PROJECT

ON
Improvement in current data entry and data collection methods, construction and
implementation of a system that involves auto-generated graphical
representation of CTQ process parameters for the Banbury department, blasting
and cementation and Industrial press department for the DAHEJ and SAMALI
plant.

MENTORED BYMr. Manish Shukla

Guided byMr. B.K.Roy

DATA ENTRY AND DATA

COLLECTION
CHALLENGES
NEW METHOD

GRAPHICAL
REPRESENTATION

ADVANTAGES
PROPOSALS

MANUALLY USING MSEXCEL

THROUGH
PROGRAMMING
ADVANTAGES AND
DISADVANTAGES
IMPLEMENTATION
CODES
TIME ANALYSIS

DATA MOVEMENT
PROCESS
ADVANTAGE

DATA ENTRY AND DATA COLLECTION

PREVIOUS SITUATION:

Data from SCADA are first collected manually then converted to excel format.
According to SOP-CP-0102, 100% Banbury data should be collected , but since
data cannot be extracted from computer due to the machine issue, only 2025% data are collected.

Rheometer data, Mooney viscosity data, specific gravity, Physical properties

are available in excel format. Since the batch number of 20-25% of Banbury
data may not be same as that of 10% of physical properties data, it is difficult
to have some comparison analysis.
IPD has manual method of taking data completely on a hard copy and no excel
sheets.
In DAHEJ, SCADA report can be generated in excel format but rheometer
values cannot be extracted from their computer due to some system issue.

CHALLENGES
Extraction of 100% data from SCADA machine is not possible till now which is
adding to the time to note it down manually from machine.
The data of Banbury and quality are fed in different excel sheets therefore for the
some batches it was found that data of some process parameters were missing in
excel sheet and found later in registers.
Since there are lot of excel sheets consist of lots of data against lots of dates. For
comparison analysis ,it is quite difficult to refer the excel sheets date wise.
Manual error in data feeding. One of the reason being lack of dependency and
interlinking.
IPD data cannot be converted to excel sheets due to lack of manpower.
In DAHEJ, rheometer data, mooney values and sg are in pdf format and for further

NEW METHOD

A new format, that includes date wise Workbook containing sheets for different
department containing CTQ process parameters.
Title of workbook is simply the date for easy understanding and sheets will be
named as mentioned below:
BS102: data for comparison plots and analysis.
BS102 COMPLETE : contain process parameter having 100%values.
RS102 : Data for comparison and analysis .(in case the compound varies like
RS102P and
RS102EXP, format will be copied and a new sheet will be
created in the same workbook)
RS102 COMPLETE : contain process parameter having 100%values.(in case the
compound varies like RS102P and RS102EXP,format will be copied and a new
sheet will be created in the same workbook)
DFT BLASTING : data for dry film thickness for all the three paints shift wise.
IPD SHEET : data for curing time, blank generation time, loading time and
mould temperature.
BLANK : data for blank core temperature for the cold feed extruder machine.

ADVANTAGES

No multiple workbook for different process parameters to carry out analysis which
will take less time as the complete data will be present in one workbook.

Easy to understand, can be reviewed daily and question can be raised regarding
production batches going out of the specified tolerances which can be made more easy
with graphical representation.

The format is very simple to fill and it is less time consuming than filling previous
format. Moreover, since the format is a simple and easy to understand, a statistical
analysis can be done easily and precisely and will take almost no time in understanding
the format.

The storage of files will be more organised as workbook for every date will be in a
month folder and again month folder will be in year folder.

For the construction of Daily auto generated graph (will be mentioned in later slides),
coding is required and software should read and write the excel sheet, for that simple
format excel sheet is required and that software is completely working fine with this
format as tested.

PROPOSALS

Excel sheet should be maintained in the proposed format in all department

to get the production data on a daily basis.

Manually fed data can be sometimes inaccurate, In order to reduce that

,PLC(programmable logic unit) and DAQ(data acquisition system) can be
installed to automatically get data in soft copy. It will reduce the inaccuracy
as well as time consumption.

Elimination of the System issue for the extraction of data from SCADA in
SAMALI and Rheometer values in DAHEJ in excel format .

GRAPHICAL REPRESENTATION

The easiest way to study large chunk of data is through graph. Having its
application in wide area, industry like us which produces in large amount due
to which large data is recorded, benefit a lot from this method.

Graph can be generated in two ways:

Manually using Microsoft excel

Automated system to generate graph through programming.

Having some advantages and disadvantages of both the process which will
be discussed in next few slides, I have worked and compared the extent in
which industry can be benefitted in the best way possible.

MANUALLY USING MICROSOFT EXCEL

ADVANTAGES

Easy to plot graphs

Wide range of formatting available

Software is friendly.

DISADVANTAGES

Takes lot of time if taken number of graphs per day in

account.

Software requires skill in this particular field

Since it takes a lot of time, team will be required for this

particular job of plotting graphs

Graphs
generated using
MS-Excel.

THROUGH PROGRAMMING

For the plots to be generated in an automatic manner, programming is needed

to create a system where the program read the file, carry out the function, write
the file and graphs are generated. The code has been written in MATLAB.
ABOUT CODE

Code is written in manner so that anyone having preliminary knowledge of

MATLAB, can understand the code. Moreover, the comment is given
wherever it is required to show the working of that particular section of code.

