Can you put a price on your annual wastage? QI Analyst helps you to improve quality and product variability by improving the stability of your process! Webinar Content What is Statistical Process Control (SPC)? How can you use Statistical Process Control to improve your processes? Tools you need to drive SPC Ways this can interface with Wonderware A success story Short Demo Q & A This webinar is hosted by our Senior Consultant Chris Titley. Chris has worked at SolutionsPT for 13 years standing and has a masters Degree in Control Engineering and Optimisation. Previously he worked in a user capacity in the electronics industry. He now looks after the Terminal Services solutions and specifically managers ACP ThinManager offerings. Chris also has wide experience of InTouch, QI Analyst, ScadaAlarm, SPC Pro, Historian and Active Factory.

1. Wonderware Interactive Webinar Series
Helping you see more clearly
QI Analyst 8.0
Proactive Quality Control
Chris Titley
Senior Consultant

2. Agenda
► Quality – part of the manufacturing solution
► QI Analyst - Introduction
► Key Features and Benefits
► Case Study – Rencol UK
► Summary

3. Quality
► Quality is one of the three factors of OEE
► OEE = Availability x Performance x Quality
► Quality = Good Pieces / Total Pieces
► Quality is therefore important to lean
manufacturing, TPM and other
improvement schemes
▪ Can it be made easy?
▪ Can it be automated?
▪ Do I have to have a maths degree?

4. Statistical Process Control
► Statistical Process Control (SPC) is a tool to help
improve Quality by reducing Variation

5. Real-time SPC Helps Drive
Higher Plant Performance
► Real-time Statistical Process Control (SPC)
provides visual indications of process variation
► SPC enables proactive reaction to developing
process variation problems reducing the need
for expensive quality inspection activities
► SPC is a valuable tool for Six Sigma, ISO 9000
and Total Quality Management (TQM)
initiatives
Process variation must be minimized to
maximize plant output & profitability…
how can we accomplish this?

6. QI Analyst…
Your Real-time SPC Solution
QI Analyst offers...
► A rich selection of SPC charting options
▪ Generates the right information at the right time
► A powerful, customizable statistical rule base and
alarms
▪ Detects variation excursions early so you can take
action immediately
▪ QI Analyst can call a pager or send an email when an
alarm is violated… You can always stay in the loop
Helps predict harmful variation before it
results in expensive product quality issues

7. QI Analyst…
Built to be Easily Deployed Throughout the
Manufacturing or Process Enterprise
► Industry leading Wonderware plant connectivity
▪ Easily connect to thousands of plant data sources
► Distributed architecture to easily integrate into
existing plant IT structure
► Tools for the entire quality team
▪ Controller & Workstation tailored to user needs
▪ Full Integration with InTouch & Historian
• Supports custom InTouch application development

8. QI Analyst… What It Does
QI Analyst monitors, analyzes and
predicts quality departures allowing
proactive action - resulting in
improved quality and lower
production costs.

9. Who can benefit from QI Analyst?
Quality
Executives Engineers
cost of quality quality optimization
Six Sigma, TQM troubleshooting
Quality
Management
yields vs. quality Operators
process variation

10. QI Analyst… What is it?
►QI Analyst Controller ►QI Analyst Workstation
▪ Monitoring & Analysis ▪ Monitoring & Analysis
• SPC Charting, Monitoring, • SPC Charting, Monitoring,
Alarming Alarming
▪ Manual Data Entry ▪ Manual Data Entry
plus
▪ Configuration & Administration
• User accounts
• Security
• Causes & Actions
• Rules & Alarms
• Data Mapping
• Data Acquisition
Tools for the Entire Quality Team

11. Licensing
►QI Analyst Controller ►QI Analyst Workstation
▪ Seat or server based licensing ▪ Seat or server based licensing
available available
▪ No limit to the number of charts ▪ No limit to the number of charts
or variables analysed or variables analysed
Tools for the Entire Quality Team

12. Integrated or standalone
► QI Analyst can be deployed;
▪ Standalone
• Solo on just one computer
• Networked solution
▪ As part of your total Wonderware solution
• Further leveraging existing investments

13. QI Analyst Typical System Configuration
QI Analyst Controller
Nodes
Process Data from System QI Analyst
Platform/InTouch/InSQL Workstations
Other devices
(OPC etc)
Existing Process Information Server
Databases Central QI Analyst Database Clients
deployable anywhere on the network

14. SPC Charting…
Monitoring & Analysis
Data tailored to your needs
► Configurable Multi-charts * A cusum control chart is a data analysis technique
for determining if a measurement process has gone
out of statistical control. Similar to the exponentially
► Standard Charts weighted moving average control chart, it is better
than the standard xbar control chart for detecting
▪ Variable Charts small shifts in the process mean.
• X-bar & Range or Sigma
• X-Individual & Moving Range
• Moving Average & Range or Sigma
• Cusum* of Means or Individuals
• EWMA of Means or Individuals
▪ Attribute Charts
• p, np, c, u, DPMO*
▪ Special Charts & Analysis Tools
• Run, Histogram, Scatterplot
• Paretos of Nonconformities, Causes,
Actions or Rule Violations
* - Defects Per Million Opportunities

15. Flexible Charts…
Customizable Chart Elements & Statistics
Tailor each chart for
Maximum Effectiveness

16. Highly Configurable Statistical Rules…
►Wide range of industry rule
sets included
▪ Western Electric, AIAG, Juran,
Hughes, Gitlow & Duncan
►Design your own rules

