Quality Control System

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CONAD
Quality Control System Concrete Advice Pty
Ltd Melbourne, Australia Web Site
http//www.concreteadvice.com.au
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Presented by
Ken W. DayBSc, FIE(Aust), MICE(UK)FACI,
FICT(UK)Principal, Concrete Advice Pty. Ltd.)
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Concrete Advice Pty. Ltd. Where are we?
Sydney
Perth
Melbourne
We are Here
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CONAD
Quality Control System Concrete Advice Pty
Ltd Melbourne, Australia Web Site
http//www.concreteadvice.com.au
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ORIGINS OF QUALITY CONTROL

• early resistance, considered impractical
• current acceptance-seen as profitable
• rapid spread - it IS broke, DO fix it!
• Japanese used US technology in electronic and
  automotive fields
• you need to be in this for profitability,
  reputation and sales volume
• What do you need? QC? QA? How about Information
  Technology and Integrated Process Control?

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WHERE DO WE GET THE INFORMATION?

• the first law is that you do NOT type in any
  information twice!
• much of the information is obtained with the
  order
• batch data comes automatically from ALKON
• grading, SG and silt content must be entered
• compression test data can be read directly from
  test m/c to computer and transmitted anywhere
• density is important - some clients automate
  measurement

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WHO TESTS YOUR CONCRETE?

• In Australia testing used to be done mainly by
  independent laboratories
• the major concrete suppliers all had their own
  laboratories
• with our help, they were able to show that their
  testing was of higher quality and greater
  relevance than that of the independents
• the Australian Code has now been revised to favor
  testing by the concrete supplier
• in the UK we are just starting this battle along
  with Pioneer UK on the Canary Wharf Project

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SYSTEM SNAPSHOTS

• To save time, the initial presentation will use
  still snapshots taken from the CONAD system -
  questions will be welcome but some answers may be
  difficult to illustrate at that time
• I will leave time at the end for questions and
  discussion and in that section of the
  presentation, the system will be live so that
  points can be illustrated - so please have some
  searching questions and discussion ready
• however first I want to show you the menu system
  live, so that you can understand where the stills
  are coming from

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ENTER DETAILS OF CLIENTS, PROJECTS,TESTERS,
PLANT, SUPPLIER
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Batch Plant Data Interface
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Batch Plant Data Error Graph
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Batch Plant Data Error Graph
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Batch Plant Data Error Graph
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Batch Plant Error Data Graph
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Material Data Entry
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TIMELINE GRADING VARIATION
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GRADING DISTRIBUTION
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TEST DATA ENTRY
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TEST DATA ENTRY SET UP
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SPECIMEN DATA ENTRY
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ALTERNATIVE SPECIMEN ENTRY
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FULL SCREEN VIEW
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USING YOUR DATA

• the G I - G O principle
• detecting change multigrade, multivariable,
  CUSUM analysis
• semi-automatic reporting
• monitor the effectiveness of your entire operation

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DATA SELECTION SCREEN FOR ANALYSIS
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Multigrade Statistical Data 1
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Multigrade Statistical Data 2
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Multigrade Statistical Data 3
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Multigrade, Multivarible Cusum
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YOU can design and store any number of standard
report formats which then compile and print out
automatically on entering date range
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Example of automatically prepared report
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BIG BROTHER IS WATCHING!

• errors in batching operation in individual
  loads and cumulative over any period
• performance of each testing officer
• distribution of production by customer, truck,
  grade of concrete
• rate of production

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CUMULATIVE BATCHING ERROR OVER PERIOD
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CONCRETE QUANTITY PER TRUCK
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AVERAGE PRODUCTION RATE OVER DAY
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AVAILABLE GRAPH TYPES
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ACI acceptance criteria 1
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ACI acceptance criteria 2
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TESTER STATS 1
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TESTER STATS 2
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MIX OPTIMISATION

• you often hear the term - have you ever seen a
  system which can do it?
• Conad can be given up to eight coarse aggregates
  and five sands and will choose which ones to use,
  and in what proportions, to give the most
  economical mix
• it can tell you to a dollar the value to you of
  any new aggregate or sand you are offered

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MIXTABLE WORKING SCREEN
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GENERATED TABLE OF MIXES
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GRAPHS OF DATA USED TO GENERATE TABLE
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AA CONCRETE SUPPLIERS

• We have discussed what you can do for yourselves
  using Conad and Alkon
• now I want you to consider what AlkonConad can
  do for you
• the concept is that of an ALKON ACCREDITED
  CONCRETE SUPPLIER
• Someone who
• uses Conad and Alkon
• has attended a school
• has certificate of approval of QC data

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AA CONCRETE SUPPLIERS

• Three benefits are seen
• sales benefit of higher prestige
• technical assistance with problems
• economic benefit from assistance with mix design,
  materials selection etc

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AA CONCRETE SUPPLIERS

• A two part report card is envisaged
• one part for display to clients
• one part advice to operator
• may be most attractive to smaller operators who
  cannot justify their own full technical
  facilities?
• We want feedback on this please!

