IMS Messsysteme GmbH Heiligenhaus

Transcription

1 IMS Messsysteme GmbH Heiligenhaus Quality Data Management and Control in a Integrated Steel Plant Dipl.-Ing. Horst Krauthäuser

2 Agenda What is Quality? Quality Management System MEVInet-Q MEVInet-Q QData Storage MEVInet-Q DataViewer MEVInet-QDS Quality Test

3 Quality Management System MEVInet-Q Quality Management System What is Quality? Quality is conformance to requirements Total of Features, Characteristics, Properties = Requirements and Standards Online Measurement Process Data Type Product Customer Laboratory Results Usage

4 Quality Management System MEVInet-Q Components of the Quality Management System Data collection and interfaces to online measurement, process automatisation, laboratory and product planning system Post Processing for surface inspection data Database for long term storage of the product properties. Material tracking to compared different production steps. Easy and uniform access to complete and detailed measuring data Rule base evaluation for automatic quality test and decision support

5 Quality Management System MEVInet-Q 5 Quality Management System - Overview Surface Data Measuring and Technologie Data SIS Post Processing Message Receiver (On site) Data Viewer (Offline Data Evaluation) Detailed Data Display and Reporting MEVinet-Q Central DB Quality Test (Online Evaluation Service) Decision Rules Statistics and Massevaluation IMS DCL Service and Material Tracking

6 MEVInet-Q Data Storage Needs for the Data Collection The Total of all Properties that are defined in the requirements must be available. Sufficient density and details of the measurement data (from random sample to continuous online measurement in all dimensions) is needed Accuracy of the measuring data must be better than the limits Measuring data will be stored related to the finished product Measuring data must be assigned to Product ID of the finished coil. Measuring data must be assigned to length and width position of the finished product. Length changes after the measuring position has to be considered. Suitable Data types to store complex data is required.

7 MEVInet-Q Data Storage Quality Data for Steel Production Thickness, Profile Temperature Mechanical Properties Roughness Coating Flatness Length Width Internal Defects Surface Defect

8 MEVInet-Q Data Storage Data Types for Measuring Data Single Values Weight, Length, Sample Measurement Length Profile Center Thickness, Width, Temperature Cross Profile Thickness Profile, Temperature Profile Coating Profile, Flatness... Defect Map Surface Defects, Internal Defects Images Surface Defects, Strip Head and Tail

9 MEVInet-Q Data Storage MEVInet-Q- SIS Post-Processing Objectives Verification of the inspection results Data Reduction Filtering of not needed data Results Simple reviewing of the inspection result Reliable data Reduced d needs of storage capacity

10 MEVInet-Q Data Storage MEVInet-Q System Integration

11 MEVInet-Q Data Storage MEVInet-Q Interfaces HSM, PLTCM,... CGL Common Thickness Gauge Coating Gauge Width Gauge Air Knife Control Flatness Process Data Process Data Recorder Surface Data Strip Classification General Strip Data Material Tracking Data SIS Level 3 Level 3 Database Interface Database Interface IMS M-Server - Win XP IMS Extractor Service IMS Surface Import Send Recv Data Exchange Table Database Interface Send Recv Data Exchange Table Database Interface Tm1-File Tm1-File Tm1-File Tm1-File Tm1-File IMS Import Service Remote Access MS-SQL Server 2008 HSM TCM CGL SL Material Tracking Firewall IMS DCL Service Data Viewer Print Spooler Backup

12 MEVInet-Q DataViewer Visualisation and Evaluation of the Quality Data MEVInet-Q database contain the complete and detailed length- and finish product based quality data. Visualisation and evaluation is needed for different tasks: Improve Production Output Product Block / Release Process Assign Rework Check Customer Complains Support Maintenance

13 MEVInet-Q DataViewer Visualisation and Evaluation of the Quality Data MEVInet-Q DataViewer as central tool for the visualisation and evaluation of the quality data. Simple selection of data Comprehensive opportunities to display the quality data Mass evaluation over multiple records sets Data tracking over different lines Designer to create custom views Mathematical function library Easy access to the data in the MEVInet-Q database

