i

A STUDY ON STATISTICAL PROCESS CONTROL THROUGH SMART

MANUFACTURING IN WABCO INDIA

By

SRINIVASAN.P. V

Register No. 412518631096

Of

SRI SAI RAM ENGINEERING COLLEGE

A PROJECT REPORT

Submitted to the

FACULTY OF MANAGEMENT SCIENCES

In partial fulfilment of the requirements

For the award of the degree

Of

MASTER OF BUSINESS ADMINISTRATION

ANNA UNIVERSITY

CHENNAI – 600 025

JUNE 2020
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BONAFIDE CERTIFICATE

This is to certify that this project report titled “A STUDY ON STATISTICAL

PROCESS CONTROL THROUGH SMART MANUFACTURING IN

WABCO INDIA” is the bonafide work of Mr. SRINIVASAN. P.V (Reg. No:
412518631096) who carried out the work under my supervision. Certified further, that to the best
of my knowledge the work reported herein does not form part of any other project report or
dissertation on the basis of which a degree or award was conferred on an earlier occasion on an
this or any other candidate.

Dr. V. HEMANTH KUMAR Dr. K. MARAN

Signature of the Guide Signature of the Director

INTERNAL EXAMINER EXTERNAL EXAMINER

iii
 iv

DECLARATION

I, P. V. SRINIVASAN, hereby declare that the project report, entitled “A STUDY ON

STATISTICAL PROCESS CONTROL THROUGH SMART

MANUFACTURING IN WABCO INDIA” submitted to the Anna University Chennai
in partial fulfilment of the requirement for the award of the degree of MASTER OF BUSINESS
ADMINISTRATION is record of original and independent research work done by me during
June 2020 under the supervision of Dr. V. HEMANTH KUMAR, Department of Management
studies, and it has not formed the basis or other similar title to any candidate of any university.

Place: Chennai

Date: (P. V. SRINIVASAN)

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ABSTRACT
The study includes effectiveness of Analyzing and Implementation of Statistical process Control
in WABCO India Limited. SPC (Statistical Process Control) is an industry standard
methodology for measuring and controlling quality during the manufacturing process. The
Existing System of Statistical Process Control has some barriers in Production. The objective of
the study is to Analyze the barriers in Existing System of Statistical Process Control. The
Improvement in Existing Statistical Process Control is Analyzed and implemented using new
system. The Output also successfully achieved in proposed Statistical Process Control.
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ACKNOWLEDGEMENT

First of all, I thank and praise God Almighty for the countless blessing that he showered the
blessings upon me to complete this project work.

I am thankful to our Founder Chairman MJF. Ln. LEO MUTHU and Chief Executive
Officer Mr. SAI PRAKASH LEO MUTHU for providing excellent environment and
infrastructure at Sri Sai Ram Engineering College, Chennai for the moral support for project
work.

I would like to express my sincere thanks to Dr. A. RAJENDRA PRASAD, Principal of Sri
Sai Ram Engineering College, Chennai for his moral support to complete the project work.

I extent my heartfelt thanks to Dr. K. MARAN, Director and Professor, Department of

Management studies, Sri Sai Ram Engineering College, Chennai for his valuable idea’s
guidance and support for the successful completion of this project work.

I also thank to faculty guide Dr. V. HEMANTH KUMAR, Professor, Department of

Management studies, Sri Sai Ram Engineering College, Chennai who kindly inspired me to
undertake and complete this project work.

Last but not the least I also thank the “WABCO INDIA LTD” for helping me directly in the
fruitful completion of my project.

(SRINIVASAN P V)
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TABLE OF CONTENT
ABSTRACT iv
ACKNOWLEDGEMENT v
LIST OF TABLES viii
LIST OF FIGURES ix
LIST OF CHARTS ix
CHAPTER NO. TITLE PAGE.NO.
INTRODUCTION 1
1.1 Introduction of the Study 1
1.2 Industry Profile 7
1.3 Company Profile 9
1.4 Review of Literature 12
I
1.5 Need for the Study 20
1.6 Objectives of the Study 20
1.7 Scope of the Study 20
1.8 Research Methodology 21
1.9 Limitations of the Study 22

DATA ANALYSIS AND INTERPRETATION 23

II 2.1 Existing System 23

2.2 Analysis of Existing System 25
2.3 Proposed System 28
FINDINGS, SUGGESTIONS AND 38

III CONCLUSION
3.1 Findings 38
3.2 Suggestions 39
3.3 Conclusion 40

BIBLIOGRAPHY 41
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LIST OF TABLES
TABLE NO TITLE PAGE NO
1.1 Types of Characteristics 10
2.1 Challenges and Occurrence 26
2.2 80-20 Rule 32

LIST OF FIGURES
FIGURE NO TITLE PAGE NO
1.1 Production Process 1
1.2 Types of Variation 3
2.1 Existing Process Flow 24
2.2 Proposed Process Flow 28
2.3 Raspberry pie kit 29
2.4 Raspberry pie kit Case 29
2.5 RS232 Cable 30
2.6 USB Hub 30
2.7 Power Source Cable 31
2.8 Heat Sink 31
2.9 Working of Server 35
2.10 Output of Proposed System 37

LIST OF CHARTS
CHART NO TITLE PAGE NO
2.1 Pareto Chart 26
2.1 Pie Chart 33
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1.INTRODUCTION TO THE STUDY

1.1 STATISTICAL PROCESS CONTROL:

SPC (Statistical Process Control) is an industry standard methodology for measuring and
controlling quality during the manufacturing process. SPC data is collected in the form of
measurements of a product dimension / feature or process instrumentation readings. It was
developed by Dr. Walter Shewhart of Bell laboratories in 1920’s. Later it was expanded by
Japanese quality guru Dr. W. Edward Deming.

Statistical data are collected from the process and analyzed to understand the process behavior,
predict the process performance and decide the course of action. Quality data in the form of
Process measurements are obtained in real-time during manufacturing. This data is then plotted
on a graph with pre-determined control limits. Control limits are determined by the capability of
the process, whereas specification limits are determined by the client's needs.

