Return Standby 1 A B E F J
Order Matching Standby

M Y
Order Shipping Standby Delivery Wait Sales Standby

Total Judgement Standby

Item Change Standby

Standby

Product Yard Progress Code

STS Cold Rolling Production

Shipping Control Product Yard

Quality Judgement

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4. Introduce whole process of order and material Whole Process

Material Material Yard Port POSCO PLANT STS Cold Coil Product Yard Customer

Financial Office Manage Managing Financial

Sell

Order Customer

Mar Ket Delivery Ing

POSCOVST Manufacturing Work Order Work Result PLANT

Pur Cha Sing

Order POSCO Delivery Buy

Produce

- ZRM, VBA - SPM, SL, CTL - CPL 35

4. Introduce whole process of order and material System Layout

The overseas system consists of ERP for general business information, Marketing for customer information, MES for production information, and PCS and PLC for facilities.
Budget Management

ERP GSI

Purchase Master Purchase (PO)

Fixed Asset (FA) Debt Manage ment (AP)

Settlement (GL) Stock Manage -ment (INV) BOM Cost (CST) Production Record (WIP)

Credit Managemen t (AR)

Company Unit

Quality Design

Marke ting

Sales Production Plan Material Order

Order Processing Process Management

Sales Management Shipping

MES

Standard Manageme nt

Cold Rolling Control Quality Management

Cold Rolling Operation Circulating Material

Shipping Control Cold Rolling Yard

Factory Unit Line Unit Equipment Unit 36

L2 L1

PC (Operation PC, Ground/Mobile Station, Measuring PC)

PLC, DCS, Instrument

4. Introduce whole process of order and material ERP System - GSI

Human Resource Management Tax AR (Account Receivable) GL (General Ledger) eBTax (Tax Control) INV (Inventory Management)

Budget (Budget Control)

AP (Account Payable)

FA (Fixed Asset)

Sales Manag.

Shipping

PO (Purchasing Man.)

POSAPPIA (MRO Item Mang.) e_Procurement

Order Entry Quality Design Operation Process Control

WIP (Work In Process)

CST (Cost Management) BOM (Bill Of Material)

[Index]

ERP

Local

Extension

37

4. Introduce whole process of order and material Marketing System

Making Plan how to sale to customer & how to produce at plant

Sales Production Plan

Have to buy material from POSCO for produce product

Financial Office

Material Order
Managing Have to receive order form customer

Manage Sell
Financial B/S Order Customer Delivery Mar Ket Ing B/S Manufacturing B/S Work Order Work Result
- ZRM, VBA - SKP, SL, CTL - CPL

Order Processing
What kind of quality product will make

Quality Design
Make Delivery Order and Instruction to plant

POSCOVST

Pur Cha Sing B/S

Order POSCO Delivery

Shipping
Calculation sales money with customer

Buy

Sales Management
Manage the progress status for order & material PLANT

Progress Management

Produce

38

4. Introduce whole process of order and material MES System

Financial Office Managing

Manage
Pur Cha Sing B/S

Sell
Order Customer Delivery B/S Mar Ket Ing

Financial B/S POSCOVST Manufacturing B/S Work Work Order Result PLANT

Order POSCO Delivery

Buy

Produce
Make work order for each plant line and Working sequence adjustment of work order unit

- ZRM, VBA - SKP, SL, CTL - CPL

Check & judging for appearance / mechanical / component of product

Cold Rolling Control

Receive work order and gather work result, Tracking & monitoring for plant operation

Quality Judgment
Receive delivery order and delivery to customer

Cold Rolling Operation

Manage material coil and product coil in the yard

Shipping Control
Manage roll & chock & bearing of plant

Cold Rolling Yard

Circulating Material Mgmt. 39

4. Introduce whole process of order and material System Process Marketing Sales & Production Planning
Forecasting S&P Planning Order Capacity Sales Planning Assign Production Customer Forecasting Order Material Mgt Order Order/Material Status

Input Order

Order Acceptance
ITEM/Price Routing

Sale Management
Sales Product Sales Results

Check Capacity Order Confirm

Prod Matching

Matching

Material Purchase

Progress Management
Abnormal Process Delivery Analysis Input Material

Shipping & Distribution

Transport Mgt Shipping Order

Order/Quality Design

MES

Cold Rolling Control

Task Planning Task Scheduling Re-Scheduling Work Order Progress Mgt

Quality Judgment
Test Sample Product judgment Lot Chemical Testing Work Order Test Sample Final Judgment Warehousing

Purchased Product Matching Material Shipping Progress Matching Work Order Results accomplishment

Shipping

Control

Delivery Work Progress Actuals Processing Move Receipt

Business

Standard Mgt

Standard

Master Mgt Meta Mgt Archive/Purge Security

Actual Results Rejected Materials

Cold Rolling Production

Work Order Operations Actuals Processing Operation Monitoring Request For Feeding Lifting / Lowering Down

Final Judgment

Rebuildable
Management Repair Mgt
Usage Mgt
MFG Actuals

Cold Rolling Yard

Task Actuals Processing Yard Monitoring Yard Task Analysis

Target Task Determination Scheduling Selecting Command

40

4. Introduce whole process of order and material We should make result according to work order
1st product Grade Prime
Customer request Order Satisfied Kept Delivered to customer directly Good Middle

