Škoda simply clever

1. Škoda simply clever Q-DAS - ŠKODA - VW - 2005

2. Fuskova auf englisch G.B.Show Pygmalion (Prof. Higins to Lise Doolitle): „A woman, who utters such disgusting and depressing noises has no right to be anywhere, no right to live! The language, you try to speak is a language of Shakespeare and Milton and the Bible.“ SORRY Q-DAS - ŠKODA - VW - 2005

3. Agenda • Who is ŠKODA – seen as a customer of us? • Any general remarks or questions? • How was the project progress? (Acquisition, Planning, Implementation) • Any obstacles to be mastered? • What are the main project attributes? • Exempla of reports • What have we learned? Q-DAS - ŠKODA - VW - 2005

4. Who is ŠKODA – as our customer? • We have been being THE supplier of SKODA for at about 7 years - as: • Consultants in different statistical problems • Lecturers for statistical traininglast but not least • User support for qs-STAT Q-DAS - ŠKODA - VW - 2005

5. Any general remarks? • Boom of data collection projects – why? • Simply so: • Do we have our results of measurement in a digital form? • Do we have a network? • Do we have THE qs-STAT to analyse? Let us collect our data Q-DAS - ŠKODA - VW - 2005

6. Bunch of questions: • What kind of data would we like to collect and analyse? Are there: • Quality characteristics (Dimension fit, Hardness,..) • Process parameters (Temperature, Pressure,…) • Logistic figures (Throughput, Machine idle time,..) • ...? Q-DAS - ŠKODA - VW - 2005

7. Bunch of questions: • What kind of requirements with which priority would we like to fulfill? Are there: • External: • Acts of low • Norms and company standards • Customer requirements • ...? • Internal needs: • of quality assurance • of production engineering • of management • ...? Q-DAS - ŠKODA - VW - 2005

8. Bunch of questions: • What infrastructure are we allowed to use: • What kind of network, • What interfaces, • What kind of Data base, • What server capacity and performance, • ...? Q-DAS - ŠKODA - VW - 2005

9. How was the project progress? Acquisition: • How to convince about the pay back of a data collection project? • To work out benefits the project brings to: • Management • Production Engineering • Quality Assurance Q-DAS - ŠKODA - VW - 2005

10. How was the project progress? Acquisition: • Management benefits: • Unification and increase of transparence in the reporting of quality status of production processes • Enabling of event based reporting (Warning system) • Establishment of long term monitoring of trends Q-DAS - ŠKODA - VW - 2005

11. How was the project progress? Acquisition: • Production Engineering benefits: • Possibility of comparison between production lines • Monitoring of the status of production machinery in long term trends • Acceleration of the information flow between measuring lab and production staff • Enabling of the de-central online monitoring of production processes by a foreman Q-DAS - ŠKODA - VW - 2005

12. How was the project progress? Acquisition: • Quality assurance benefits: • Correlation of the 100%-final-check results with the data of SPC-stations in the entire depth of the production chain • Replacement of manual Quality Control Cards by electronic QCCs • Initiation of the characteristics qualification • General introduction of VW-standards for capability studies (PFU, MFU) Q-DAS - ŠKODA - VW - 2005

13. How was the project progress? Acquisition: • What about our competitors? • Gedas - as 100%-VW daughter the born competitor • Tigra – as developer of SKODA-own data collection and analysis software in M5 hall Maintenance and support of our ORACLE Server Obligation to implement qs-STAT-server in this software No competitors more Q-DAS - ŠKODA - VW - 2005

14. How was the project progress? Acquisition: • What about bribe? No cent !!! Q-DAS - ŠKODA - VW - 2005

15. How was the project progress? Planning Q-DAS - ŠKODA - VW - 2005

16. How was the project progress? Planning: • Description of IST-Status in the infrastructure • Classification of data sources • Design of data flow and collection • Assessment of data volumina • Book of duties comprising precise K-keys definition • Project plan: tasks, responsibility, milestones • … Q-DAS - ŠKODA - VW - 2005

17. How was the project progress? Planning: Q-DAS - ŠKODA - VW - 2005

18. How was the project progress? Planning: Q-DAS - ŠKODA - VW - 2005

19. How was the project progress? Implementation: • Surprisingly enough, even in spite of thorough planning, “uncountable” problems and obstacles arouse during the implementation phase. • I would like to share our experience with you regarding three of them that possibly can be encountered in any similar project. Q-DAS - ŠKODA - VW - 2005

