From a University of California proposal, with some
changes, Haas TCM has developed a statistical process control application
known 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
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