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International Journal of Advanced Engineering Research and Technology (IJAERT) 176

Volume 2 Issue 6, September 2014, ISSN No.: 2348 8190

DEVELOPMENT & APPLICATION OF V&V MODEL TO TYRE


INDUSTRY PROCESS FOR PRODUCTION & QUALITY IMPROVEMENT
A.U.Gawner1
1
IBMRD, Ahmednagar-414001, India.

ABSTRACT
Over the last few years, significant development has
been established in process of SDLC to run the process
or system effectively to get Quality of product & to
increase the production. There are number of SDLC
model such as Water fall, Spiral ,Iterative Model , V&V
Model, Big Bang Model etc.. We here develop the AUG
V&V Model for process industry which is complete
replica of V&V Model & Implement on Sub System of
Tyre Industry i.e. on Tyre Building Machine(TBM).
Which was provided us very good result. We reduced
the Curing Cycle by 177 Second is huge achievement
without compromising the Quality. By doing this we
increase production 6 tyre/per day/per machine,180
tyre/month/machine& 2160 tyre/year/machine. Also It
provide the total documentation , Control & Manage
Process.

development model(SDLC) Such as Waterfall Model,


Iterative Model, Spiral Model, V&V Model, Big Bang
Model etc Which are Special used in Software Industry.
In order to apply these models to process industry there
is need to tune some phases of these models.
As all outputs are the result of processes, continuously
improving customer satisfaction requires the continuous
improvement
of
processes.
Improvement
is
accomplished by enhancing the ability of the process to
deliver value to the customer. By doing research on
SDLC, we design AUG V&V Model which is replica of
V&V Model of SDLC. Check out the result on Tyre
Industry Porcess For Tyre Building Machine.

II.

SDLC V& V Model

Following figure shows


model(Fig.1).

different phases of V&V

Keyword AUG, Operation, Quality Control &


Assurance, TBM, V&V Model

I.

INTRODUCTION

Operation is that part of as organization, which is


concerned with the transformation of a range of inputs
into the required output (services) having the requisite
quality level. Management is the process, which
combines and transforms various resources used in the
operations subsystem of the organization into value
added services in a controlled manner as per the policies
of the organization.
In order to have a proper operation management with
required Quality, we need to manage the process in well
define manner, which will fulfill process objective.
Continuous quality improvement process assumes and
even demands that a team of experts in field as well as a
company leadership actively use quality tools in their
improvement activities and decision making process.
There are three premises that underlie the intense interest
in continuous process improvement by the quality
profession: All work is a process, All processes vary,
Process variation equals to reduced quality.
This implies, in turn, that meeting engineering
requirements is not good enough. After all, engineering
requirements are an allowance for variation. To define
the well definite process there are number of system

Fig.1. V& V Model of SDLC


New AUG V& V Model For Process Industry
This New AUG V&V Model(Fig.2) is Complete replica
of SDLC V&V Model for Software Project. By
changing the stage & Phase required for Process industry
we present here the New Model called as AUG V& V
Model. Here AUG stand for Amol Uttamrao Gawner
Here also First V stand for Verification & Second V
stand for Validation

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International Journal of Advanced Engineering Research and Technology (IJAERT) 177


Volume 2 Issue 6, September 2014, ISSN No.: 2348 8190

When problems with quality occur due to missing terms


& meaning, requests to change the system may be
initiated and change requests impact cost, schedule, and
scope of a project.
The SyRS is used as the basis for the design and
implementation of the system. Development of the SyRS
is performed iteratively with the activities within the
System Design process. Refer to the System
Requirements Specification Instructions for the
fundamental characteristics of requirements.

Fig.2.AUG V&V model for process industry


1. Verification
Verification is process of confirming whether system
meet its Specification. It is process of reviewing,
inspecting deliverable throughout the life cycle. It is
process of examining a process or sub system or
components to discover its defects. Verification is
usually performed by inspecting without execution of
system. Verification Model include the following
Important phases for process industry in order to develop
strong, Qualitative & Quantitative product. Different
phases are as follows[1].
1. Requirement.
Find out requirement of System .What will be our
system?
2. Functional Specification.
Finalize the Functional Specification of System. To
establish a common understanding of the system
requirements between the project team and stakeholders.
System requirements are elicited from stakeholders,
analyzed, and presented in a System Requirements
Specification (SyRS). The SyRS describes functions and
capabilities of the system; business, organizational, and
user requirements; safety, security, human-factors,
interface, operations, and maintenance requirements;
design constraints and qualification requirements.