20. Any obstacles to be mastered? Obstacle 1 or „Start no project without involving the IT-Department“ Q-DAS - ŠKODA - VW - 2005

21. Any obstacles to be mastered? • A data network was necessary for the data collection in the engine production hall. The computers used in measurement stations and machines were unfortunately not compliant to the ŠKODA-standard for PC (aimed at office environment). On the other hand, both the hardware and the system software have to cope with other challenges in the production environment, as compared to the office computers. Q-DAS - ŠKODA - VW - 2005

22. Any obstacles to be mastered? • Solution Q-DAS - ŠKODA - VW - 2005

23. Any obstacles to be mastered? Obstacle 1b or • Our realised solution as described above brought the attention of the security department to another problem: the firewall forwards all communication of qs-STAT clients in the office network directly to the Oracle-server. This contradicts some other security standards (three-tier-architecture). „Start no project without involving theIT-Security-Department“ Q-DAS - ŠKODA - VW - 2005

24. Any obstacles to be mastered? Obstacle 2 or „Q-DAS interface is not the same as Q-DAS interface“ Q-DAS - ŠKODA - VW - 2005

25. Any obstacles to be mastered? All favorite suppliers of measurement products are involved in our project as data source. There was one functionality at least – that we necessarily needed - by all of them, which: • either will be implemented in the very next software version, • or has been implemented in a release, new hardware is necessary for, Q-DAS - ŠKODA - VW - 2005

26. Any obstacles to be mastered? • or the specified K-keys were supported in the interface, but, in spite of this fact, there was no possibility in the measuring software to capture them, • or nobody – with the exception of the software developer himself – was able to configure the interface… … and “he is no more our employee”… , • or, ... Q-DAS - ŠKODA - VW - 2005

27. Any obstacles to be mastered? Solution • We had to learn: • How to configure the UMESS interface • How to develop Hommel input dialogue • How to configure the ADCOLE interface • … • We developed an back-end process, that manages the data collection and “cleans” the ASCII data before the Q-DAS-upload loads them into the data base Q-DAS - ŠKODA - VW - 2005

28. Any obstacles to be mastered? Obstacle 3 or „Don’t touch a running system“ Q-DAS - ŠKODA - VW - 2005

29. Any obstacles to be mastered? • We have implemented three CMM-Reporting stations (in the meantime we have implemented 4 more). One CMM-Reporting station had to replace an old „isle solution“. By far the most efforts were needed for the configuration of this particular old station. The dialogue among my very kind colleague and the operators and foremen went off approximately like: • Operator 1: Why is this button here and not…? • Operator 2: Why can I not see all information from the Zeiss protocol, including the addresses • Operator 1: Why am I to wait for so long? • My colleague: I should fulfill the requirements even then, when I don’t understand them! Q-DAS - ŠKODA - VW - 2005

30. What are the main attributes? • Since 01.01.2005, the ORACLE-Data base has been activated • We are storing at about 12.000 characteristics of SPC-Measurement places, lab and 15 sorting machines (100%-check up) • We expect at about 150.000.000 records per year • We are reporting daily and weekly to at about 20 responsible management members – unfortunately we don’t report by long term analysis yet. Q-DAS - ŠKODA - VW - 2005

31. Automatické zpravodajství Q-DAS - ŠKODA - VW - 2005

32. Automatické zpravodajství Q-DAS - ŠKODA - VW - 2005

33. Automatické zpravodajství Q-DAS - ŠKODA - VW - 2005

34. What have we learned? a lot!!! • From the point of view of our customer From the point of view of our „mother“ Q-DAS - ŠKODA - VW - 2005

35. What have we learned? • Customer • The acceptance of data collection must be supported in an active way: i.e., after our project has been finished, the main work begins. • It is very important for us to „stay in house“ for consulting (maintenance contract) and training. • Even if we reach at about 70% acceptance by customer, we can say our project was successful Q-DAS - ŠKODA - VW - 2005

36. What have we learned? • „mother“ • We have lost unnecessarily a lot of time because of our poor knowledge according the configurations possibilities in our products • We have lost unnecessarily a lot of time because of our poor knowledge according the bugs in our products that were already recognised by the development team We would wish to have a possibility to read only access the Q-DAS bugs data base! Q-DAS - ŠKODA - VW - 2005

37. I need a cup of coffee now Q-DAS - ŠKODA - VW - 2005