Fig: 1.1
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1.1.1 Principles of Variation:

All the Measurement Systems will have some variation in the system. In order to
effectively use process control measurement data, it is important to understand the concept of
variation. No two products or characteristics are exactly alike, because any process contains
many sources of variability. The differences among products may be large, or they may be
immeasurably small, but they are always present. The diameter of a machined shaft, for instance,
would be susceptible to potential variation from the machine, tool, material, operator,
maintenance, environment and measurement system. Some variation in the process cause short-
term, piece-to-piece differences. Other sources of variation tend to cause changes in the output
only over a long period of time. It is possible to mathematically model the variation pattern in the
output of any process. If stable; the pattern can be described by a distribution. The variation can
be traced to two basic sources; the fig shows the concepts of variation.
• Common Cause: The common cause refers to the many sources of variation that
consistently acting on the process. Common cause within a process produces a stable and
repeatable distribution over time. This is called “in a state of statistical control.” Common
causes yield a stable system of chance causes. If only common causes of variation are
present and do not change, the output of a process is predictable.
i. Inherent to process,
ii. Follows predictable pattern
iii. Can’t be reduced without process redesign or high cost
• Assignable Cause: They refer to any factors causing variation that affect only some of the
process output. They are often intermittent and unpredictable. Special causes are signalled
by one or more points beyond the control limits or non-random patterns of points within the
control limits. Unless all the special causes of variation are identified and acted upon, they
may continue to affect the process output in unpredictable ways. If special causes of
variation are present, the process output will not be stable over time.
i. Not inherent
ii. Doesn’t follow any pattern / Sporadic.
iii. Can be eliminated.
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Fig: 1.2
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1.1.2 Process Capability:

Process capability is the repeatability and consistency of a manufacturing process relative to the
customer requirements in terms of specification limits of a product parameter. Process capability
is determined by the variation that comes from common causes. It generally represents the best
performance of the process itself. Process capability is the range over which the natural variation
of the process occurs as determined by the system of common causes. It is the ability of the
combination of people, machine, methods, material and measurement to produce a product that
will consistently meet design specifications. Process capability of a process is the extent of
variation in the Quality characteristic of the process output, when the process is operating in a
state of Statistical control under a given set of conditions. Concerns with the ability of the
process to produce output meeting specifications consistently. Takes into account variation
caused by all the possible sources of variation. Data for Process Capability Analysis should be
collected over a period of time. The proportion of output that can be produced within design
specifications measures process capability; in other words, it is measure of uniformity of process.
Process capability can be measured if all special causes have been eliminated and the process is
in the state of statistical control. Process capability is important to both product designer and
manufacturing engineer. A process capability study allows one to predict, quantitatively, how
well a process will meet designed to yield specific information about the performance of the
process under specified operating conditions. The six steps involved in the process capability
study are: -
1. Choose the representative machine or segment of the process.
2. Define the process conditions.
3. Select a representative operation.
4. Provide materials that are of standard grade with sufficient amount for uninterrupted study.
5. Specify the gauging or measurement method to be used.
6. Provide a method of recording measurements and conditions, in order, on the unit procedure.
It is measured by the formula
CP = USL-LSL
____________
6σ
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1.1.3 Process capability index:

Process capability index (Cpk) is a statistical tool, to measure the ability of a process to
produce output within customer's specification limits. The importance of process capability is in
assessing the relationship between the natural variation of the process and the design
specifications. This is often quantified by a measure known as the Process capability index. The
process capability index CP is defined as the ratio of specification in a single quantitative
measure. Two important facts about the CP index should be pointed out. One relates to the
process conditions and others relates to the interpretation of the values that have been calculated.
The calculation of CP has no meaning if the process is not under statistical control. The natural
spread 6 sigma should be calculated using a sufficient large sample to get a meaningful estimate
of the population standard deviation sigma. Control Charts are the main statistical technique used
to conduct process capability
Cpk = min (CPU; CPL)
UCL = Upper control limit
LCL = Lower control limit
σ = Standard deviation of process

1.1.4 Theory of Control Charts:

Control charts can be used to monitor or evaluate a process. There are basically two types of
control charts, those for variables data and those for attributes data. The process itself will
dictate which type of control chart to use. The data can also be collected and recorded as
individual values or an average of a group of readings. Control chart is a graphic aid to detect
quality variation in output from a production process. As opposed to the aim of acceptance
sampling (to accept or reject products already produced), control chart help produce a better
product. The charts have three main applications like to determine the actual capability of
production process, to guide modifications for improving the output quality of process, and to
monitor the output. The monitoring function shows the current status of output quality and
provides an early warning of deviation from quality goals. Control charts have two principle
divisions: attributes and variables. Attribute control can be further divided into charts for
percentage defectives and chart for the number of defects per unit. The main interest in the
variables is control over changes in the average and the range of measurements. Control chart for
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all these considerations follows the same basic format of mean value bounded by upper and
lower control limits. It is the calculation of the control limits that distinguishes the type of chart.
In Compressor Machining they are using variable data. The some of the works of control charts
are
• Gives signal before the process starts deteriorating
• Aids the process to perform consistently and predictably
• Gives a good indication of whether the problems are due to operational faults or system
faults
• Provides a common language for communicating the performance of any process
• Provides a record of process performance
• Simple to use and can be maintained by the operator himself.
One of the most widely used control charts for variable data is the X-bar and R chart.
Attribute Charts:
If the data derived from the process are of a discrete nature then an attribute type of chart would
be used.
Example: go/no go, acceptable/not acceptable.
Variable Charts:
If the data derived from the process are of a continuous nature then a variable type of chart
would be used.
Example: diameter, length.
Within each chart type there are several chart combinations that can be used for further
evaluation process. Some more common types of charts are Average (X bar) and range charts,
individuals (i) chart, moving range (MR) chart, etc., belong to the variables chart family. Charts
based on count or present data (e.g., p, np, c, and u) belong to the attribute chart family.
Theory of X Charts
In X chart, means of small samples (3-5) are taken at regular intervals, plotted on a chart, and
compared against two limits. The limits are known as upper control limit (UCL) and lower
control limit (LCL). These limits are defined as under:
LCL = X - A2 R and UCL = X + A2R
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Where,
X is the target mean and factor A2 depends on sample size. The process is assumed to be out of
control when the sample average falls beyond these limits. X-bar represents the average or “mean”
value of the variable x. The X-bar chart displays the variation in the sample means or averages. Once the
chart is setup, the operator or technician will measure multiple samples, add the values together then
calculate the average. This value is then recorded on a control chart or X-bar chart. The range of the
subgroups is also recorded. The sample measurements should be taken and recorded in regular intervals,
including date and time to track the stability of the process.
Theory of Range (R) charts
In these charts, the sample ranges are plotted in order to control the variability of a variable. The
centreline of the R chart is known as average range. The range of a sample is simply the
difference between the largest and smallest observation. The Range chart shows the variation
within the subgroup. The range is simply the difference between the highest and lowest value.
If R1, R2... Rk, be the range of k samples, then the average range (R bar) is given by:
The upper and lower control limits of R chart are:
Upper control limit:
UCL = D4*Rbar
Lower control limit:
LCL = D3*Rbar

1.2 INDUSTRY PROFILE:

The global auto component industry could be next big success story after software,
pharmaceutical, BPO, textile.
1.2.1 History
Manufacturing is the production of products for use or sale using labour
and machines, tools, chemical or biological processing or formulation and is the essence
of secondary industry. The automotive industry in India is the fourth largest in the world. In
1897, the first car ran on an Indian road. Through the 1930s, cars were imports only, and in
small numbers. An embryonic automotive industry emerged in India in the 1940s. Hindustan
Motors was launched in 1942, long-time competitor Premier in 1944,
building Chrysler, Dodge, and Fiat products respectively. Mahindra & Mahindra was
 8

established by two brothers in 1945, and began assembly of Jeep CJ-3A utility vehicles.
Following independence in 1947, the Government of India and the private sector launched
efforts to create an automotive-component manufacturing industry to supply to the automobile
industry. In 1953, an import substitution programmed was launched, and the import of fully
built-up cars began to be restricted. India became the fourth largest auto market in 2018 with
sales increasing 8.3 per cent year-on-year to 3.99 million units. It was the seventh largest
manufacturer of commercial vehicles in 2018. The Two Wheelers segment dominates the
market in terms of volume owing to a growing middle class and a young population.
Moreover, the growing interest of the companies in exploring the rural markets further aided
the growth of the sector. India is also a prominent auto exporter and has strong export growth
expectations for the near future. Automobile exports grew 14.50 per cent during FY19. It is
expected to grow at a CAGR of 3.05 per cent during 2016-2026. In addition, several
initiatives by the Government of India and the major automobile players in the Indian market
are expected to make India a leader in the two-wheeler and four-wheeler market in the world
by 2020.