3. Design of System
Design the system as per functional specification Detail.
This is to determine and document in sufficient detail
how the system is to be constructed. The system design
must meet system requirements and standards. The
system design is the top-level system architecture and
identifies all components of hardware, software, and
manual operations. In addition, it identifies system-wide
design decisions, concept of execution, interface design,
and requirements traceability to design components.
. Identification and resolution of unallocated
requirements, design flaws, and problems positively
impact the quality of and customer satisfaction with the
implemented system. In addition, flaws and problems
corrected early in system development have less of an
impact on a projects schedule and budget.
4. Develop Sub System
This is to construct and unit test the product described by
the Design Description.
Consider that this activity consists of performing
detailed design, coding, and testing for each process unit
to satisfy the requirements and design described in the
Requirements Specification and Process Design
Description. In addition, consider that this activity also
contains tasks to perform detailed design and coding of
databases and interfaces between process units and
items, and planning and execution of unit tests.
It is important to consider that tasks within this activity
include test planning. As discussed in the System
Development Life Cycle Models section, planning and
execution of testing is integrated throughout the life
cycle. Initiation of test planning occurs within the
System Requirements activity and iterative refinement of
the test plan occurs throughout subsequent life cycle
activities. Initiation and refinement of test scenarios also
occurs, as necessary.
5. Develop Whole System
This is to construct and unit test the process components,
parts, sub parts product described by the Design
Description.

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International Journal of Advanced Engineering Research and Technology (IJAERT) 178


Volume 2 Issue 6, September 2014, ISSN No.: 2348 8190

Consider that this activity consists of performing


detailed design, coding, and testing for each process unit
to satisfy the requirements and design described in the
Requirements Specification and Process Design
Description. In addition, consider that this activity also
contains tasks to perform detailed design and coding of
databases and interfaces between process units and
items, and planning and execution of unit tests.
6. Installation Of Sub System
Same as per Installation of Whole System. In this phase
only we have to don installation at micro level or
components level.
7. Installation of Whole System
This is to ensure that aggregates of units tested during
the unit test phase can be successfully integrated into a
process item, as designed.
Consider that tasks within this activity include
preparation for and execution of the tasks documented in
the Integration Test section of the Test Plan. This
activity should be tailored to include tasks to integrate
aggregates of units and determine if the aggregate
satisfies requirements.
8. Release For Use
This is to complete deployment preparation and
deployment of the system, as documented in the
Deployment Plan.
Consider which tasks are required for assuring that the
deployment plan is finalized, reviewed, approved, and
executed, resulting in an operational system. Initiation of
test and deployment planning occurs within the System
Requirements activity and iterative refinement of those
plans occurs throughout subsequent life cycle activities.
When deployment tasks are successful, the result is the
implementation of the system designed based on the
documented requirements. When problems occur with
the deployment, the contingency planning tasks
documented within the Deployment Plan may be
executed to mitigate or eliminate additional risk.
2. Validation
Validation [1] is process of confirming whether
system meets users specifications. It is process of
execution something to see how it is behave. It is
process of executing a system or components to expose
its faults. Validation Model Include following Important
Phases. They are
1. Requirement Review.
2. Functional Review.
3. Design review.
4. Check Sub System.
5. Check Whole System.

6. Commissioning Sub System.


7. Commissioning of Whole System.
8. Check out Final Result.
All above phase are the validation Phase. In each Phase
we have to validate the each component with system
requirement & Specification. We have to check out each
activity without consideration with inner structure of
project. We have to check out the system , sub system,
components, sub components whether each part work
individually as per Functional Specification & Also
work properly as per system requirement when connect
in system. Ultimately we are interested in whole system.
As a whole System , it should perform well & Fulfill the
project requirement Qualitatively & Quantitatively.

III.

IMPLEMENTATION OF AUG V&V


MODEL

Here Our study is limited up to the Tyre Building


Machine. Tyre Building Machine is of BOM (Bag - OMatic) Company. Which consist of -High Pressure Line,
Hot Water Line, Shaping Pressure Line, Cold Water
Line, Drain Line, Platen Line ,Cold Water Return Line,
Air Line
Apart from this,
It consist of HMI, Control Panel with PLC Program ,
Solenoid Valve Control assembly.
Different Piston Valve on Different pressure line control
by Solenoid Valve Control Assembly & Solenoid Valve
Control Assembly get Control according to PLC
Programming. PLC programming consist of Curing
Cycle of Tyre. There are different curing cycle for
different Tyre. Curing Cycle for BOM of 7.50- 16 type
of Tyre is as follows.
TABLE I: CURING CYCLE for BOM of 7.50- 16
TYPE of TYRE

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Sr.
No
1

Step No

Process

Required Time
in Second
Step 1
H.P. Purging 10
+ Shaping
2
Step 2
H.P
710
3
Step 3
H.W.D.E.
60
4
Step 4
H.W.C.
780
5
Step 5
H.W.D.E.
240
6
Step 6
C.W.C.
300
7
Step 7
Drain
60
8
Step 8
Vacuum
30
Total Period Of Curing Cycle in 2180 Second
Second

International Journal of Advanced Engineering Research and Technology (IJAERT) 179


Volume 2 Issue 6, September 2014, ISSN No.: 2348 8190

By Applying the AUG V&V Model, i.e. By Reviewing


Whole Process as per Specification & Standard ,
Checking Layout, Removing Delay, Redesign
By
applying AUG V& V Model, We are able to achieve
the Quality of Product ( Tyre).Also able to increase the
Production at tremendous level.
1. New Curing Cycle By applying AUG V&V Model.
By Appling AUG V&V Model to BOM & Assembly,
we reduce curing cycle time by 177 second. Our New
curing cycle is as follows.

