Implementing a Quality Information System

2. Implementing a Quality Information System GopiRajaratnam March 2014

3. Agenda • Overview of QIS implementation • Application Architecture (Before QIS) • Application Architecture (After QIS) • What Advantages did BATA get from this Implementation • How MES Quality Module was extended • Further MES Quality Module Benefits

4. QIS Concepts • SPC • Statistical Process Control • A method of quality control based on statistical methodology • Control Chart • One of the “Seven Basic Tools of Quality” • Time series plot of measurements with respect to “Control Limits” • Ideal for stable systems and allow the user to identify and react to potential out-of-control situations • Allows data from the process to assist in prediction of future performance of the process

5. QIS Concepts • Histogram • Another one of the “Seven Basic Tools of Quality” • Graphical representation of the distribution of data • Estimate of the probability distribution of a continuous variable (what is Six Sigma) • Other Seven Basic Tools • Cause & Effect Diagram • Check Sheet • Pareto Chart • Scatter Plot • Flow Chart

6. QIS Concepts • Provides configurable control limits and control rules • Provides immediate analysis and feedback and control rule violations

7. QIS Concepts SAP Reports & Analysis Systems QIS Field Device • Product Information is retrieved from SAP • Automated product parameter are retrieved from Field devices. • Resulting data is then sent to a Reporting and Analysis System

8. QIS Concepts QM Spec Sample Sample Plan Results Characteristic(s) Sample Frequency • QM Spec: Product & Process Spec in context of items, equipment, & operations • Sample Plan: what Characteristics to collect and when to collect them • Sample Frequency: Allows you to define sample plan frequencies • Sampleis an instance of all the components described before • Characteristics: the parameters of a product or process that has to be measured: • Variables are measurements that can assume any value • Attributes always occur in integer amounts

9. Overview of QIS Implementation • History of the Client Solution • Developed In-House since the mid 90’s • Developed over 10-15 years (ad hoc) • Microsoft Access Databases and Forms in Lab and Back Office • Wonderware InTouch UI’s on Factory floor and in Lab • Utilising InTouch SPC Pro • End result was a very sophisticated solution, but due to the ad hoc nature of development was poorly designed with many disparate systems, and inadequate architecture design

10. Overview of QIS Implementation • History of WW Australia Consultancy with Client • Actively Consulting with customer for improvements and upgrade options of SPC Pro solution since Mid 2000’s • Goal was to Migrate them to an off the shelf solution • Mid 2012 forces aligned which enable the migration to proceed • Significant restructuring of manufacturing environment • Significant restructuring of IT Support Services • Migration of the application environment to Windows 7 and Server 2008 • MS Access will not be supported by IT Supporting services! • Developer was retiring from the business!!! • SPC Pro was no longer supported

11. Overview of QIS Implementation • Implementation Partner – Crossmuller • Endorsed System Integrator • Strong knowledge of manufacturing process • Experience with SAP integration • Experience in Laboratory System Management and System Design • Pivotal Role in • Understanding MES QM  Client System data structures • SAP  MES integration • Implementation Testing and Delivery • Leveraging QIS for further integration into other Production areas with the client

12. Overview of QIS Implementation • Project Team: • WW Australia • System Integrator • Small team, but able to achieve more with WW MES • Customer: • Project Team - Business Analysts (‘000’s, ‘tongue in cheek’) - Business SME’s • Jokes aside, they did have a large and impressive project footprint

13. Overview of QIS Implementation • MES Quality Module Released • Development commenced using MES QM BETA for a period of 3 months • After MES QM release migration of most development was possible • Overall ‘Quality’ of the MES QM was fantastic, even in its BETA stage!

14. Application Architecture (Before QIS) • Modules • InTouch UI’s (SPC Pro, SQL Access) for factory floor & Laboratory • Access DB’s (40+ individual databases!) • Access forms for Back Office and Laboratory • Custom ActiveX’s

15. Application Architecture (Before QIS)

16. Application Architecture (After QIS) • Modules • System Platform • MES (Operations & Quality) • Custom Web Services and SAP Integration • Software Toolbox OmniServer • Workflow available for future integration

17. Application Architecture (After QIS) Hosted on the Cloud

18. QIS Before and After

19. QIS InTouch UI List of samples ready for testing &a sample in progress waiting for results to be recorded directly from the testing device

20. QIS InTouchUI Sample Result

21. QIS InTouch UI The control limits and Spec Limits are calculated based on a custom algorithm that the customer uses which is defined globally for each site

22. QIS InTouch UI Chart displays designed to meet the customer’s requirements using included charting controls that were part of MES QM

23. QIS InTouch UI Custom capability study review screen. Cpand Cpkresults shown in the background grid. The interface allows the user to easily access the sample histogram by double clicking on the characteristic of interest in the first grid.

24. Extended MES functionality • All Samples are created ad hoc via MES API • In general a Sample is a collection of several QM Spec definitions • Typically a sample is created from a single QM Spec definition • Sample review screen developed to assist staff with product release and compliance procedures • Utilise short term QM Specs (Permits) which allow the user to produce to a modified specification for a period of time (number of shifts) • Data Log captures contextual information regarding Permit • Utilise Samples & Data Logs to create the concept of Oven Heats for Moisture analysis. • Each Oven Heat contains a number of Moisture Samples contained in Tins. • Data Log Captures Heat data and Tin data and links to Sample data

25. Extended MES functionality • Permit: • QM Spec Versions to hold the Permits • Permit was a temporary alteration to a characteristics target & limits • We implemented the concept of major &minor versions Datalog configuration: All contextual information that is required when creating a permit is shown

26. QIS InTouch UI • Permit creation form • Allows custom active time for the QM Spec • Permits were set to expire between 1 to 7 days from the time created

27. QIS InTouch UI • Custom sample review UI showing each sample taken for the required period • Capability Study done on larger sample sets relates to a more accurate measurement

28. Extended MES functionality • Oven Heats We also implemented the concept of Controlled Reference Material (CRM) tests so that the results of Oven Heats could be related to a standard result

29. QIS InTouch UI • Custom oven heat Sample Interface for allocating samples to an oven heat • Sample Selection Panel in the middle with Tin ID assignment for traceability • Results panel at the bottom

30. QIS InTouch UI • This is the oven heat weigh out UI. • It steps the user through each tin in the order that they were put in the oven • Results contextualised with the Target &Specs for each Char observed.

31. Wonderware MES Software/QualityFeatures and Benefits • Automation of quality sampling procedures with enforcement or direct from plant equipment or control systems • Increased operational efficiency with improved accuracy of quality data and reduced cost of quality • Dynamic quality sample management for ever-changing production schedules and on current work order execution status • Higher operational agility while securing compliance/safety • Near real -time SPC Monitoring of sampled data with notifications of rules and limit violations • Increased product quality and reduced losses through tighter control and faster response to non conformance or deviations. Food safety is a BIG area!

32. MES QM Benefits (Food)

33. Thank You!