14 MEVInet-Q DataViewer DataViewer - Data Selection Query Definition Can be individual extended with all value data from the database Query Results Example: Select all coils of a day

15 MEVInet-Q DataViewer DataViewer - Display of Data Length Profiles of Thickness, Speed, Wedge and Crown

16 MEVInet-Q DataViewer DataViewer - Display of Data Thickness Profile

17 MEVInet-Q DataViewer DataViewer - Display of Data Cross and Length Profile of Coating

18 MEVInet-Q DataViewer DataViewer - Display of Data Hot Strip Head and Tail

19 MEVInet-Q DataViewer 19 DataViewer - Display of Data Defect Map, Defect Length Distribution, Thickness and Temperature Length Profile IMS Messsysteme GmbH

20 MEVInet-Q DataViewer DataViewer - Mass evaluation over multiple l records sets / f Longtime time trend over average crown/wedge of 69 coils - including zoom to thickness length profile of the selected coil.

21 MEVInet-Q DataViewer DataViewer - Mass evaluation over multiple records sets Statistical distribution of coating deviation per week

22 MEVInet-Q DataViewer DataViewer - Data tracking over different lines Comparing thickness of hot mill exit and tandem entry p g y with taking into account of the cut off and rolling direction.

23 MEVInet-Q DataViewer DataViewer - Designer to create custom views Design Window Database Toolbox Data Bindings Calculations

24 MEVInet-Q DataViewer DataViewer - Mathematical ti Function Library Use mathematical expression or included function library Example: Add two length profiles of the coating weight of top and bottom side

25 MEVInet-Q DataViewer DataViewer - Mathematical ti Function Library C# C f Use C# Code for more complex calculations Example: Calculate length out of tolerance.

26 MEVInet-Q DataViewer DataViewer Easy Access DataViewer can run over server installation. Local client installation is not necessary. Display over Web Client. DataViewer pages will be automatically converted to web page

27 MEVInet-QDS Quality Test MEVInet-QDS Quality Test Automatic comparison of product characteristics with customers requirements Instant testing of quality when the coil is produced Reduce time consumption for manual evaluation Repeatable results that do not depend from an individual inspector Flexible rule design that can quick adapt to shifting requirements

28 MEVInet-QDS Quality Test MEVInet-QDS System Components Editor to specify customers requirements as rules Version management and release system for rules Simulation to test the rules Rule Processor for instant quality test HMI to visualize the quality test results Archiving of quality test results Interface to production planning system

29 MEVInet-QDS Quality Test MEVInet-QDS Rules Signal Flow Rules will be selected depending on the setup data Calculation of a characteristic quality value. Testing of the Characteristic Quality Value against the limit values

30 MEVInet-QDS Quality Test MEVInet-QDS Rule Editor Rule Tree with Rule context Quality Test Set Quality Test Rule Link Rule Definition with predefined function or C# Code Online Validation of Rule Syntax Version Management System IMS Messsysteme GmbH

31 MEVInet-QDS Quality Test MEVInet-QDS Simulation Offline Simulation to Verify the Results before launching a new rule Compare the results of different rules Usage of the complete historical MEVInet-Q Database IMS Messsysteme GmbH

32 MEVInet-QDS Quality Test 32 MEVInet-QDS Results IMS Messsysteme GmbH

33 MEVInet-QDS Quality Test Display of the Rule Results Online display with the Message Viewer to see the instant results Graphical display of the results Link to the detailed results pages in the MEVInet-Q DataViewer Flexible notification of different users with different needs. IMS Messsysteme GmbH

34 MEVInet-QDS Quality Test Quality Test Integration MES Release System Release / Downgrade Update OnHold / Release b MEVInet-Q OnHold / Release Quality Inspector Level 2 OR OnHold / Release Level 2 Rules Manualy OnHold / Release b Quality Test Rules Measuring Data Process Data Surface Inspection Quality Inspector Production Line Measuring Data Process Data Surface Inspection Optimise Operator

35 Quality Management System MEVInet-Q Summary Detailed length- and product based quality data. Uniform visualization and evaluation Automatic quality test Reducing customer complains Increasing yield Possess optimisation due to instant feedback IMS Messsysteme GmbH

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