Automating the processing of Mill Test Certificates (MTCs)/ Material Test Report (MTR) / Certificate of Analysis (COA) presents a significant challenge due to the diverse range of chemical and physical properties found in these reports for raw materials. While MTR processing is crucial for quality assurance, it is often time-consuming. Fortunately, there is a more efficient way that can lead to substantial cost and time savings for fabricators and material customers.

Explore the 6 Steps to Automate MTC Processing

Understanding Mill Test Certificates:

A Mill Test Certificate (MTC)/ MTR/COA is a vital quality assurance document that certifies the exact chemical and physical properties of a material. MTRs, also known as Certified Mill Test Reports, Mill Test Certifications, Mill Inspection Certificates, or Certified Material Test Reports, ensure that a metal product complies with specific standards set by international organizations.

Key Information in Mill Test Certificates:

Mill Test Reports typically include details such as the country of production, physical and chemical property specifications, precise size or shape dimensions, and compliance with standards organizations like ANSI, ASME, or ASTM. These reports serve as evidence of a metal product's origin, traceability, and the processes involved in its creation.

Challenges in Automating MTC Processing:

Automating the processing of MTCs is challenging due to various factors, including the vast number of fields in the reports, differing layouts among manufacturers, poor image quality from printing and scanning, and the presence of multiple languages in international distribution.

Importance of MTC:

MTCs play a crucial role in quality assurance and compliance, with ASME certification requiring them to be kept on file for up to three years after product use. Maintaining this critical data in a database is essential for tracking and reporting purposes.

Six Steps to Automate MTC Processing:

1. Digitization / Image Processing: Remove non-text elements from the digital copy of the test report.
2. Optical Character Recognition: Recognize all languages and text characters on the material test report using OCR.
3. Machine Learning / Training: Train software to identify the document as an MTC, allowing for the recognition of additional attached documents.
4. Build Data Models: Create data collection models for important information on the MTC.
5. Human Data Review: Conduct a human review to ensure accuracy and flag uncertainties for further investigation.
6. Data Integration: Integrate MTC data and the digital copy of the document with existing quality software or reporting tools.

Discover how Star Software, an intelligent document processing platform, makes automating the review processes for mill test reports efficient and effective.

A Certificate of Analysis (COA) Report/ Material Test Report (MTR)/Mill Test Certificate (MTC) is a quality assurance document provided by the manufacturer that certifies the chemical and mechanical properties of a material, often related to metal products. It serves as a comprehensive record, detailing the production conditions, testing methods, and compliance with industry standards.

Importance of COAs/MTRs/MTCs:

• Quality Assurance:
• COAs ensure that materials meet specified standards and requirements, assuring end-users of the product's reliability and safety.
• Traceability:
• COAs provide traceability by documenting the source of raw materials, manufacturing processes, and testing procedures, helping in case of recalls or issues.
• Compliance:
• Industries such as construction, aerospace, and manufacturing have stringent regulations. COAs demonstrate compliance with these standards.
• Product Integrity:
• COAs confirm that the product conforms to the intended specifications, preventing the use of substandard materials in critical applications.

Varieties of Certificate of Analysis Reports

Various COAs/MTRs are employed across diverse industries, each serving distinct purposes. The following are some prevalent types:

1. Mill Test Report (MTR): The manufacturing sector commonly utilizes this MTR, generated by the material manufacturer. It furnishes details on the physical and chemical characteristics of the material.
2. Heat Number Traceability Report: Widely employed in the oil and gas industry, this report documents the material's production journey. It encompasses details such as the raw materials used, the heat treatment process, and any inspections conducted during production.
3. Inspection Test Plan (ITP): Outlining testing and inspection procedures during production, the ITP features a checklist specifying the tests to be conducted and the corresponding specifications.
4. Material Certification: Issued by third-party testing laboratories, this report certifies that the material has undergone testing and meets the specified requirements. Commonly utilized in the construction industry, it attests to the material's compliance with set standards.
5. Material Test Certificate (MTC): Serving as a generic term encompassing various MTR types, the MTC provides comprehensive information on the material's properties and composition. It may include any combination of the details mentioned above.

Understanding COA/ MTR Content:

• Material Composition:
• Breakdown of the chemical composition, ensuring it aligns with the specified requirements.
• Mechanical Properties:
• Details on mechanical tests like tensile strength, yield strength, and elongation provide insights into material performance.
• Heat Treatment:
• Information on any heat treatment processes, essential for certain materials to achieve desired properties.
• Testing Methods:
• Explanation of the testing procedures employed, including non-destructive testing, visual inspection, and more.

How to decipher a Certificate of Analysis ( COA)/MTR report?

Deciphering a COA report may pose a challenge, especially for those not frequently engaged with such documents. Complicating matters, COA formats lack a standardized structure, and the documents are commonly translated from other languages, adding an extra layer of complexity. However, amidst these challenges, when navigating a Certificate of Analysis/Mill Test Report, it's reassuring to know that the verification of the material's physical and chemical composition remains a consistent aspect, irrespective of the document's origin.

Reading an COA/MTR/MTC – Step 1

The initial examination of an MTR commences with a physical assessment of the material either on the shop floor or within the warehouse. Verification involves confirming the presence and clear identification of the heat number on the material's surface. A comparison between this number and the corresponding MTR is conducted to ensure alignment. Basic surface and edge measurements are then performed to affirm that the material adheres to project specifications based on physical dimensions and thickness.

Reading an COA/MTR/MTC – Step 2

Moving to subsequent inspection steps, individuals need to consult the relevant ASME/ASTM/EN standards section corresponding to their project's material requirements. Here, the chemical composition table is located, and a comparison is made between the percentage values presented in the MTR and the acceptable range specified in the table. Common elements include Carbon (C), Chromium (Cr), Copper (Cu), Manganese (Mn), Molybdenum (Mo), Nitrogen (N), Nickel (Ni), Phosphor (P), Sulphur (S), and Silicon (Si).

Reading an COA/MTR/MTC – Step 3

Following the examination of the chemical analysis, attention is directed to the mechanical property table associated with the same specification. A parallel process is undertaken, comparing the measured values in the MTR with the acceptable range outlined in the mechanical properties section. Essential mechanical properties for assessment encompass tensile strength, hardness, charpy impact test results, and yield strength.

Once these three components undergo a satisfactory review, the MTR can be archived, digitized, and linked to the material, signifying its clearance for progression to the subsequent stage in the production process.

Challenges Faced by QA/Engineering Departments:

• Manual Documentation: The traditional process of manually collecting, organizing, and documenting MTRs can be time-consuming and prone to errors.
• Data Integrity: The risk of data entry errors and misinterpretation can compromise the accuracy of recorded information.
• Storage and Retrieval: Managing large volumes of MTRs becomes challenging, affecting the ease of retrieval for audits or reference.

Introducing Automation:

To overcome these challenges, QA/Engineering departments can consider implementing automation solutions. Automated systems can:

• Streamline Data Entry: Automation reduces the need for manual data entry, minimizing errors and improving data integrity.
• Centralized Storage: A centralized digital repository allows for easy storage, retrieval, and sharing of MTRs, enhancing accessibility and audit readiness.
• Real-time Monitoring: Automated systems enable real-time monitoring of production processes, ensuring timely identification and resolution of discrepancies.

Conclusion:

MTRs are indispensable for ensuring the quality and integrity of materials in various industries. As technology advances, embracing automation can significantly enhance the efficiency of QA/Engineering departments, making the process of managing and documenting MTRs more seamless and less time-consuming. By adopting automated solutions, organizations can not only improve data accuracy but also stay ahead in an increasingly competitive and regulated environment.