International Journal of Advanced Engineering and Management
Vol. 3, No. 4, pp. 127-133, 2018
Murtada Elshiekh, Khalid Eltayeb and Osama Mohammed Elmardi Suleiman, “Development of Quality Control System
for Cement Manufacturing using Software Techniques,” International Journal of Advanced Engineering and
Management, Vol. 3, No. 4, pp. 127-133, 2018
Development of Quality Control System for Cement
Manufacturing using Software Techniques
Murtada Elshiekh1*, Khalid Eltayeb2 and Osama Mohammed Elmardi Suleiman3
1,2Department of Manufacturing Engineering, Faculty of Engineering and Technology- Nile Valley University – Atbara – Sudan
3Department of Mechanical Engineering, Faculty of Engineering and Technology- Nile Valley University – Atbara – Sudan
Corresponding author E-mail: [email protected]
Abstract—The cement material is considered to be of great
importance in different aspects of building development
projects and as a commodity for export and investment.
Accordingly, the product should be compatible with the
standard specifications within manufacturing stages to
ensure acceptable quality. This research paper focuses on
creating a system that monitors and records daily readings
of cement physical tests at quality laboratories of cement
factory and accordingly the control charts for each test
were established. The importance of control charts for the
variables lies in the expression of the system status (inside
or outside the control limits); normally the points which
are located outside the borders indicate that the system is
out of control. But in some cases, the points are within the
control limits but took an abnormal distribution. First, the
system determines the style of pattern type, analyzes and
then finds out the expected causes and suggests the
solutions. The system was tested by inserting different
records in different intervals of time; the results obtained
were reasonable and had explained the effectiveness of the
Keywords—Quality control; Control charts; patterns;
Recently, the River Nile State had witnessed a great leap in
cement industry due to the fact that all production elements
were available; raw materials (lime stone), which is available
in most areas extending from Atbara to Abu Hammad.
Moreover, the availability of transport means (paved roads and
railway tracks) linking production sites with national markets
and ports of export, in addition to the availability of power
sources and skilled labors . Based on the above-mentioned
reasons, the policy of supply and demand overshadows the
local and regional market, making these companies at a big
challenge to obtain the trust and the customer satisfaction.
Due to an increasing competition in products, consumers have
become more critical in choosing products. The quality of
products has become more important. Statistical process
control (SPC) is usually used to improve the quality of
products and reduce rework and scrap so that the quality
expectation can be attained.
II. PROBLEM STATEMENT
All the industries and institutions are keen to optimize the
profit, and to be friendly with environment. This will help
these companies to keep its position and status within the
market, such process will be maintained by developing and
promoting the manufacturing systems as well as applying the
total quality control principles.
Control charts are the most popular charts widely used in
industry to detect abnormal process behavior. The most
typical form of control charts consists of a central line and two
control limits representing the specifications of the product
and the variant range limits. This provides a useful method
for monitoring variations in the product manufacturing
process. However, these control charts do not provide
pattern-related information because they focus only on the
latest plotted data points.
There are five cement factories in River Nile State; all these
factories are highly recommending improving their quality
control system (mainly the physics lab) to be within the
present international market competition. The process is
applied through monitoring and documenting the results of
different trails, analysis and decision making.
III. THE OBJECTIVES
The purpose of this research is to develop a quality control
system of cement manufacturing using software technique,
which is aiming to achieve the following objectives:-
To record daily results for various physical tests.
To draw control charts for variables (average, X), (range,
R) for any period of time required.
To find different patterns, then analyze and identify
corrective action accordingly for each pattern.
To Display the results of all tests at any time and obtain
General information about the system, which includes
machines, production stages, and sequence of operations etc,
Historical data of previous physical test results were
collected, and the causes of poor quality were analyzed.
Computer program created by using Visual Basic language
will be used to control the quality and to evaluate and indicate
the subgroup pattern and its analysis.
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