1.2.2 Evolution of Indian auto component:

The India auto component industry has always been riding over the Indian automobile industry
started as small in 1940’s supplying components to Hindustan Motors and premier automobiles.
In the 1950’s the arrival of Telco, Bajaj, and Mahindra & Mahindra led to steadily increasing
production. The leading auto component manufacturers (OEMs) in the world are ford, General
Motors, Delphi, and Caterpillar.

1.2.3 Market Size

Overall domestic automobiles sales increased at 6.71 per cent CAGR between FY13-19 with
26.27 million vehicles getting sold in FY19. Domestic automobile production increased at 6.96
per cent CAGR between FY13-19 with 30.92 million vehicles manufactured in the country in
FY19. In FY19, year-on-year growth in domestic sales among all the categories was recorded in
commercial vehicles at 17.55 per cent followed by 10.27 per cent year-on-year growth in the
sales of three-wheelers.
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Premium motorbike sales in India crossed one million units in FY18. During January-September
2018, BMW registered a growth of 11 per cent year-on-year in its sales in India at 7,915 units.
Mercedes Benz ranked first in sales satisfaction in the luxury vehicles segment according to J D
Power 2018 India sales satisfaction index (luxury).
Sales of electric two-wheelers are estimated to have crossed 55,000 vehicles in 2017-18.

1.2.4 Investments
In order to keep up with the growing demand, several auto makers have started investing heavily
in various segments of the industry during the last few months. The industry has attracted
Foreign Direct Investment (FDI) worth US$ 22.35 billion during the period April 2000 to June
2019, according to data released by Department for Promotion of Industry and Internal Trade
(DPIIT).

1.2.5 Industry Scenario:

The $74 billion Automobile industry is expected to reach $300 billion by 2026. India's annual
production has been 29.08 million vehicles in 2018 as against 25.33 million in 2017, registering
a healthy growth of 14.8%. The industry is expected to reach $135 billion by 2020 and $300
billion by 2026 at a CAGR of 15%. In FY 2018-19, sale of passenger vehicles has increased by
2.70%, two-wheeler by 4.86% and three-wheeler by 10.27% as compared to FY 2017-18.7 In
April-March 2019, overall automobile exports grew by 14.50%. The overall Commercial
Vehicles March 2019, overall automobile exports grew by 14.50%. The overall Commercial
Vehicles segment registered a growth of 17.55% in April- March 2019.

1.3 COMPANY PROFILE:

1.3.1 about WABCO
WABCO was founded in the United States in 1869 as Westinghouse Air Brake Company. They
were purchased by American Standard Companies Inc. (American Standard) in 1968 and
operated as the Vehicle Control Systems business division within American Standard until we
were spun off from American Standard on July 31, 2007. Subsequent to our spin-off, American
Standard changed its name to Trane Inc., which we herein refer to as “Trane.” On June 5, 2008,
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Trane was acquired in a merger with Ingersoll-Rand Company Limited (Ingersoll Rand) and
exists today as a wholly owned subsidiary of Ingersoll Rand.

1.3.2 WABCO INDIA

WABCO India traces its roots to Sundaram Clayton, a JV between the TVS Group and
UK-based Clayton Dewandre in 1962. The company has the distinction of being the first in the
country to win the Deming Prize and the Japan Quality Medal. WABCO took majority control in
2009 in the brakes division of Sundaram Clayton Limited thus effectively capitalizing significant
growth opportunities in India by investing in technologies required to maintain its strong market
position, and responding to the future needs of the Indian commercial vehicle market for
advanced driver safety and efficiency vehicle control systems. Headquartered in Chennai,
WABCO India is committed to the long-term success of its customers by leveraging WABCO's
powerful global technology portfolio. WABCO India has 5 manufacturing plants located across
country in Chennai (Tamil Nadu), Mahindra World City (Tamil Nadu), Jamshedpur (Jharkhand),
Pant Nagar (Uttara hand) and Lucknow (Uttar Pradesh).

1.3.3 Theory of characteristics:

The WABCO India products are safety based one. The products produced from WABCO India
have more safety related concern thus each part of the products is described by characteristics.
The characteristics are assigned to all the operations in production of products and assembly of
the products. There are several numbers of characteristics in our company. There are 473
Characteristics in Compressor Machining Area. The characteristics denote some significance
related to the output of the product. The Characteristics is the output characteristic which we
want to measure and improve. The characteristics are denoted as <1>, <2>. <1> is for safety and
<2> is for significance

<1> Safety Which can cause Accidents

<2> Significance Which can cause
breakdown and failure of
Brake

Table: 1.1
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In order to monitor and control the <1>, <2> characteristics the SPC is following by checking the
samples of each product in a frequency of time.

1.3.4 Zero ppm:

Generally, the PPM is abbreviation of parts per million, which means number of
defective parts per million. The WABCO India manufacturing Complete Brake System and
Solutions. Hence the company is manufacturing safety related product there should be no defects
in the product. Hence, they are following zero ppm programs. In order to achieve zero ppm, the
process should be more controlled under limits. By using the Digital SPC the zero ppm can be
achieved in the way of close monitoring of the process.

1.3.5 WABCO INDIA Products:

WABCO India is a leading supplier of technologies and services that improve the safety,
efficiency and connectivity of commercial vehicles in India. WABCO India excels in pioneering
breakthrough innovations that bring industry-leading solutions to the commercial vehicle
industry in India and worldwide. The company is a world-class manufacturer and local market
leader in advanced braking systems, conventional braking products and related.
WABCO is a leading global supplier of electronic, mechanical, electro-mechanical and
aerodynamic products for the world’s major manufacturers of commercial trucks, buses and
trailers, as well as passenger cars. They engineer, develop, manufacture and sell integrated
systems controlling advanced braking, stability, suspension, steering, transmission automation,
as well as air compression and processing. These systems improve vehicle safety, efficiency and
performance while reducing overall vehicle operating costs. We estimate that approximately two
out of every three commercial vehicles with advanced and conventional vehicle control systems
worldwide are equipped with our products. For passenger cars, including sports utility vehicles
(SUVs), they supply products for sophisticated, niche applications. They continue to grow in
more parts of the world as we increasingly provide additional components and systems
throughout the life of a vehicle, from design and development to the aftermarket. By leveraging
fleet connectivity, WABCO mobilizes vehicle intelligence to advance fleet safety, efficiency and
security.
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1.3.6 Components of WABCO products:

• Air Compressor
• Air Dryer
• Brake chambers
• Spring brake actuators
• Dual brake valve
• Integral pedal unit
• System protection valve
• Air tanks
• Brake hoses
• ABS products
• Vacuum booster
• Clutch booster

1.3.7 Mission
We thrive by offering our customers outstanding products and services that improve vehicle
safety and efficiency. Thanks to our passion for innovation, global capability, commitment to
excellence in execution and engineering heritage, we are uniquely equipped to deliver
differentiated results.

