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

©O

n lin

e Pr

o-Q

MS

Implementation of ProQMS - On line SPC system

by

DSS Systems & Software Technologies Ltd(DSS)

©O

n lin

e Pr

o-Q

MS

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.

©O

n lin

e Pr

o-Q

MS

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

©O

n lin

e Pr

o-Q

MS

Pro-QMS

Now we look at the Block diagram to understand ProQMS.

©O

n lin

e Pr

o-Q

MS

DBData Storage &

Retrieval

Real Time Quality Data Online data collection

from Measurement Systems on plant-floor

DashboardWeb based Multi-level Monitoring

Pro-QMS

Online SPC, MSA – Charts,

Analytics, Reports &

Alerts

©O

n lin

e Pr

o-Q

MS

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 & RajgurunagarAnd Many more……….

©O

n lin

e Pr

o-Q

MS

Implementation

DSS successfully implemented ProQMS (On line SPC system) at more than 50 major clients all over India:

Few case studies are provided here:

©O

n lin

e Pr

o-Q

MS

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.

©O

n lin

e Pr

o-Q

MS Tata Motors – PCBU, Pune

©O

n lin

e Pr

o-Q

MS Tata Motors – PCBU, Pune

©O

n lin

e Pr

o-Q

MS

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.

©O

n lin

e Pr

o-Q

MS Case Study

Greaves Cotton

©O

n lin

e Pr

o-Q

MS

Narasipur Precision Pvt. Ltd. Chakan(NPPL)

©O

n lin

e Pr

o-Q

MS

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.

©O

n lin

e Pr

o-Q

MS

NPPL - FRONT HOUSING

6 Parameters checked with Diatest Gauges with digital dials & connected to PC. Screen showing ProQMS software dashboard.

©O

n lin

e Pr

o-Q

MS

NPPL - FRONT HOUSING

Screen showing online SPC charts for monitoring a parameter

©O

n lin

e Pr

o-Q

MS

NPPL – REAR HOUSING

12 Parameters checked with Diatest Gauges with digital dials & connected to PC. Screen showing ProQMS software dashboard.

©O

n lin

e Pr

o-Q

MS

NPPL – REAR HOUSING

Screen showing online SPC charts for monitoring a parameter

©O

n lin

e Pr

o-Q

MS

Super Auto India Ltd, Chakan

©O

n lin

e Pr

o-Q

MS

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

©O

n lin

e Pr

o-Q

MS 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.

©O

n lin

e Pr

o-Q

MS

SUPER AUTO – CLUTCH HOUSING

Inspection station with 3 parameters monitored at Clutch Housing work station.

©O

n lin

e Pr

o-Q

MS

SUPER AUTO – CLUTCH HOUSING

©O

n lin

e Pr

o-Q

MS

SUPER AUTO – CLUTCH HOUSING

3 Feedback boxes indicating process feedback with Cp/Cpk

©O

n lin

e Pr

o-Q

MS

SUPER AUTO – CLUTCH HOUSING

Data Collection Switches for each parameter.

©O

n lin

e Pr

o-Q

MS

SUPER AUTO – CLUTCH HOUSING

Central PC – monitoring parameters through Dashboard

©O

n lin

e Pr

o-Q

MS 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.

©O

n lin

e Pr

o-Q

MS

Thank You