By P Dalal

1
Welcome

• By P Dalal Co. Pvt. Ltd.
• ( Exclusive licensee of GE Fanuc make VSPC s/w
  h/w and IBR Germany make Column gauges, SPC s/w
  h/w)

2
Company Profile

• 58 years of history of serving Indian Industry in
  quality control systems Products
• Online SPC system (s/w h/w GE fanuc USA IBR
  Germany, IPPC IEI Taiwan, column gauge ,IBR
  Germany)
• Precision measuring instruments
• 3. CMM 3D vision measuring machines
• 4. Multigauging fixture solutions
• 5. Gear cutters ( Luren, Taiwan)

3
What is statistics?

• What are the first thoughts come in your mind
  when you hear the word statistics?
• Do you use statistics anytime?
• Many people hate statistics.
• Some believe that it is very difficult to
  understand.
• Some of you are ready to quit the class.
• But Wait ..

4
And think about

• Do you understand the theory of Television or
  telecommunication?
• Do you watch TV?
• Do you talk on the telephone?
• Do you understand aerospace Engg.?
• Do you ride on airplane?
• Do you understand Theory of statistics?
• Do you use statistics?

5
What is statistics?

• Even though theory behind statistics is hard to
  understand, we use it everyday
• extensively.
• To talk about sports.
• To shop intelligently.
• To complete tasks at home or at work.

6
Statistics
Used to predict
Deterministic
Used to replace many numbers with few
Descriptive
Whatever way we use data,there must be a way to
collect organize the data.
7
Few fundamentals of Descriptive Statistics
Mean - It is arithmetic average of all
observations. Mid-range - It is mid-point
between the highest lowest observations. Mode
-It is most commonly occurring
observations. Median - It is the middle
observation when all observations are
arranged in order of magnitude
8
Variation is Every where

• The time it took to get to the work today, the
  time it
• took to get to work in the past and time it will
  take to
• get to work in the future all vary.
• The assemblies you put together vary , too.
• The assembly methods vary.
• The parts from suppliers vary.
• Variation is the reason behind inconsistencies.

9
Causes of variation
10
Capability v/s performance
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Statistic Process Control
? SPC Traceability of data

• Treceability for detail analysis
• Max. 50 categories with 300 subcategories for
  each category
• Max. 50X30015000 treceability search criterias

• Definition of Max. 1500 charactaristics
• Data collection from digital gauges with
  hardware interfaces and/or calcualtion from Maths
  formulae
• Real time Charts plotting statistical
  calculations for each characteristics

12
1. Accuracy Precision
13
Why SPC?

• Please refer to following Figure

14
Online SPC
A Powerful tool for Process Control taking your
business to World class Excellence
competitiveness
FROM CIMWORK (GE FANUC) IBR German With P
dalal Company The sole licensee distributor in
India
15

• Migration from
• Paper Based
• Manual data capturing Control system to
• Computer Based
• Automatic data capturing Control system

16
NO DATA, NO IMPROVEMENT
Use Online SPC for Continuous process data
harvesting
The 1st step towards improvement (6 sigma)
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Why Process Control ?
To reduce Variation in Process outputs
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CONTINUAL REDUCTION IN PROCESS VARIATION
6 SIGMA GOALS
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Why Six Sigma?
Environmental Change vs. Organizational Change
Dissatisfied Customers lost loyalty result
in Future shocks
Exponential change in Business Environment
Continuous organizational Change
Change
Continual Organizational Change
Time
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Why Six Sigma?
21
On Line SPC Can help you to Achieve 6 Sigma
Goals
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5 STEPS FOR 6 SIGMA JOURNEY
VSPC SHARE
D
DEFINE
10
M
MEASURE
100
A
ANALYSIS
75
I
IMPLEMENT
0
C
100
CONTROL
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Decide key Quality Characteristics to be measured
Use Online SPC for data capturing to evaluate
existing performance
Set Goals for improvement
Use Online SPC further for sustenance of process
performances in long term
24
Quality concept for a Statistical process
control with Online SPC system by ? P DALAL
CO. PVT. LTD.
25
Benefits of on-line SPC

