Chemical Management
Process Systems Software Management (Haastec)

From a University of California proposal, with some changes, Haas TCM has developed a statistical process control application know as Haastec®. Haastec® is currently being used for coolant, lubricant and washer systems in Automotive Power-Train Plants and on paint detackification, water treatment and wastewater treatment at Automotive Assembly Plants. Haastec® can be utilized on any system that requires system testing, control, and charting. Data is downloaded to Haas corporate offices on a monthly basis to allow benchmarking between plants by our technical specialists. All coolant and washer data is correlated to production for benchmarking purposes.

The application is based on a database of all systems in the plant which includes information regarding system location, department, end product, capacity and approved products. It can be used to track an unlimited number of systems making it ideal for both central systems and individual sumps.

Each system can be assigned an unlimited number of parameters for record keeping and charting. All test frequencies and methods will remain the same and any changes will be submitted to the plant for approval. Typical tests include concentration, tramp oil, sediment, pH, conductivity, biological growth, and total alkalinity. In addition to these system parameters, Haastec® can track other readings and data including operating temperatures, machine speeds, amperages, circulation rates, and production throughput to determine overall system efficiency. All chemical additions are also tracked in Haastec® to allow correlation of usage and cost with system operation. Standard parameters are included with the initial installation of Haastec®, however, additional parameters can be added by the customer to meet specific requirements.

Test data can be entered into Haastec® in several ways. In facilities where the on-site team performs the testing and records the data, the information is added through easy-to-use data entry screens. However, if the data is collected by plant personnel (as a result of local work rules) or Tier II suppliers, the data can be imported for analysis and reporting through Haastec® through the use of a Microsoft Excel template. In addition to eliminating the need to train a variety of personnel on Haastec®, or distributing the system over the plant network, this feature enables easy input of historical data during the transition process.

In addition to importing from Excel or similar electronic formats, Haastec® can receive data directly from a PC based real time data collection, testing and systems control unit. It is modularized and can monitor and control fluid perfomance parameters, fluid system parameters and or machining parameters. These include; pH, concentration, water hardness, fluid level, water added, filter vacuum (PSI), pump amperage, tooling power draw, and cycle time.

All test parameters are assigned two upper and two lower control limits. These limits or alarms are highlighted “yellow” to indicate the need for proactive maintenance or further testing, or “red” for immediate corrective action. All alarm conditions are noted with the entry of data into the system. These include simple alarm conditions (one alarm only) or complex alarms based on multiple conditions existing simultaneously. These alarms can be of a “work order” type that require closing by a specific user.

In addition to these alarms or notifications, Haastec® is readily programmable in a symptoms - root cause - solution sequence to make 80% of the fluid associated engineering decisions typically required in a metal working facility. These corrective actions include calculations of additive or concentrate quantities based on system capacity as well as notification procedures for emergency conditions.

All events, including alarm conditions, corrective action recommendations, chemical additions, and system dumps, can be logged permanently for use in trouble shooting and quality control issues.

The data is available in a variety of formats, including a “System Flag Report” which details all alarm conditions for a given system for a given time frame. The report includes all pertinent data from the first alarm through system conformance. Reporting formats can be adjusted for each application and can include reports on the system design parameters as well as historical results. All stored information is available for reporting including historical events, chemical additions, metering pump settings and test results.

Reports and graphs can be generated in Crystal reports for immediate printing or exported directly to Excel for customization. Reports are distributed to customer personnel and usually posted for general review on the company intranet or physically near the actual system. Charts are available as line or bar graphs, depending on user preference and can be posted electronically as necessary.

Haas TCM works with customers to develop process control limits, sampling procedures, and frequencies. Test frequencies and control limits will be established to insure proper operation of the various systems, and to provide trending information for proactive maintenance. All routine testing will be accomplished on-site with off site laboratories used for problem solving or backup. All changes in procedures and/or test frequencies will be approved by the customer before implementation.

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