1.3.8 Market Leadership:

Virtually every Indian commercial and off-road highway vehicles manufacturer relies on
WABCO range of air brake equipment more than set of brake equipment supplied as of fitment.
Currently on road, serve as the testimony to the fact besides, a vast network of 220 wholesale,
More than 120 service centres and 110 workshops.
The WABCO Products are having 94% market shares in the Market. There are customers like
Daimler, Ashok Leyland, Volvo, Tata motors etc., and they are fully using the company products
only.
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1.4 REVIEW OF LITERATURE:

Radu Godina, João C.O. Matias, Susana G. Azevedo [1] (2016), Proposed the improvement
of the quality of a process through the use of SPC in an enterprise of the automotive industry
makes a brief review of concepts related with the methodology and aims to demonstrate all the
advantages associated with its use as a method for improving quality and reducing waste. To
accomplish this, after being completed the sample collection, the interpretations of control charts
and its analysis, it was made a study of the existing methodology of implementation of SPC in
the same process, and it was sought a way to adapt it to the reality of the company. Briefly, the
development of this work led to a deepening of knowledge around the management method or
set of tools for managing processes - the statistical process control (SPC) with respect to its
scope, its embracement and its implementation in the reality. The main objective of this paper is
to present the application of a systematic approach to the use of Statistical Process Control (SPC)
across the several stages of production of a specific "X" piece in a plant with the purpose of
improving the quality in its manufacturing processes. The approach proposed can be applied at
other stages of the process, contributing significantly to the reduction and/or elimination of
failures in the production process, allowing the fulfilment of the quality targets set by the
management company to other ones.

Harsimran Singh, Harsimran Jeet Singh Sidhu, Amandeep Singh Bains [2] (2016)
They have attempted to implement some statistical process control (SPC) techniques in the
industry that is offering its customers the widest and latest range of sealing solutions for various
applications in the automotive industry. Only two main techniques i.e. cause and effect diagram
and control charts are implemented in this industry out of seven SPC techniques. The present
work deals with the study of defects in clamp coining tool of an automotive industry. It is found
that after implementing the SPC tools to remove the root causes, the percentage rejection is
reduced from 9.1% to 5% and reduction in cost is achieved. The risk of accident is avoided if the
inclusion of worker is avoided with the machine. Rejection rate also get reduced to a large
extent. New work piece is made with proper dimension and accurate as required. According to
drawing work piece is required. Even the production time get reduced with new concept.
Production gets enhanced. Finally, they have got the result of implementation with the safety
point of view; no accident is there while manufacturing the clamp coining tool as there is no
 14

requirement of holding the mandrel. Least rejection trend is there in clamp coining tool. Less
production time to be taken by the manufacturing of clamp coining tool.

Er. Harpreet Singh Oberoi, Mamta Parmar, Harpreet Kaur, Rahul Mehra [3] (2016)
They have stated that variability in process performance often results in waste and rework. For
improvement in quality and productivity process variation needs to be reduced. Many techniques
are available for quality improvement. Statistical Process Control (SPC) is one such TQM
technique which is widely accepted for analysing quality problems and improving the
performance of the production process. The process capability index Cpk, measures a process's
ability to create product within specification limits. The higher the Cpk, the narrower the process
distribution as compared with the specification limits, and the more uniform the product. As the
standard deviation increases, the Cpk index decreases. At the same time, the potential to create
product outside the specification limits increases. The Cpk index can never be greater than the
Cp, only equal to it. This happens when the actual process average falls in the middle of the
specification limits.

Dr. D. R. Prajapati [4] (2012) found that statistical process control (SPC) techniques in the
automotive industry is offering customers the widest and latest range of sealing solutions. SPC
analysis may easily help in improving the efficiency of the manufacturing process thus
decreasing the number of defective products, thus saving a lot of re-work cost and valuable time.
For each specific product the suggested preventions can considerably decrease the loss to the
industry in terms of both money and time. Although, improvement in rejection level of all the
other products of the industry is noticed, shocker seals were the main concern because the
rejection level of this product was more than 9.1%. The basic requirements of the manufacturing
processes are studied then the statistical process control of the specific process is found out. SPC
analysis may easily help in improving the efficiency of the manufacturing process thus
decreasing the number of defective products, thus saving a lot of re-work cost and valuable time.
For each specific product the suggested preventions can considerably decrease the loss to the
industry in terms of both money and time. After implementing the required suggestions
/recommendations for shocker seals, it is found that process capability is improved and it is
greater than required.
 15

Sarina Abdul Halim Lim and Jiju Anton [5] (2014) investigate SPC is applied in the food
industry with huge benefits in the business to diverse stakeholders .SPC implementation in the
food industry is beneficial and guidelines relating to SPC implementation in the food industry
has resulted in a slow adoption. Although there are limitations and barriers impeding the
implementation, if the implementation was done correctly and greatly facilitated, SPC can be a
versatile technique for managing quality improvement in the food industry and sustaining the
quality of food products. With this background on SPC implementation frameworks, systematic,
useful and practical guidelines will be able to be developed for the food industry and
subsequently the implementation efforts in the food companies will be much more
accommodating. The development of practical and useful guidelines to assist food manufacturers
with the implementation of SPC is suggested able to address such issue. This systematic review
concluded that there is a need for further research into the SPC deployment aspect addressing
how to deploy SPC in the food industry in a systematic manner.

Pavol Gejdos [6] (2015) studied the tools of statistical process control, through which we can
achieve continuous quality improvement. The advantage of these tools is that they can identify
the effects of the processes that cause unnatural variability in processes that result of errors and
poor quality. The results clearly show that through the DMAIC model can systematically
improve quality. Histograms show the contribution of the normal distribution of frequencies
monitored quality characteristics while Shewhart control charts show that the investigated
processes are under statistical control. He concluded that SPC as a very effective tool in
ensuring process stability and benefits of the use of SPC with DMAIC (Define, Measure,
Analyse, Improve and Control) improvement model. This combination of tools is very suitable
for achieving the desired objectives of quality improvement and efficient manner can help solve
all tasks and problems of the process of quality improvement. Infusion of new ideas into the
body of commonly accepted SPC knowledge has been much too slow and has led too much of
the criticism regarding the relevance of SPC in the current manufacturing environment.