• Company-wide visibility of Process
  Performances and its behavior
• Process optimization through experimentation
• Time Saving in Experimentation For Process
  Optimization
• Reduction in SPC monitoring time due to
  automatic data capturing
• and plotting
• Easy data movement and handling through LAN
• Stratification of data based on traceability
  fields (Raw material, shift, tool, operator,
  time etc)
• Data export to MS-Excel and ERP systems
  Connectivity to Multi- Gauging systems

26
Benefits of on-line SPC

• Reduction in rework/rejection by visual control
  by operator
• Reduce process variation for better fitment in
  assembly
• Reduce inspection time by sampling predicting
  through charts
• Eliminate post inspection manpower for the
  post inspection, patrol inspection
• Improve tool life save cost to tools
• Reduction in machining time of next operation
  by keeping variation of earlier operation less
• Help in reconditioning of machine and improving
  performance of machines
• Help in initiating corrective/preventive
  action to avoid losses, to increase productivity

27
Analogy to Traffic Signal
A control chart is like a traffic signal, the
operation of which is based on evidence from
samples taken at random intervals. A green
signal - Process be allowed to
continue without adjustment A
yellow signal - Wait and watch
trouble is possible A red signal - Process
has wandered Investigate and adjust
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Stop Investigate/Adjust
Go No action on Process
Wait and Watch
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Histogram in 9 steps
Gather Data
Tabulate Data
Count Data -n
Find Range-R
Find No of classes
Find Class width-k
Class Boundaries
Determine Frequency
Draw Histogram
30
Product Range On Line SPC Solution Systems
Standard Options
Gauge Check
Rs . 95000
Marposs Italian Make HBT Probe
Model 3424014600 measuring range 1mm
Metronics USA Make Gauge Check Model GC110
Single Phase with SPC (Retrofitting Existing
Conventional Air Gauge with Mechanical Dial)
31
Product Range On Line SPC Solution Systems
Standard Options
IBR German Make C-200 with ComGauge Software
Rs . 190000
IBR German Make C-200 Column Gauge IBR German
Make Comgage Software with Dongle Key IBR
Industrial PC Standard Monitor 15" Dialog
India
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Features of IBR Column Gauge

• 1.Working on Highly Sensitive Piezoelectric
  Crystal interface.
• The high sensitivity allows resolution up to 0.1
  micron.
• A piezo sensor with new design of compact
  microprocessor based electronics allows highest
  precision and stability.
• In-built errors of an air to electronic
  conversion in diaphragm are eliminated by piezo
  crystal.
• 2. Compact robust design with integrated AE
  converter.
• In-built air to electronic converter reduces
  space occupied by column
• Reduces the influence of external disturbances
  leading to error
• Robust and can be used under rugged operating
  conditions

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Features of IBR Column Gauge

• 3. Automatic Calibration
• Highly sophisticated measurement programmed
• simplifies measurement and gauge calibration
• The automatic calibration offset and gain) is
  made by the
• programming of 2 master values,
• single master for zero setting,
• 3 masters for reducing linearity error.
• Calibration through IBR ComGage Software.
• No adjustment for measurement error is required.
• Automatic zero adjustment by external trigger
  i.e. foot switch,

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Features of IBR Column Gauge

• 4. The three colored column displays
• Green, yellow, red for programmable tolerance
  points.
• 4 tolerance points representing relative
  deviations from
• nominal value.
• Flashing of tolerance points when measured values
  are
• out of tolerance limits (enable or disable as per
  user choice)
• Desired Column Display movement
• Column Moves from bottom to top.
• 2.Column moves from centre to top or bottom
• 3.column moves from top to bottom

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Features of IBR Column Gauge

• 5. Display of absolute or comparative
  measurements values for units in mm or inch
• 6. Multigauging mode
• connection of 4 independent pneumatic gauge
  heads to single column
• Sequencing of 4 Gauges with automatic or
  manual selection
• 7. Opto-RS232 data output for automatic gauging
  application with computers PLC units.
• 8. Auto stopping of machine when measured value
  out of Tolerance limits
• 9. Dynamic Mode Display of Min, Max, TIR Mean
  values