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AA CONCRETE SUPPLIERS

• you can easily email to us your QC and Mix
  directories
• we can then advise on mix revision and material
  selection from both technical and economic
  viewpoints
• a major attraction is that of efficiency
• data self-explanatory, advice very accurate and
  reliable-very different cost and time reqd. to
  calling in a consultant

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MIXTABLE INPUT
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BATCHING SEQUENCE
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MIX CODE INTERPRETATION
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THE END
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CONAD

• Features
• Benefits

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CONAD - Features and Benefits

• MANAGEMENT
• Reduce costs
• Reduce variability
• efficient use of materials
• Improve staff efficiency
• Computerised control of concrete data
• Efficient data entry, data retrieval
• Selection of operator designed or standard
  reports
• Interface of data between systems

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CONAD - Features and Benefits

• TECHNICAL
• Easy data retrieval for every truck load of
  concrete
• Combined Batch, Field tests and Material data
• Produce better concrete with control over mixes
• Cope with variability in available materials
• Use of a selection of statistical tools e.g
  CUSUM, Direct Plot Auto-detect, Strength
  development curves
• Improved Strength Prediction and detection of
  change
• Ranking all mixes in order of departure from
  target
• Accurate mix adjustment for maximum economy
• Flexibility in use of materials

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CONAD - Features and Benefits

• TECHNICAL (cont.)
• Performance feedback to Laboratories
• Identification of sources and extent of testing
  error
• Performance feedback to Plants
• Out of tolerance batching, equipment maintenance
• Material quality feedback to suppliers
• detecting change in material quality
• mix adjustment to compensate for variation in
  materials
• Production Control
• analysis of material usage and delivery details.

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CONAD - Features and Benefits

• TECHNICAL (cont.)
• Country Code or Other Specific Requirements
• Can add Special Reports to CONAD on request
• CONAD configuration number to meet specific
  requirements such as auto-detection
• Use of features in Laboratory
• Direct capture, specimen diaries, checks,
  printouts, etc
• Recall events with QA Diary
• In-situ early age strength prediction

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CONAD - Features and Benefits

• SALES (Customer comment response)
• Provide Customers with Reports
• Official or unofficial company reports
• Mix comparison reports
• Specific project notification reports
• Project/client specific invoices for testing
  services
• Reputation enhancement

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CONAD - Features and Benefits

• IT MANAGERS
• Standalone or networking of data
• Data archiving, download/combine features
• Year 2000 compliance
• Save to file export data features
• Interfaces with other systems or equipment
• System administrator controlled logon security
• Developed in Borland Delphi software, one of the
  most powerful and flexible available

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CONAD - Features and Benefits

• Other
• CONAD support / maintenance
• We are particularly proud of our reputation for
  prompt attention to client requests
• We invite you to contact any of our existing
  clients for confirmation.
• We find clients prefer immediate issue of
  updates, themselves participating in final
  adjustment, so avoiding delay in implementation
• CONAD change control register
• We maintain a register of all system amendments
  and provide updates of the register on request
  
  

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CONAD

• Current
• Clients

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Current CONAD Clients

• CSR Readymix (Australia)
• Nationwide, 200 plants
• BORAL Concrete (Australia)
• Nationwide, 200 plants
• ALPHA (South Africa)
• PIONEER (Singapore, Malaysia)
• PIONEER (UK)
• CSR (China)
• RMC (Malaysia)
• Hormigon Hercules (Ecuador),

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Current CONAD Clients

• Other clients with CONAD on trial
• APASCO (Mexico)
• DUFFERIN(Canada)
• Pioneer (Philippines)
• Partek (Finland)

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CONAD
SYSTEMS
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CONAD - Test Result Entry

• Product / Mix Details Setup
• Field Sheet Data Entry
• Alternative Laboratory Specimen Entry
• Specimens for Test / Specimen Reports
• Daily Reports
• Other Types of Tests e.g. Shrinkage
• Invoicing / QA Diary Options

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CONAD - Batch Plant Data

• Batch Variation Processing
• Batch Variation Quantity/Cost Analysis
• Production Analysis
• Grading Variation

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CONAD - Materials Control

• Material Entry
• Material Reports
• Edit Plant Material Costs

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CONAD - Combined Analysis

• Single/Multi-Grade, Direct/CUSUM Analysis
• Other Combined Analysis Features
• Search Criteria, Graphing, Report Design, Target
  Strengths, Auto-Detection
• Other Standard Analysis Reports
• Normal Distribution, Strength comparison,
  Strength Gain, Running SD, Testing Frequency
• Client Requested Reports
• Plant/Tester Stats, Country Code Specific

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CONAD - In-situ Early Age

• Temperature Monitoring
• Equivalent Age / Actual Age Relationship
• In-situ Strength Vs Actual Strength

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CONAD - In-situ Early Age
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CONAD - Internationally

• Pre-printed forms, e.g. CSR China Test Report
• Incorporation of further languages in CONAD
• Units conversion, e.g. US units (CONAD mini)
• Variable sieve sizes in CONAD
• Windows Control Panel Regional Settings

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CONAD - Mix Control

• Cement Margins / Benchmark
• Mix Design Alternatives
• Auto-mix
• One mix fine tune, trial mix
• Quick mix
• Mix tables

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CONAD - Maintaining Mixes

• Alternatives
• Manually adjust mixes one at a time
• Central technician electronically updates tables
  of mixes in batching computer
• Locate Mixtables program in batching computer,
  central technician updates strength performance
  and materials data, tuned for slump and
  temperature at plant

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CONAD
SUMMARY
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CONAD - Summary

• Concrete Advice
• Features and benefits of CONAD
• Current CONAD clients
• CONAD - Quality Control Systems
• Test Result Entry
• Batch Data
• Materials Control
• Combined Analysis
• In-situ Early Age
• International use of CONAD
• Mix Control