B.P. Mahesh & M.S. Prabhuswamy [7] (2010) illustrates the step by step procedure adopted at
a soap manufacturing company to improve the Quality by reducing process variability using
Statistical Process Control. Span of one year, many easily executable Remedies were
 16

implemented then the entire study was repeated again for the production lines. Post
implementation study revealed that defects rate drastically came down thus reducing the process
variability. Improvements in Cp and Cpk values were obtained.

S. Raja lingam, Awang Bono, Jumat Bin Sulaiman [8] (2012) reviewed that in injection
moulding the processing condition has critical effect on the quality of the moulded products.
Since there are many process parameters involved in an injection moulding process,
identification of the critical parameters is very important. This paper presents a case study for
identifying the critical factors and its level affecting a plastic injection moulding process of a
plastic cell phone shell call Front Cover by deployed some of the 7 QC Tools. The Pareto
diagram help to identify that the highest defects (30%) was contributed due to shrinkage. The
shrinkage defects because the length and width of the Front Cover below the given specification
limit. The Course and Effect diagram help to decide to select the mould temperature, injection
pressure and screw rotation speed as the machine input parameters (factors) and the length and
width dimensions of the Front Cover as the response of the experiment. A full factorial design of
experiments was conducted to study the effect of three injection moulding process parameters
versus shrinkage defect. Finally, the critical process parameters and its level influencing the
shrinkage were identified and the confirmation run shows that the shrinkage defect eliminated to
zero percentage.

Farzana Sultana, Nahid Islam Razive, Abdullahil Azeem [9] (2009) intended to combine the
Hourly Data System (HDS) and Statistical Process Control (SPC) practices to improve
manufacturing performances in manufacturing companies. The focus of their work is to find out
the frequencies and time duration of machine breakdowns as well as the major causes of
breakdowns affecting productivity. In this research SPC is used to increase total output
identifying major loss times from various machine breakdowns using HDS. They have obtained
result which shows that any breakdown can cause a huge cost and the best approach to address
any breakdown is the preventive measure. The economic analysis has clearly affirmed the fact
that any preventive measure assuming the breakdown patterns can help a lot in terms of revenue
generation. If one can get any signal of probable breakdown in the coming operation time, he/she
can take the preventive actions and can save a huge amount of money avoiding the consequent
 17

breakdown or stoppage time. This only can be done by analysing the recent and past breakdowns
and the causes of those breakdowns. But this is not the right way to minimize the causes of
breakdowns. More efficient technique is to focus on those specific issues that can affect a
company in the long run. Long term corrective/ preventive actions are also needed to minimize
or reduce these issues. Although SPC is primarily used as a quality control tool, it can also be
used to improve the manufacturing performance of a factory.

Jaakko Kujala [10] (2006) examined on the applicability of SPC in non-repetitive processes
and open systems, non-routine processes and project-based business activities. He also analyzed
on assumptions of production processes consisting of identical repetition in closed or closable
systems. Where these assumptions do not hold, SPC cannot be applied directly. The applicability
of SPC in non-repetitive processes and open systems, non-routine processes and project-based
businesses is examined. Guidelines for adjusting the logic of common and specific causes for
project-based businesses. They also proposed guidelines for adjusting the logic of common and
specific causes for project-based businesses are proposed. They believe that the distinction
between specific and common causes and between transactional and contextual environments is
significant in project-based business. However, discovering higher-order commonalities in
idiosyncratic, non-routine environments also requires higher order learning. Much remains to be
done in developing tools and techniques for measurement and monitoring of project-based
businesses.

Paveletic D, SkovicMand Paliska G [11] (2008) has approached a paper which dealing with
one segment of broader research of universality and systematizes in application of seven basic
quality tools (7QC tools), which is possible to use in different areas: power plant, process
industry, government, health and tourism services. The aim of the paper was to show on practical
examples that there is real possibility of application of 7QC tools. Furthermore, the research has
to show to what extent are selected tools in usage and what reasons of avoiding their broader
application are. The simple example of successful application of the quality tools are shown on
selected company in process industry. Research has been conducted in order to define role and
importance of seven basic quality tools (7QC tools) within quality management system. It is
shown that 7QC tools can be used in all process phases, from the beginning of a product
 18

development up to management of a process, on day to day basis, in systematic manner. The

research has shown that the application of basic quality tools in industry and services are not so
common. It is necessary to point out that quality tools are not so wide spread as expected,
although they are quite simple for application and easy for interpretation.

Rahman M, Zail R, Nopiah Z, Ghani A, Deros B, Mohammad Nand Ismail A [12] (2009)
has studied and addresses the case study on the implementation of SPC in eight manufacturing
companies. The case study involves interviews and questionnaire surveys with the company
representatives, as well as observations on their environment. Other key issues which were felt to
be crucial to this study will also be discussed. The results of the case studies have shown that the
implementation of quality SPC has encountered some barriers related to system and
management, attitude, organizational culture, machine and equipment’s, facilities, cost and
training issues. This paper has presented the case studies conducted in eight companies. The case
study performed was able to differentiate between the case companies as to the level of SPC
adoption, types of SPC software, problems and advantages of its application. For overall
observation, almost all companies in this study have found that SPC is very useful to improve
their quality process. As the result, they managed to reduce the customer complaint, improve
productivity and increase profitability.

Hector Ramirez and Eloy Mendoza [13] (2015) investigated how the augmented reality (AR)
can help to the SPC, to guarantee the quality of the products by reducing the times of training, or
showing instructions on real-time of how the staff need to measure this value correctly. Today
companies invest on statistical process control (SPC), where they seek to measure key values in
the manufacturing processes, to maintain the quality in the products. The problem is that the
measurement of these values can be affected by the expertise of the staff because of poor
training, a high staff turnover, or because the complexity of the process. For this experiment two
groups of young engineers were given a set of instructions to do a quality process measuring. On
one team a manual instruction was provided and on the other team an application of augmented
reality where the subject can watch on site the instructions on real time of the process. With the
analysis of the results it was determined that the group with the augmented does the process up
to 30% faster.
 19

C. J. Corbett e J.-N. Pan [14] (2002) studied recent work on measuring and evaluating
environmental performance of a process using statistical process control (SPC) techniques. They
recent work on measuring and evaluating environmental performance of a process using
statistical process control (SPC) techniques, and they propose using process capability indices to
evaluate environmental performance in terms of the risk of non-compliance situations arising.
They have explored how process capability indices have the potential to be useful as a risk
management tool for practitioners and to help regulators execute and prioritize their enforcement
efforts. Together, this should help in setting up useful guidelines for evaluating actual
environmental performance against the firm’s environmental objectives and targets and
regulatory requirements, as well as encouraging further development and application of SPC
techniques to the field of environmental quality management and data analysis. In this paper,
they describe a detailed quantitative procedure for monitoring and evaluating environmental
performance. They have showed how an appropriate modification of existing statistical quality
control techniques, in particular the CUSUM chart and corresponding process capability
analysis, can be very useful for environmental process management and monitoring.

