Client Case Studies
Ascometal: SPC Project in metal Industry
Company overview, Ascometal
In 1999 Ascometal joined the Lucchini group, the European leader in specialist steel products used in automotive bearings, springs and oil, gas and mining products. Production sites are situated in France and Italy.
Introduction
The aim of the project was to introduce an automated quality management and process control system to replace the paper based system previously used at the Le Cheylas site in France.
Due to the complex and sensitive nature of the manufacturing process, the engineers knew that statistical process control was required and had initially introduced a paper based system. However, this did not prove to be very successful or popular with the shopfloor operators. The main problems were :
- Operators were forced to collect and chart a large number of measurements
- Data analysis was not real time which is critical in a continuous process
- Understanding the critical relationships between product and process attributes was not improved
The engineers decided they wanted a computerized system but after this all too common bad experience with manual SPC, convincing the operators of its effectiveness was going to be difficult. It was decided to introduce SPC Vision on a new machining process as a trial.
Automated thanks to SPC Vision software
In order to set this in place, Ascometal consulted several companies specializing in SPC. Infodream was the only one who was able to interface with the existing manufacturing IT systems, measurement devices and sensors.
SPC Vision has been incorporated within the installation of the WDH50 lathe. Measurements are taken using a laser device which is interfaced directly with SPC Vision. Automatic real time sampling of the acquired measurements is done automatically by SPC Vision and real time analysis is done to provide instant feedback to the production operator. The reports and analysis is available across the organization in real time and is utilized by numerous departments such as engineering, quality and design.
Technically, the project was quite challenging with several bespoke software developments required. Devices were connected to computers containing the following software:
- Interface software between device and computer.
- Management program, developed by Infodream, in order to manage the different interfaces.
- SPC Vision software.
A SQL server database has also been installed in the factory’s server. Then, every measure is automatically processed in SPC Vision and saved in a central database.
With the automation of the SPC follow-up, the manufacturing line has gained in precision and productivity:
- The calculation of the control limits for each product has been integrated, so, the targets and Cpk limits are now objectives.
- Scrap is automatically rejected if Cdc specifications are exceeded.
- When control limits are exceeded, an alarm is created and an auto catch-up of the characteristic is started.
When there is more than 500kg of scrap, a product management assisted by computer sheet and an analysis of the five “why” is created.
Originality of the installation:
The particularity of the installation of SPC Vision at Ascometal is unique. In case of limits being exceeded, SPC Vision initiates a feedback loop and the software adjusts the process to make it as accurate as possible.
Conclusion:
Within 5 years, quality problems related to dimensional problems were halved. SPC Vision Software also resulted in a drastic reduction in response time for production and quality problems thanks to a better visibility and communication. Finally, losses due to adjustment and non-quality has reduced from 140 000 kg to less than 95 000 kg.
In addition to productivity improvement and time saving, SPC automation brought to Ascometal a shared point of view of its process. SPC Vision has become an essential tool for the offline analysis.
Thanks to the software, the Ascometal team was able to collect new information and to discover different things about:
- Mechanical functioning and incidence on the functioning speed.
- Real-time adjustment on process tools: reactivity on lathe and rolling mill.
- Management and reaction modes
- Deposit of productivity.
- Realities of equipments functioning
With this project, Ascometal finally succeeded in getting involved its whole team in a performance improvement project.
According to Ascometal’s operators, “After 5 years of SPC, we wonder how we could work before”, the software has been installed in every workshops and the say that they “can’t operate without SPC Vision”.