Run time is reduced as much as possible to save time. Time analysis is

shown after few slides.

Minimum input from the users to reduce the chances of error.

Separate code has been written according to the sheets in the proposed
format for easy understanding and minimum error.

Also, documentation has been done on how format should be filled and code
should be run to get required plots.

ADVANTAGES

Time consumption is very less if taken total number of graphs per day in account.
Requires no particular person for this particular job.
Code is written in such a way that it can give the plots Shift wise also. One of the
advantages of having data in soft copy rather than hard copy.
Code can be changed/written in such a way that even statistical analysis can be
done with minimal time and without engaging extra manpower for it.
The variation in the graph within the tolerance limit like sudden peak or depth
due to some manual or machine error or problems can also be studied and
analysed and solutions can be given at much faster rate.

DISADVANTAGES

Code is written for particular format that means it will not work if format is
changed.

Requires highly skilled to understand the code. (only in case of code malfunction)

KEY ISSUES DURING IMPLEMENTATION

Implementation of the proposed system requires the daily data entry in the required
format and software will give you the required plots. Following are the key problems
in which some of them are solved and some are not.

Initially, In DAHEJ the format looked too long to be filled on a daily basis but it is
solved as they are now able to give me data (not all) on daily basis.

In DAHEJ, there is a problem in extraction of rheometer data in excel format from

machine, which is making some delay in filling process.

In SAMALI, there is problem in extraction of SCADA report in excel format which is

delaying the filling process.

In SAMALI, enough manpower is not there for data entry to be done for IPD.

CURRENT STATUS

The program has been already tested for 5 days.

The documentation of the data entry and running the code is already done
and shared with the concerned people in DAHEJ.
For now, due to the above mentioned problem, it has not been implemented
in SAMALI but the code has already been written for SAMALI plant which is
slight different due to change of shifts.

Link to the codes

PLOTS

DAHEJ

SAMALI

Comparison graph for BS102

Banbury data

BS102.m

BS102.m

Process parameter having

100% data (BS 102)

BS102COMPLETE.m

BS102COMPLETE.m

Comparison graph for RS102

Banbury data

RS102.m

RS102.m

Process parameter having

100% data (RS 102)

RS102COMPLETE.m

RS102COMPLETE.m

IPD DATA

IPDSHEET.m

IPDSHEET.m

BLANK CORE TEMPERATURE

BLANK.m

BLANK.m

DRY FILM THICKNESS DATA

DFT.m

DFT.m

MONTHLY TREND (BS102)

MONTHLY TREND BS102.m

MONTHLY TREND BS102.m

MONTHLY TREND(RS102)

MONTHLY TREND RS102.m

MONTHLY TREND RS102.m

TIME ANALYSIS
MANUAL METHOD USING MS-EXCEL
Graphs :
BS 102
: 5 X 2 (SHIFTS)
= 10
BS102 COMPLETE
: 3 X 2 (SHIFTS)
=6
RS 102
: 8 X 2 (SHIFTS)
= 16
RS 102 COMPLETE : 5 X 2 (SHIFTS)
= 10
IPD SHEET
: 2 X 3 (SHIFTS)
=6
BLANK
: 1 X 3 (SHIFTS)
=3
DFT
: 1 X 3 (SHIFTS)
=3

AUTO GENERATED PLOTS

Graphs :
Run time of program
BS 102
19 sec
BS 102 COMPLETE
9 sec
RS 102
20 sec
RS102 COMPLETE
11 sec
IPD SHEET
18 sec
BLANK
9 sec
DFT
11 sec
Total time taken to plot all graph (per day) =
97 sec
= 1:37 min

Total graphs
to be
made (excluding
monthly
Manual
method
is taking
1 hr 40 min
48 sec whereas auto generated method takes 1 min
trend)
:
54
37 sec.
Time taken to make a graph (on an
average) : 1:52
Total time taken

DATA MOVEMENT
Data sheets from different departments of
two different plant need to be accumulated
at certain place so that program can read
and plot it as well as can be seen by
concerned officers.
In order to do that a system for transferring
data has to be introduced so that any
person having permission to see that data
and plots can open it provided it should be
user friendly and have security to the data.

One idea that can be implemented with

no extra cost is
THROUGH LAN

ADVANTAGE

High security : since LAN can only work inside the plants and head office, No
fishing of data can be done.

Accessed by limited people : folder containing data and plots can be shared to
limited people by allowing the others domain name to read/write folder.

User-friendly : Unlike e-mail that needs downloading data and keeping it in

one folder to run the program, shared folder on LAN needs no downloading.
Concerned officers can write the file on the same folder and get the plots.
This will also help in data entry from different departments.

Accessible by multiple users: provide access to multiple user to see the folder
at the same time. Program are also compatible with the shared folder as
tested.

THANK
YOU

NEW METHOD FOR DATA ENTRY AND COLLECTION METHOD ,

No multiple workbook for different process parameters

Easy to understand, can be reviewed daily

simple to fill, less time consumption than previous format
The storage of files will be more organised

ADVANTAGE OF AUTOMATED PLOT GRAPHICAL REPRESENTATION

Time consumption less

Can get plots shift wise

Get all the plots in 1 min 37 sec which is 1hr 40 min 38 sec in case of doing
the same manually in MS-excel.
Gives production information almost accurately without engaging any
person and in no time.