Below 2nd product 5th product 9th product

1st N-order

Not satisfied Non-order product Order matching delivered to customer

To-Do

Status

Lower (by-product or scrap)

When coil is manufactured at last operation (SL), we judge its grade. 1. If it satisfies our quality condition, we assign 1st grade. Otherwise we assign 2nd or 9th 2. Although coils grade is 1st, if it doesnt satisfy customers request (Order content), we assign it to be non-order product. So, its import for us to make result according to work order (customer).
41

4. Introduce whole process of order and material Work order - All process in our system consists of work order and result

Sales & Production Planning

Order Acceptance

Sale Management

Material Purchase

Progress Management

Shipping & Distribution

Order / Quality Design Order MES CRC System Result

Order Matching Status Order MES Yard System Result

MES CRP System

Order

Result

Order

Result

P/C PLC Facilities

42

4. Introduce whole process of order and material Work order

Sales & Production Planning Order Acceptance Sale Management

Material Purchase

Progress Management

Shipping & Distribution

Order / Quality Design Order MES Shipping Control Result

Order Matching Status Order

MES Yard System Result

MES CRP System

Order

Order

Result

Order

Result

Load Unload

CLTS (Crane and Buggy)

P/C (Process Computer)

P/C PLC Facilities

43

4. Introduce whole process of order and material Work order

Sales & Production Planning

Order Acceptance

Sale Management

Material Purchase

Progress Management

Shipping & Distribution

Order Matching Status Marketing (Shipping & Distribution) Order MES Shipping Control Result Result Order Result Order Result Order MES Yard System

Shipping Order Transportation Order

44

5. Some introduces 2nd Factory is under construction

Finish : 12. 2, 150 Thousand Ton

Start : 10.12.13

Layout of 2nd Factory

2nd Factory
CAPL #1 ZRM Hot Coil Material Yard #2 ZRM CBL TLL STL SPM Product Yard

1st Factory

85 Thousand Ton

ZRM : Sendzimir Mill, CAPL : Cold Annealing & Pickling Line, SPM : Skin Pass Mill, TLL : Tension Levelling Line, STL : Slitting Line, CBL : Coil Build-up Line

45

5. Some introduces Codes of Material Number

Material Number (13 digit or character)

XX
Code of company

X
Factory of company

9
Sequence

Spilt number
Factory of company

Code of company : POSCO family has unique its code

Code H6 GU 29 97 98

Company

POSCO-VST POSCO-AST POSCO-ZPSS (China) POSCO-Vietnam POSCO-Mexico

Sequence : From 00001 ~ To Z9999 - 09999 10000, 99999 A0001, A9999 B0001 Spilt number : Assign sequentially A~Z, 1~9 according to spilt result

e.g. H6A00001, H6AA1010A,

Cod Factory Code Factory e A AST CBL D AST STL VST #1 VST - #2 ZRM ZRM ZPSS2 CBL ZPSS1 CBL QPSS CBL B AST - #1ZRM E AST CTL ZPSS1 ZPSS2 #1ZRM #1ZRM QPSS- #1ZRM C AST - #2ZRM F ZPSS2 ZPSS1 #2ZRM #2ZRM G ZPSS3 CBL QPSS H ZPSS3 - ZRM #2ZRM S VST SL W VST - CTL 46 (Hot) U VST SL P VST - PZM

5. Some introduces Some Codes

1. Works code : A (c.f. POSCO Pohang P, Kwangyang K) 2. Factory operating codes
POSCO Type Oper Fac A B C D E F G H J K L M N P Q R S T U V W #1 9 ZRM ZRM2 ZRM3 CRM CRM2 CRM3 CAPL CAPL2 CAPL3 BAL BAL2 BAL3 SPM CPL TLL STL SPM2 CPL2 VAF VAF2 #2 T TRM TRM2 VST WIDE 9 #1ZRM #1ZRM(2) #2ZRM #2ZRM(2) C-APL #1VBA #1VBA(2) #2VBA #2VBA(2) SPM TLL CTL (cold) SL #2PSL SL(hot) CTL (hot) SPM VST PRECISON Q R #1PBA SPM #1PBA(2) PTL #1PBA(3) PDG #1PSL #1PSL trim1 #1PSL trim2 #1PSL trim3

P #1PZM #1PZM(2) #1PZM(3)

47

5. Some introduces Database and Data

We retrieve data from database and display on screen There are many data types, namely, Number, Date, and Character
- Number : Size, tolerance, control range, permitted limit, quantity , Value, count, rate, pressure, temperature, density, speed, depth, illumination, brightness, angle, diameter, & etc.) - Date : For Time, Day, Month, Year Data - Character : For letters type column

LOV (List of Value)

Character

Date Number
48

5. Some introduces STS Terminologies

BAF : Batch Annealing Furnace CPL : Coil Preparation Line APL : Annealing & Pickling Line CGL : Coil Grinding Line CPE : Coil Packing Equipment CRM : Cluster Mill ZRM : Sendzimir Mill BAL : Bright Annealing Line SPM : Skin Pass Mill TLL : Tension Levelling Line CPL : Coil Polishing Line SHL : Shearing Line STL : Slitting Line HR : Hot Rolled Steel CR : Cold Rolled Steel FH : Full Hard

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Q&A
Thank you (Xin Cam On)