17. Powerful Statistical Alarms
► Highly configurable
alarms
► Violations shown in
RED
Alarms alert you in real-
time (email, pager) so you
can act immediately…
minimizing scrap, re-work
and non-value added
activities

18. ChartService and Viewer
► ChartService, Monitors SPC
Charts 24/7
► ChartService Viewer provides
green light/red light chart status
indicators
▪ Click on red light indicator to view
real-time SPC chart and alarm
violations
▪ Allows at a glance monitoring of a
large number of critical process
parameters
▪ Viewer can be embedded in HMI,
web application or any ActiveX
container application for maximum
implementation flexibility
Process Databases

19. Industry Leading Wonderware Connectivity
Easily connect to:
 Thousands of plant floor devices through InTouch
 Process data stored in any Historian
 Any OPC server (QI Analyst is a OPC client)
 Any ODBC or OLE DB data source
 Gauges and measuring devices
►QI Analyst saves engineering time
►Eliminates expensive custom integration work

20. Data Collection… Automatic or Manual
► Automatic Data Collection
▪ InTouch (SuiteLink)
▪ Historian (SuiteLink)
▪ OPC Server (QI Analyst is OPC client)
▪ OLE Automation (programmatic)
▪ Gauges and measuring devices
► Manual Data Collection/Entry
▪ Provides for Direct Operator Input
▪ ActiveX Control
▪ Data Editor & Data Entry Assistant

21. InTouch & Historian Data
Access…

22. Link to External Data (Wizard)
Makes Connecting to 3rd party
data Sources a simple Process
Start…
Finish… Results

23. Designed for Efficient System
Administration
►Install Admin
database anywhere
on the network
►Single user interface
for all admin options
►Define Users and
Groups with specific
system rights

24. FDA 21 CFR Part 11 Ready
► Supports Regulated Industries
▪ Pharmaceutical, Food & Beverage, Power
Generation and others
► Integrated Window Security
▪ Helps manages user access rights via
standardised security model
► Audit Trails Built-in
▪ Parameter, alarm and data changes
Lowers the Cost of Implementing
Validated SPC Solutions

25. Audit Trail Support
►Regulated applications demand audit trials
►QI Analyst 8.0 supports the tracking of changes to:
▪ Parameters
▪ Alarms
▪ Data Changes

26. Share Your Results with the Enterprise…
►InTouch or InTouch for System Platform
▪ Provide operators with real-time SPC
information
▪ Proactively react to process variation
▪ Reduce scrap, re-work, non-value added work
►Information Server
▪ Keep plant decision makers informed of plant
quality issues in real-time
▪ Content tailored to user level
▪ Low cost web-based content delivery
►Custom Industrial Applications
▪ Readily Include QI Analyst ActiveX or COM
objects
▪ Easily connect to wide range of data
sources

27. Case Study
RENCOL TOLERANCE RINGS

28. Case Study
► Rencol Tolerance Rings Ltd
▪ Bristol UK
Rencol Tolerance Rings is a specialist manufacturer producing high
specification components for varied applications. The company wanted to
automate its quality assurance processes and to gain additional insight into its
product quality. Rencol chose Wonderware’s QI Analyst™ software in both trial
and full role-out stages, Quality is now far easier to achieve and customers
can be provided with full statistical information.
1000’s of tolerance rings that are used in Hard Disk Drives, Starter motors,
steering columns etc – making mass produced items fit together perfectly.
They have deployed over 15 seats of QI Analyst.

29. Tolerance rings?
- A kind of
sprung bush
that takes up
the varying
tolerance of
components
that need to fit
together
accurately

30. Rencol QI Analyst workstation
The rings are
stamped out of
strip metal and
formed to
shape, they are
then sampled
by various
gauges and
data inputted to
the quality
system – in real
time.

31. QI Analyst at work
- An actual QI
Analyst display
from Rencol

32. Key results – from a customer...
Continuous Improvement…
Rencol is an ISO 9001 company and also carries
numerous quality approvals for the Automotive
(such as TS16494) and other industries. Given the
nature of Rencol’s business, SPC is to be found at
the heart of the company’s culture. QI Analyst
software is a key component of quality certification
and is part of annual re-validation audits. Rob Lockyear, HDD Quality Engineer, says, “QI
Analyst software has given us many
advantages since we fully deployed, continuous
accuracy being the obvious, but we now have
very timely information that is based upon a
professional product that is helpful in customer
retention and in new customer acquisition”.
“QI Analyst is at the heart of our Continuous Improvement
programme” – Jim Smith, MD
http://www.wonderware.co.uk/success-stories/all/
“QI Analyst software removes the stress from Quality Assurance”.
Rob Lockyear, Rencol Tolerance Rings

33. SUMMARY

34. QI Analyst helps to deliver…
► Successful Six Sigma, ISO 9000 and Total Quality
Management (TQM) Initiatives
► A flexible set of tools capable of interfacing and
integrating with a myriad of Plant Information Systems
► Real-time process variation data enabling better decisions
from the plant floor to the executive suite
► Bottom-line Results… Lower costs, higher profits

35. QI Analyst...
► Does the heavy statistical work for you
► Does the work in a standards-related way
► Delivers maximum and sustainable benefit
► Does not require a maths degree!
More at:
http://www.wonderware.co.uk/products-and-technology/qi-analyst/16/

36. Our WebEx series...
► Forthcoming ► System Platform
attractions... ► 10th November
► Information Server
► 17th November

37. Questions & Answers

38. Powering intelligent plant
decisions in real time

39. Powering intelligent plant
decisions in real time.