7
8

Step 7
Drain
50
Step 8
Vacuum
20
Total Period Of Curing Cycle in 1193
Second

900
800
700
600

TABLE II: NEW CURING CYCLE for BOM of 7.5016 TYPE of TYRE
Sr. Step No
Process
Required
No
Time
in
Second
1
Step 1
H.P. Purging + 8
Shaping
2
Step 2
H.P
680
3
Step 3
H.W.D.E.
55
4
Step 4
H.W.C.
720
5
Step 5
H.W.D.E.
220
6
Step 6
C.W.C.
240
7
Step 7
Drain
50
8
Step 8
Vacuum
20
Total Period Of Curing Cycle
2003 second

500

Reducing Curing Cycle By 10 second is consider a huge


achievement , because each second is work as multiplier
to second, minute, day, month & year. Here we Reduce
the Curing Cycle by 177 second is a Huge, Huge
achievement. That will increase the tremendous amount
of production.

700

Previous Time
In Second

400

Ideal Time in
Second

300

New Time in
Second

200
100
Step 1
Step 2
Stap 3
Step 4
Step 5
Step 6
Step 7
Step8

Fig.3.Line Diagram for Curing Cycle Steps


800

600
Previous Time In
Second

500
400

Ideal Time in
Second

300

IN

200

Let see the how it will increase the production . As per


the research team & Technical Analysis, Ideal Curing
Cycle for BOM of 7.50- 16 type of Tyre is
TABLE III: IDEAL CURING CYCLE for BOM of
7.50- 16 TYPE of TYRE
Sr.
Step No
Process
Required
No
Time
in
Second
1
Step 1
H.P. Purging + 8
Shaping
2
Step 2
H.P
670
3
Step 3
H.W.D.E.
55
4
Step 4
H.W.C.
710
5
Step 5
H.W.D.E.
210
6
Step 6
C.W.C.
240

100

New Time in
Second

Step8

Step 7

Step 6

Step 5

Step 4

0
Stap 3

INCREASE

Step 2

ANALYSIS OF
PRODUCTION

Step 1

IV.

Fig.4. Bar Diagram for Curing Cycle Steps


By observing All above table of Curing Cycle,
Time required for the Ideal Curing Cycle
= 1193 Second,
Current Curing Cycle ( Previous)
= 2180 Second
& New Curing Cycle
= 2003 Second.

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International Journal of Advanced Engineering Research and Technology (IJAERT) 180


Volume 2 Issue 6, September 2014, ISSN No.: 2348 8190

So,
Total No of Batches per day as per the Previous Cycle
time
=24*60*60/2180
=86400/2180
=40 Batches/Day
= 40* 2 Tyres Production / Day= 80 Tyres/ Day
Total No of Batches per day as per New Cycle time =
86400/2003
=43Batches/Day
=43*2Tyres/Day
= 86 Tyres / Day

Cureing Cycle For 7-1516 type of tyre


88
86

Increase in production per day due to application of


AUG V& V Model
= New Production Previous Production
= 86 80
= 6 Tyres /Day
Monthly Increase in production due to application of
V& V Model= 6 * 30 = 180 Tyre / Month
For One Year = 180 * 12= 2160 Tyres/ Year

V.

CONCLUSION

Over the last few years, significant development has


been established in process of SDLC to run the process
or system effectively to get Quality of product & to
increase the production. We here Develop the AUG
V& V Model & Implement on Sub System of Tyre
Industry. Which was provided us very good result.
Reduced the Curing Cycle by 177 Second is huge
achievement. Also It provide the total documentation
& Control & Manage Process Which is good for Long
term History & to rectify the error.

84

ACKNOWLEDGEMENT

82

I am very much thankful to MTL who gave me the


chance to work with them. I am also thankful Prof. (Dr.)
Arun Ingale, Director, IBMRD, Ahmednagar who gave
me the valuable guidance. I also extend my thanks to
Prof.(Dr.) V.S.Pendase & Prof. P.B. Suryawanshi who
encourage & guide me through out the project for good
work.

Cureing Cycle
For 7-15-16
type of tyre

80
78
76
Production of Production of
Previous
V&V Model
Process

REFERANCES
Fig.5. Bar Diagram For Comparative Increase In
Production

Cureing Cycle For 7-1516 type of tyre


2500
2000
1500
1000
500
0

[1] Texas Department Of Information Resourc


[2]Http://En.Wikipedia.Org/Wiki/Systems_Development
_Life_Cycle
[3]Http://En.Wikipedia.Org/Wiki/Agile_Software_devel
opment
[4] Http://Agilemanifesto.Org/
[5] Http://Www.Agilealliance.Org/
[6] Www.Rockwellautomation/Solutions/Oem

Cureing Cycle
For 7-15-16
type of tyre

Fig.6. Bar Diagram showing Increase in Production Per


Day, Per Month, Per Year

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