Paliska G., Pavletic D. and Sokovic M [15] (2007) they have studied with one segment of
broader research of universality systematizes in application of seven basic quality tools (7QC
tools). The research was carried out in different areas that include power plant, process industry,
government, and health and tourism services. The aim of the research was to show on practical
examples that there is real possibility of application of 7QC tools. Conducted research has
showed that there is possibility of systematic application of all of the 7QC tools in the frame of
company’s overall quality management system. The research has also showed that 7QC tools are
not so wide spread as expected, although they are quite simple for application and easy to
interpret. It is necessary to point out that quality tools are not so wide spread as expected,
although they are quite simple for application and easy for interpretation. It is clearly showed
that 7QC tools can be used in all process phases, from the beginning of a product development
up to management of a process, on day to day basis, in systematic manner. In research, it is
experienced certain discomfort towards quality tools. This state can be changed through
continuous staff education and training.
 20

Antonio. Costa [16] (2007) analyzed the performance of X chart with variable sample size and
variable sampling intervals. He compared the performance of his charts with Shewhart X charts
and noticed that the charts proposed by him outperforms Shewhart X chart with a large margin.

1.5 NEED FOR THE STUDY:

• In Present Statistical Process Control, the sample data is checked and being entered in
Microsoft Excel Software by the Operator manually. Therefore, there is a possibility of
error.

• The Digital Statistical Process Control is, to overcome the problems in Manual Statistical
Process Control, and to alert in case of any defects and can take appropriate action.

• The Digital Statistical Process Control will eliminate the manual errors and records the
exact dimensions values.

• The time taken for operator is consider while manual entry of each sample. In Digital
SPC the sample data are directly recorded on that time itself.

1.6 OBJECTIVE OF THE STUDY:

• To understand the Manual Statistical Process Control in WABCO India.

• To find out the problems in Manual Statistical Process Control.

• To propose a new system of Digital Statistical Process Control and find out the viability.

• To Implement Proposed system in terms of working.

1.7 SCOPE OF THE STUDY

The Scope of project is to implement the Digital Statistical Process Control for two Compressor
Machining lines namely Crankcase line and Honing line. This Project will Scale up to others
Machining and Assembly lines in WABCO India. Further the same project can be implemented
in other WABCO plants in India.
 21

1.8 RESEARCH METHODOLOGY:

Research Methodology is defined as a highly intellectual human activity used in the investigation
of nature and matter and deals specifically with the manner in which data is collected, analyzed
and interpreted.
Meaning:
A Research can’t be conducted abruptly. Researcher has to proceed systematically in the already
direction with the help of a number of steps in sequence. To make the research systemized the
researcher has to adopt certain methods.

The methods adopted by the researcher for completing the study are called research
methodology. In other words, research methodology is the simply the plan of action for a
research which explains in details how data is to be collected.

1.8.1 Research Design

The Statistical Process Control is analyzed by using the relevant tools and techniques. The
research follows the Analytical Research Design.

Meaning:
It involves the in-depth study and attempt to explain complex phenomenon. Analytical
Research is primarily concerned, with testing hypothesis and specifying and interpreting
relationships, by analyzing the facts or information already available

1.8.2 Data Collection:

Type: Secondary Data
Source of Data:
The study on statistical process control through smart manufacturing in WABCO India is mainly
based on secondary data. The study focuses on statistical process control of WABCO India.
Data pertaining process capability and process capability index of the process were collected
from the company process.
 22

1.8.3 Tools & Techniques:

The tools are mainly used to project the analyzed study in a pictorial or graphical manner. The
tools used for my study analysis are listed below.
Quality Tool:
The Pareto Chart is used in this project for analyzing the need for new system.
Pareto Chart:
A Pareto chart is a type of chart that contains both bars and a line graph, where individual values
are represented in descending order by bars, and the cumulative total is represented by the line. A
Pareto Chart is a graph that indicates the frequency of defects, as well as their cumulative impact.
Pareto Charts are useful to find the defects to prioritize in order to observe
the greatest overall improvement. The Pareto chart or diagram analyses the frequency of
problems or causes in a process. A Pareto Chart is a graph that indicates the frequency of defects,
as well as their cumulative impact. Pareto Charts are useful to find the defects to prioritize in
order to observe the greatest overall improvement.

1.9 LIMITATIONS

• The project is implemented only for two lines in compressor machining namely Honing
cell and Crank case cell.
• Time is major constraint since the on-going project is cannot scale up to all over plants
within the short period of time.
• The scaling of project to other plants in India is not comes under Project scope.
 23

2. DATA ANALYSIS AND INTERPRETATION

2.1 EXISTING SYSTEM:

In WABCO India, the whole compressor machining area is using separate personal
computer here they are called industrial computers for every cell. The computers are located near
to the Machines. The industrial computers are can be Worked by either Machine operator or Line
Quality persons. There are 43 Air gauge Stations in Compressor machining area. As I mentioned
earlier in 1.7, the scope of my project study is only for 2 cells in Machining area. Here also
separate industrial computers are placed. Both cells are using Microsoft Excel software for
entering the checked sample data.

According to Statistical Process Control pattern, the machined parts from the machine
should be checked for the Customer Specific Requirements. It can be done by checking 4 parts
for every 2 hours. This is frequency of Statistical Process Control for every sample data is
entered.

2.1.1 Working of Existing System:

According to Statistical Process Control pattern, the frequency of sample parts checking
is being checked for 4 parts in 2 hours. Once the parts are checked, the operator or line quality
person will enter the values of each dimension like diameter is checked which is being displayed
in the digital air gauge unit. Those values are entered in two software which depends upon line.
They are Pro QMS Statistical Process Control software and Microsoft Excel. But widely
Microsoft Excel software is being used. The both software are based on manual entry. The
present system of statistical entry is done by the following figure.
 24

Fig: 2.1

2.1.2 Challenges in Existing System:

In existing system some of the challenges are faced by the management are listed below:

• Currently they following manual entry by operator and line quality person so there might
be possibility of errors while entering the data.
• Basically, data retrieval is not uniform to all machines. It differs from each computer
system to system.
• They are following a frequency of 4 parts for 2 hours for checking the sample. There
might be delay in time for entering data in software.
• There are two software for entering the checked sample data so it makes confusion
among the machine operators. They are pro QMS software and Microsoft excel.
• The excel is also used for entering the sample data after it is checked. So, it may generate
situation like loss of data or even system corruption. So once system is corrupted, we
cannot retrieve the past data.
 25

• According to 5s system concept, the place should be utilized effectively in manufacturing

and production area. But the industrial computer stations are utilized more space as it
consists of many components.
• According to Statistical Process Control pattern if 7 sample groups are continuously in
out of control region then the process is not capable, in such case the remarks and action
taken to remarks for the out of control parts are missing in the computer data.
• In some system in some cells, if the parts go to out of control or nominal value they are
not entering and taking into account like data are not entered for that particular parts. So,
the frequency of data also mismatched.
• The industrial computers in some cells are not working while the production is going on.

