In the planning stages, companies have to find answers to the following questions

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1 Škoda Simply Clever The brand Škoda is known to German drivers for several years now. They associate only reliable, well-equipped cars with the product names such as Octavia and Fabia. Both offer excellent price-performance ratios. Today the location in Mlada Boleslav is a modern plant providing the complete range of electronic data processing equipment to improve technologies, to optimize logistics and to keep a high quality standard. Škoda s partnership with Q-DAS CZ has played an important role for this goal since Last year, Škoda required the implementation of a comprehensive data recording system in engine and transmission plants. This article is a project chronicle and presents all problems and solutions in detail. It was written in order to encourage other companies to face this challenge. In General In recent years, projects for the implementation of process data recording systems have boomed. Many of them are not planned correctly. But what are the reasons? In the planning stages, companies have to find answers to the following questions What is process data? Process data means o quality characteristics. o process parameters. o logistic quantities. o Which requirements does the company want to meet? And which priority does it give to them? Are there o external requirements such as laws standards and guidelines customer requirements

2 o internal requirements of quality technology management What kind of infrastructure is available? o Which type of network? o What kind of interfaces? o Which type of servers? o. Companies will realize quickly how important it is to prioritize tasks. Prioritization is required for the definition of project goals. Step 1: Project Authorization To reach authorization for the project, the main task was to convince the management of the project s profitability. Therefore, we set clear and specific goals in a workshop. Interested representatives of different departments helped to define them. Management Goals Standardize and facilitate the reporting system of the production process quality. Enable event-driven reports (warning system). Enable long-term trend watching. Technological Goals Make production lines comparable. Observe the state of production facilities on a long-term basis. Accelerate the data flow between metrology labs and operators.

3 Enable online production monitoring for foremen. Quality Goals Merge defect statistics of hundred percent final inspections with statistic from the SPC stations. Replace the manual operation of quality control charts by electronic QCCs. Make the comparison between different measurement technologies possible. Introduce the VW Process Capability Study/Machine Capability Study industry-wide. IT Goals Increase the network security. Step 2: Project Planning We determined the present situation and prepared a draft for the data flow in the future, of course. In addition, we created requirement specifications for the Q-DAS interface including detailed information about K field keys. We estimated data volumes to select the Oracle server Every person involved was quite confident. Nobody believed that any unforeseen event could interrupt the implementation. Step 3: Project Implementation Starting Point The project was launched on June 1, Our project team consisted of Škoda and Q-DAS CZ employees. We worked on the creation of the infrastructure or we took over data formatting tasks. Problem 1 or Never Start a Project without Involving IT Divisions A production hall was to be integrated into the network. The measurement and machine computers did not meet the requirements of the Škoda guideline for standardized computers within the company s administration network. Apart from that, the hardware and operating system in production have to meet demands that are different from those in the administration network. Solution

4 To solve this problem, we reorganized data flows (see fig. 1). A technology network was created interfacing measurement and machine computers. A firewall separates the technology network from the Škoda network. Only the firewall makes it possible to integrate measurement and machine computers. The technology network includes a concentrator organizing processes running in the background such as the Q-DAS CZ Process for data recording (an organizing process for the data recording from different computers ensuring that individual data sources cannot be affected by power failures) the Q-DAS Upload the Q-DAS Reporting Problem 2 or Q-DAS Interfaces Are Different Our project brings different data sources of all renowned manufacturers of measuring instruments together. But the problems were all the same. We needed at least one function of every manufacturer that was either not supported until the release of the next version.

5 or that was released in a version that required new hardware. or that supported our desired K field key but could not be integrated into the measuring program well. or nobody except the software engineer knew how to configure the interface. or Solution We wrote an additional background program for the concentrator - the Q-DAS CZ Process for the subsequent improvement of data conversion. We tried to create a flexible and user-friendly program. Problem 3 or Do not Touch a Running System Three CMM Reporting stations were planned. One of them was to replace a small, old isolated application. Efforts to configure the imitation of the former solution were five times greater than the efforts to implement a new reporting station. This task was quite complicated for measurement programs and the Q-DAS team. Experiences Companies have to face psychological resistance when implementing a new system. Even if they want to install a far better system from an objective point of view, the resistance should not be underestimated. It is always difficult to establish something that is different from what people are used to. These are our experiences so far and here are the most important facts about the project. Project Data We started using the Oracle database on January 1, SPC stations, metrology labs and 15 sorting-machines (hundred percent inspections) record about characteristics. Our data volume is expected to amount to about individual values per year. Report Examples The automated Reporting System forwards

6 daily reports about sorting-machines. weekly reports about critical and significant characteristics in all stages of the production process. monthly cumulative summary reports. The module Long-Term Analysis creates a history of the characteristics listed in reports.

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