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Implementation of ProQMS - On line SPC system by DSS Systems & Software Technologies Ltd ( DSS )

Implementation of ProQMS - On line SPC system by DSS Systems & Software Technologies Ltd ( DSS ). DSS - Profile. Business Areas : Quality systems consulting. Development of software products for quality management like Pro-QMS. Software services for Domestic and Export.

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Implementation of ProQMS - On line SPC system by DSS Systems & Software Technologies Ltd ( DSS )

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  1. Implementation of ProQMS - On line SPC system by DSS Systems & Software Technologies Ltd (DSS)

  2. DSS - Profile • Business Areas : • Quality systems consulting. • Development of software products for quality management like Pro-QMS. • Software services for Domestic and Export. • Implementation of ERP. • BPO, education and training. • ISO 9001:2008 certified (by DNV) & SEI CMM level 4 compliant. • Microsoft Gold partner , Oracle Gold Partner.

  3. ProQMS – DSS’ On line SPC system • Pro-QMS was developed about 10 years ago and today has evolved into a world class On-line Quality Management System for the shop floor. • This system has been evolved based on Technology, Quality standards requirements, Customer requirements & our own research on the subject. • Pro-QMS has been well accepted by the Industry and implemented at many organizations across India

  4. Pro-QMS Now we look at the Block diagram to understand ProQMS.

  5. Real Time Quality Data Online data collection from Measurement Systems on plant-floor Dashboard Web based Multi-level Monitoring Pro-QMS Online SPC, MSA – Charts, Analytics, Reports & Alerts DB Data Storage & Retrieval

  6. Partial List of Major Customer Tata Motors, Passenger Car Unit - Pune Sundaram Clayton Ltd – Padi, Chennai Greaves Limited – Ranipet & Aurangabad Anand Group – Spicer & Gabriel Limited M&M vendors – NPPL & Super Auto Amtek Group - Gurgaon Delphi TVS - Chennai Amalgamations group - Chennai Rane Group – Chennai,Aziznagar, Medhchal,Trichy Rexroth Bosch – Bangalore Ankit Fastners, Bangalore Helvoet India Ltd – Loni, Pune Vanaz Engineers - Pune RSB Transmissions - Jamshedpur, Sanaswadi KOEL vendors- Kolhapur Ahmednagar Forgings – Chakan, Pune Forge Pro India Pvt Ltd – Bangalore Wabco TVS - Chennai Brakes India - Chennai Bilcare – Singapore & Rajgurunagar And Many more……….

  7. Implementation • DSS successfully implemented ProQMS (On line SPC system) at more than 50 major clients all over India: • Few case studies are provided here:

  8. Case Study – Tata Motors PCBU • Requirement – Monitor the CTQ’s on the component shops. Solutions Provided: • Started with – Implementation of Pro-QMS at Trans-Axle Machining (Hard) shop – For Part Parameters with Feedback to Operators. • Extended it to Engine shop – part Parameters. Advantages – Could take timely corrective actions in the shop based on the feedback from Pro-QMS. • Then implemented customized solution at Heat Treatment plant – for Monitoring Process Parameters. • Extended the system to Trans Axle Assembly shop. – for Monitoring Torque & Angle. • Extended Pro-QMS to Engine Assembly Shop • Engine Testing shop & • Trans Axle - Housing Shop • Plans to implement Pro-QMS at Sanand plant also.

  9. Tata Motors – PCBU, Pune

  10. Tata Motors – PCBU, Pune

  11. Case StudyGreaves Cotton • Light Engines Unit 2 - Ranipet • Implemented Pro-QMS on 12 stations across the plant in the Engine shop. Working fine for 4-5 years now. • Light Engines Unit 1 & 4 – Aurangabad • Now implemented the system at these 2 units with about 10 cells together, monitoring about 80 parameters.

  12. Case StudyGreaves Cotton

  13. Narasipur Precision Pvt. Ltd. Chakan (NPPL)

  14. Details of NPPL implementation • Provided 2 separate inspection stations for Front & Rear Housing. Special tables have been made to keep the Diatest Gauges & PC. • All Diatest Gauges with digital dials have RS232 output. Data is directly collected into the PC from the gauges on the click of data collection switch. • Facility for entering component Sr. number is given. Once all the predefined parameters for that part are checked & data is collected then automatically it will increment the component Sr. no. • Advantages of ProQMS • SPC analysis for the collected data can be seen instantaneously. • Display of Trends, Cp/Cpk value, Control Charts helps the concerned persons to take timely corrective action. • Separate monitoring station is provided for detailed Offline analysis of the current data & historical data for Process improvement projects. • Data can be used for internal/external presentations, Audits, Customer reports. • As data is available with Component Sr. no, it helps for traceability.

  15. NPPL - FRONT HOUSING 6 Parameters checked with Diatest Gauges with digital dials & connected to PC. Screen showing ProQMS software dashboard.

  16. NPPL - FRONT HOUSING Screen showing online SPC charts for monitoring a parameter

  17. NPPL – REAR HOUSING 12 Parameters checked with Diatest Gauges with digital dials & connected to PC. Screen showing ProQMS software dashboard.

  18. NPPL – REAR HOUSING Screen showing online SPC charts for monitoring a parameter

  19. Super Auto India Ltd, Chakan

  20. Details of implementation at Super Auto • Implemented ProQMS in new machine shop for following M&M parts • Oil Sump • Operation - Reaming • Parameters – ID 12 & ID 28.25 • Front Cover • Operation – Reaming • Parameter – ID 8.0 • Operation – Boring • Parameters – ID 58.5 & ID 73 • Clutch Housing • Reaming Setup 1 • Parameters – ID 14, ID 18 • Reaming Setup 2 • Parameters – ID 14.03, ID 52

  21. Details of ProQMS at Super Auto • Diatest Gauges kept near to the manufacturing machines for Inspection. • Data is collected through cables into a central PC as soon as data switch is pressed by operator after checking the particular parameter. • As soon as data is received by the PC, Feedback system sends signal back to the operator & a yellow lamp glows (Acknowledge) in the feedback box provided at the station. • After 3/5 (based on the subgroup size) readings, Green/Red lamp glows in the feedback box, indicating current process status. Also the current Cp/Cpk value is updated in the feedback box for each parameter respectively. • Charts & other details are available on the PC.

  22. SUPER AUTO – CLUTCH HOUSING Inspection station with 3 parameters monitored at Clutch Housing work station.

  23. SUPER AUTO – CLUTCH HOUSING

  24. SUPER AUTO – CLUTCH HOUSING 3 Feedback boxes indicating process feedback with Cp/Cpk

  25. SUPER AUTO – CLUTCH HOUSING Data Collection Switches for each parameter.

  26. SUPER AUTO – CLUTCH HOUSING Central PC – monitoring parameters through Dashboard

  27. Advantages of ProQMS • Display of Trends, Cp/Cpk value, Control Charts helps the concerned persons to monitor the process & take timely corrective actions. • Data is always available for internal/external presentations, Audits, Customer reports. • Analysis of the current data & historical data for Process Improvement projects.

  28. Thank You

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