2.2 ANALYSIS OF EXISTING SYSTEM:

The analysis is done and data is taken continuously 1 month. The data collected from overall
compressor machining area. The analysis can be done using Pareto chart. The data are collected
and plotted as chart using Pareto chart.

Pareto Chart:
The Pareto chart is one of the seven Quality tools. The purpose of a Pareto diagram is to separate
the significant aspects of a problem from the trivial ones. By graphically separating the aspects
of a problem, a team will know where to direct its improvement efforts. Reducing the largest
bars identified in the diagram will do more for overall improvement than reducing the smaller
ones. The principle is based on the significant few things will generally make up 80% of the
whole, while the trivial many will make up about 20%. In the Manual Statistical Process Control
the challenges are marked and plotted as Pareto chart.
 26

SI. Problems Occurrence Cumulative % of Cumulative

No Occurrence contribution %
1. Remarks not entered 60 60 30 % 30%
2. Delay in response 32 92 16% 46%
3. Delay in entering data 28 120 14% 60%
4. Difficult in data retrieval 24 144 12% 72%
5. System shutdown 16 160 8% 80%
6. Manual entry error 12 172 6% 86%
7. No entry 12 184 6% 92%
8. No separate entry system 8 192 4% 96%
9. System boot problem 8 200 4% 100%
Total 200

Table: 2.1

Chart: 2.1
 27

INTERPRETATION:

From the table above it is inferred that in the month of February 2020 the challenges in
tracking the Statistical Process Control are recorded and occurrence of that challenges are also
noted.

• It clearly shows that not entering the Remarks for the out of control data covers the major
portion of the Challenges. It covers 30% of the data.
• The delay in response covers 16% of the data. When the System in out of control, the
response for rectification is delayed.
• Delay in entering the data contributes to 14% of the challenges. While the production is
there the entering the SPC is delayed.
• Difficulty in data Retrieval covers 12% of the challenges. The cumulative data is getting
difficulty while retrieval process.
• System shutdown contributes to 8% of the challenges. While production itself the
systems are shutdown.
• Manual entry error contributes 6% of the challenges.
• No entry contributes to 6% of the challenges. While production time the values are not
entered.
• No separate entry system covers 4% of the Challenges. In some cells the single system is
used for entering two cells.
• Others contribute some 4% in difficulties.
 28

2.3 PROPOSED SYSTEM:

The proposed system is prepared by considering both cost and effectiveness to the WABCO
India. The proposed system is developed by considering the challenges continuously faced by
existing system. The main aim of proposed system is to give profitable to company in terms of
cost, space utilized, time, and effectiveness in the process.

The software used in proposed Statistical Process Control is developed fully by our company and
it will be used uniformly to all the cells.

Fig: 2.2
 29

2.3.1 Components in Proposed System:

1. Raspberry-pie Kit:

Raspberry Pi is an ARM based credit card sized SBC (Single Board Computer) created
by Raspberry Pi Foundation. Raspberry Pi runs Debian based GNU/Linux operating
system Raspbian and ports of many other OSes exist for this SBC. The Raspberry-pie kit is also
called as Mini CPU. This kit is used to do any operation which similarly done by the CPU. The
kit should be programmed before by the programming language.

We are using Python Programming language for programming the kit. The programming is
nothing but pre defining of the operations such as Mean calculation, Range calculation for the
each sub group in the X chart and range chart.

Fig: 2.3

2. Raspberry-pie kit Case:

The case is the covering unit for Raspberry-pie kit. It is made up of plastic material mixed with
fiber elements. The case is used to protect the raspberry-pie kit from heat surface and make sure
the working of the Raspberry-pie kit in good condition.

Fig: 2.4
 30

3. RS232 Cable:
A serial port complying with the RS-232 standard was once a standard feature of many types of
computers. Personal computers used them for connections not only to modems, but also to
printers, computer mice, data storage, uninterruptible power supplies, and other peripheral
devices. Here this cable is used for transferring the data from Air gauge unit to the Raspberry-pie
kit.

Fig: 2.5

4. USB Hub:

The USB Hub is generally a junction device for connecting two or more USB cables. The USB
Hub is used here for the same purpose. The RS232 cables for the Air Gauge units are being
connected to the USB Hub.

Fig: 2.6

5. Power Source Cable:

The Power source cable is used for giving Power supply to the Raspberry-pie kit. The power
Source cable is always connected to the power supply in order to make sure the working of
Raspberry-pie kit continuously.
 31

Fig: 2.7

6. Heat sink:
A heat sink (also commonly spelled heat sink) is a passive heat exchanger that transfers
the heat generated by an electronic or a mechanical device to a fluid medium, often air or a liquid
coolant, where it is dissipated away from the device, thereby allowing regulation of the device's
temperature at optimal levels.

Whether We're over clocking your Pi, running it in a hot environment or just want our Pi to look
awesome, our high-quality Raspberry Pi heat sink kits can help to reduce the operating
temperature of the Raspberry Pi's SoC and LAN chip, and extend its life.

Fig: 2.8
 32

2.3.2 Improvements made in proposed system:

The analysis is made possible using pareto chart and it is explained in section 2.2. After
analyzing the problems in Existing system. The changes should be made in proposed system.
That is purpose of the analysis.

According to pareto char principle, if problem occurs in any process first, we have to split the
percentage % of problems into two categories as 80% and 20%. That is why the Pareto chart is
also known as 80-20 rule. In 100% of the problems we have 80% of the problems are called as
Vital one and 20% of the problems are called as trivial few or useful many. The 80% of the
problems are contribute more while compared with 20%. For this purpose, we have created a
chart using the below table.

SI. No Challenges % of occurrence Cumulative %

1. Remarks not entered 30 % 30%

2. Delay in response 16% 46%

3. Delay in entering data 14% 60%

4. Difficult in data retrieval 12% 72%

5. System shutdown 8% 80%

6. Manual entry error 6% 86%

7. No entry 6% 92%

8. No separate entry system 4% 96%

9. System boot problem 4% 100%

Table: 2.2
 33

Percentage of occurrence
4% 4%
6%
6%
30%
8%

12%
16%
14%

Remarks not entered Delay in response Delay in entering data

Difficulty in data retrieval System shutdown Manual entry error
No entry System boot problem No separate entry system

Chart: 2.2

In table: 2.2 the quoted challenges contribute to nearly more than 80% so this can be taken 1st
and solved in proposed system. From the chart: 2.2 the challenges which contribute more than
80% are modified or in other words rectified by following ways in proposed system

• Whenever the Process is in out of control, the valid reason for out of control is not
remarked in the existing system. Whereas in proposed system if any part while machining
went out of control it should give with proper remark. This contributes to 30% of the
problem so if the remarks not entered in proposed system then the ticket will be raised.
Then the ticket should be solved by the supervisor and operator as soon as possible.
• Delay in response which is related to time. Whenever the part is going out of control the
action should be taken immediately by the line head along with operator in order to
rectify the problem. Which can be overcome by same ticketing system. Until the tickets
solved the tickets will be notified and it will be continuously blinking in the SPC portal.
• For every 2 hours, the 5 parts should be checked and measured readings should be
entered in the software. In existing system there is delay for entering the measured
readings. It contributes to 14% of the challenges which can be overcome by live data
entry in proposed system. Since the proposed system is fully automatic entry system the
data is stored in live manner. Which tend to make the operator to enter the readings.
 34

• In existing system, some cells using excel and other cells using the pro QMS software.
So, it is difficult to retrieve the all data in one platform. This contributes to 12% of the
problems this can be overcome by SPC portal, in which all the data are collected and
stored in one platform. SPC portal is uniformly used by all cells.
• Next major one is system shutdown while machining process and manual error while
entering data in excel. Which contributes to 8% and 6% which can be rectified by live
data entry system. Whenever the operator checks the reading of the part at the time itself
the readings are entered to server. Being fully automatic system the possibility of
shutdown and errors in data entry are minimized by the live concept in proposed system.