36
Features of IBR Column Gauge
10. Grading Mode i.e. Classification of work
pieces in up to 30 classes 11. Measuring inputs
freely combinable with separate multiplier for
each input 9,9.9.99,99(i.e.0,50
A1,37B2,31C-0,09D)
12. Supporting 4 inductive probes, pneumatic
converters o r sensors with analogue voltage
signals. 13. Connectivity to all type of
pneumatic gauge heads i.e. plugs, rings, snap
gauges 14. For simple and user friendly
programming of the c100 IBR supplies a
programming reference card and the PC
programmed BC100.EXE
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Features of IBR Column Gauge
15. The programming reference card guides
through the manual programming and saves time of
intensive searching in the instruction
manual. 16. The PC programmed BC100 allows the
programming of the column through a PC. The
created configurations can be stored in files
and can be reloaded into the column later. 17.
Password protection of programmed set up.
38
Product Range On Line SPC Solution Systems
Standard Options
GE-Fanuc VSPC Software With
IEI Panel PC AFL- 12B
Rs . 240000
39
VSPC Visual SPC software will help to

• Improvement in process capability
• Reduction in rework/ rejection
• Reduction in inventory
• Reduction in inspection time manpower
• Improve throughput time
• Scientifically decide tool life
• Reduction in Customer returns/ Customer
  complaints.
• Will help you in deciding reconditioning /
  replacement of machines.
• Will help you in initiating corrective /
  preventive action based on operator wise
  analysis /shift wise analysis /machine wise
  analysis.
• March towards ZERO DEFECT

40
Features of Industrial panel PC

• Best Reliability
• Fanless System generates less heat
  maintaining above average performance.
• Rugged mechanism design
• Mounted on metal frame instead of fragile
  plastic cover
• 2. More stiffness over
  conventional material
• 3. Makes system more
  solid durable.
• IP64 front panel Waterproof dustproof.
• Anti-vibration protection Fitted with drive kit
  to increase the resistance of
• the hard drive to side shocks and vibrations.
• Networking Advantages
• Wireless anywhere
• integrated antenna for uninterrupted wireless
  connection
• high quality, uniform signals in any location
  from all direction without any
• degradation or impedance
• Most efficient in market today.
• Dual LAN Support

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Features of Industrial panel PC

• 3.IEI IQ mount design allows the AFOLUX series to
  
• be used for wide applications
• ARM design for industrial control,
• panel mount for kiosk device,
• wall mount for e-home terminal,
• stand design for thin client Application
• shop flow for manufacturing management.
• The AFOLUX series intelligent mounting design
  brings more value to you
• 4.Affordable Luxury for Multimedia application.
• High resolution brightness allows clearest
  image.
• Two integrated speakers for better sound track
  record.
• 5.Compatibility with embedded software.
• Win CE or Windows XP Embedded.
• Remote management tools application flexibility

42
Success stories
Sandvik Asia, Pune
43
Success stories
ZF India,Pune
44
Certificate
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Our Esteemed Customers

• Sandvik Asia Pune, (for 8 years)
• Bajaj Auto Ltd. Pune, Waluj.( for 4 years)
• NRB Bearings Ltd, Jalna, Waluj, Hydrabad, Thane,
  Abad( for 4 years)
• Zf India Pune( for 5 years)
• GKN sinter metal pune, nagar vendors( for 6
  years)
• Tata Holset, delhi (for 7 years)
• hitech, delhi (for 3 years)
• climate systems, delhi ( for 5 years)
• Concept engineering, mumbai (for 2 year)
• Mando India Ltd. Chennai.( for 2 year)
• Maruti Suzuki India Ltd., Gurgaon ( for 8 month)

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Customers of GE Fanuc make VSPC software in abroad

• Nissan North America, Inc.
• Water Guide
• Ideal Division, Stant Companies
• Alabama Laser
• Product Genealogy
• Electronic Material Push Pull Systems
• Powertrain Solutions
• Duracell batteries
• Toyota

• Ford, Dagenham
• BMW
• GM
• Western electricals
• Daimler Chrysler
• Vauxhall, Vectra Visualisation
• Renault
• Perodua Automotive
• Skoda
• John Deere

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THANKS.....