The other challenges are also rectified by proposed system which can be detailed explained
by upcoming section 2.3 proposed system along with in depth explanation of working of the
proposed system.
 35

2.3.3 Digital Statistical Process Control:

The proposed Statistical Process Control is fully digitalized by our company software. The
Proposed Statistical Process Control is implemented in order to overcome the Challenges faced
by the Existing Manual entry of Statistical Process Control. The sample data is being checked
and values are verified by the Digital Air gauge shown above. Basically, this system is followed
in Existing Statistical Process Control. But only difference is in exiting Statistical Process
Control the values are being entered by operator, here in Proposed Statistical Process Control the
data are entered automatically on the Time of checking the sample itself.

The Cp and Cpk values are generated by preprogramed formulas in the Raspberry-pie kit. The
Cp and Cpk values are generated by checking 32 sub-groups. The 32 sub-groups are formed by
160 samples of parts. We are using the variable data so the Mean and Range charts can be used.
For every last 32 sub group the Cp and Cpk values are generated in the display which is situated
near to the machine.

2.3.4 Working of Server and Digital SPC:

The Working is explained in Fig Shown below.
 36

Fig: 2.9

• Whenever the sample data is checked in the parts the values are displayed in the Digital Air
Gauge unit. The Machine Operator should verify the value whether it is in control or out of
control. If it is in control then he should just simply enter the PRINT button in the Air Gauge.
The manually entry system is not followed in this system.
• After the PRINT button is pressed by the Machine Operator, the Value will be transferred to
the Raspberry-pie kit through the RS 232 Cable. The cable is used for transferring the data.
• The Memory Card is placed in the Raspberry-pie kit which stores the data from the RS 232
cable.
• Our company Local Area Network is connected to the Proposed System. By using this
network, the stored data or entered data will transferred to the Company Server.
• There are two protocols in server by which the entered values are stored and analyzed in our
server one is HTPP Protocol and another one is MQTT protocol.
• The Mango DB server will store the all data entered by the Operator in Digital Air Gauge
unit through the HTPP protocol.
• The MQTT server is pre-loaded with the Python engine, which is coded with the formulae of
X bar and Range chart.
• Whenever the raw data entered, the python engine linked with the MQTT server will check
using the codes and gives output as within control limits or out of control.
• If the value entered by the Operator is within Limit then it will display the value in green
color.
• If the Value entered by the Operator is Out of control or not Specified within limits then it
will show as red color in Display.
• Side by side the raw data entered by the operator is stored in Mango DB server.
• All the Process from Machine Operator entering the print button to values Displayed in the
Monitor are processed within 3-4 Sec only even though the connection may be less.
• If there is any value entered by the Operator out of specification, then the Tickets will
generate using ticket system.
 37

• If the ticket is raised in any cell the Operator should inform to the Line Head and Line
Quality immediately so that they can analyses the root cause and precede the process for the
decisions according to the Ticket generated.
• The Cp, Cpk values are automatically calculated for 32 sub group values being entered in the
control chart.
• For each sub group the 5 samples should be checked and entered in the system. So that for
160 samples the Cp and Cpk values can be displayed.
• The Cp and Cpk values generated automatically by calculating last 32 subgroups. If 33 sub
group values are recorded, the Cp, Cpk values are generated for last 32 subgroups.

Fig: 2.10
 38

3. FINDINGS, SUGGESTIONS AND CONCLUSION

3.1 FINDINGS:
This chapter presents the summary or the research work undertaken, the conclusion drawn and
the recommendations made as on outgrowth of this study. This study is on the profile and
performance evaluations of Statistical Process Control through Smart Manufacturing in WABCO
India. On the Compressor Machining Shop in WABCO India the Two Cells namely Crankcase
and Honing Cells are completely tracked by Digital Statistical Process Control system. The
summary of findings is given below
• The study was undertaken with aim to investigate the effect of Digital Statistical Process
Control towards WABCO India.
• The study found that tracking the Statistical Process Control has Substantial impact on
productivity.
• Proper Tracking system is found to have increased in quality of the product.
• Ticket system is found to have the positive impact and can insist rectification of the
product.
• The Pareto chart shows that not entering the Remarks has major impact on the Statistical
Process Control.
• The study found that Digitalizing Statistical Process Control has Substantial impact on
productivity by decreasing the Manual works.
• Digital Statistical Process Control has major impact on reduction of time for sample data
entry.
• The study found that the spaces for placing the industrial computers are reduced by
replacing with the Raspberry-pie kit.
• The study found that the action time for out of control parts also very less.
• The study found that back up for all the entered is stored in the server, can be retrieved at
any time.
 39

3.2 SUGGESTIONS:
From the entire process the some of the suggestions are generated based on the performance of
the Digital Statistical Process Control.
• The data entered in the Digital Statistical Process Control can be used to track the Process
Capability and Process Capability Index.
• The cumulative of data collected in the Digital Statistical Process Control can be used for
the analysis purpose.
• The Separate team can be formed to monitor the overall Statistical Process Control so
that close monitoring of the process can be made easy.
• The Digital Statistical Process Control can be implemented to other cells in the
Compressor Machine shop and also in other Shop floors in WABCO India.
• The Digital Process Control can be implemented to other Plants of WABCO India in
order to track the quality of the product in efficient manner.
• The Ticketing System can be updated with the Alarm type Notification to the concerned
line head and line quality persons in order to make the products for rework if required.
 40

3.3 CONCLUSION:
The Digital Statistical Process Control is used to control the quality of the Process in the
company. In this study the difficulties in Manual Statistical Process Control are analyzed and
proposed the new system for tracking the Statistical process Control called Digital Statistical
Process Control. This study was made in the aim to analyses the Existing System in the company
and to find out the Challenges faced by the Existing system. After analyzing the Existing system,
the new system of Statistical Process Control is implemented and checked for two months. In
that period Process Capability and Process Capability Index of the two Cells are generated
successfully. Also, the study has given me an enormous opportunity to learn more about the
Statistical Process Control. It also allowed me to get more detailed understanding of the
Statistical Process Control Theories which I have learned in classroom and to convert that into a
fruitful work.
 41

REFERENCES:
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