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Quality Control SystemQuality Control System
Concrete Advice Pty LtdConcrete Advice Pty LtdMelbourne, AustraliaMelbourne, Australia
Web Site : http://www.concreteadvice.com.auWeb Site : http://www.concreteadvice.com.au
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Presented byPresented by
Ken W. DayKen W. DayBSc, FIE(Aust), MICE(UK)BSc, FIE(Aust), MICE(UK)
FACI, FICT(UK)FACI, FICT(UK)Principal, Concrete Advice Pty. Ltd.)Principal, Concrete Advice Pty. Ltd.)
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Concrete Advice Pty. Ltd. Concrete Advice Pty. Ltd. Where are we? Where are we?
We are Here
Melbourne
SydneyPerth
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Quality Control SystemQuality Control System
Concrete Advice Pty LtdConcrete Advice Pty LtdMelbourne, AustraliaMelbourne, Australia
Web Site : http://www.concreteadvice.com.auWeb Site : http://www.concreteadvice.com.au
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
ORIGINS OF QUALITY CONTROLORIGINS 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
WHERE DO WE GET THE INFORMATION?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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
WHO TESTS YOUR CONCRETE?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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
SYSTEM SNAPSHOTSSYSTEM 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
ENTER DETAILS OF CLIENTS, ENTER DETAILS OF CLIENTS, PROJECTS,TESTERS, PLANT, SUPPLIERPROJECTS,TESTERS, PLANT, SUPPLIER
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Batch Plant Data InterfaceBatch Plant Data Interface
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Batch Plant Data Error GraphBatch Plant Data Error Graph
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Batch Plant Data Error GraphBatch Plant Data Error Graph
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Batch Plant Data Error GraphBatch Plant Data Error Graph
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Batch Plant Error Data GraphBatch Plant Error Data Graph
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Material Data EntryMaterial Data Entry
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
TIMELINE GRADING VARIATIONTIMELINE GRADING VARIATION
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
GRADING DISTRIBUTIONGRADING DISTRIBUTION
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
TEST DATA ENTRYTEST DATA ENTRY
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
TEST DATA ENTRY SET UPTEST DATA ENTRY SET UP
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
SPECIMEN DATA ENTRYSPECIMEN DATA ENTRY
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
ALTERNATIVE SPECIMEN ENTRYALTERNATIVE SPECIMEN ENTRY
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
““FULL SCREEN” VIEWFULL SCREEN” VIEW
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
USING YOUR DATAUSING 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
DATA SELECTION SCREEN FOR ANALYSISDATA SELECTION SCREEN FOR ANALYSIS
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Multigrade Statistical Data 1Multigrade Statistical Data 1
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Multigrade Statistical Data 2Multigrade Statistical Data 2
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Multigrade Statistical Data 3Multigrade Statistical Data 3
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Multigrade, Multivarible CusumMultigrade, Multivarible Cusum
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
YOU can design and store any number of standard YOU can design and store any number of standard report formats which then compile and print out report formats which then compile and print out
automatically on entering date rangeautomatically on entering date range
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Example of automatically prepared reportExample of automatically prepared report
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
BIG BROTHER IS WATCHING!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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CUMULATIVE BATCHING ERROR OVER PERIODCUMULATIVE BATCHING ERROR OVER PERIOD
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONCRETE QUANTITY PER TRUCKCONCRETE QUANTITY PER TRUCK
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
AVERAGE PRODUCTION RATE OVER DAYAVERAGE PRODUCTION RATE OVER DAY
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
AVAILABLE GRAPH TYPESAVAILABLE GRAPH TYPES
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
ACI acceptance criteria 1ACI acceptance criteria 1
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
ACI acceptance criteria 2ACI acceptance criteria 2
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
TESTER STATS 1TESTER STATS 1
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
TESTER STATS 2TESTER STATS 2
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
MIX OPTIMISATIONMIX 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
MIXTABLE WORKING SCREENMIXTABLE WORKING SCREEN
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
GENERATED TABLE OF MIXESGENERATED TABLE OF MIXES
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
GRAPHS OF DATA USED TO GENERATE TABLEGRAPHS OF DATA USED TO GENERATE TABLE
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
AA CONCRETE SUPPLIERSAA CONCRETE SUPPLIERS
• We have discussed what you can do for yourselves using Conad and Alkon
• now I want you to consider what Alkon+Conad 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
• Three benefits are seen:
• sales benefit of higher prestige
• technical assistance with problems
• economic benefit from assistance with mix design, materials selection etc
AA CONCRETE SUPPLIERSAA CONCRETE SUPPLIERS
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
• 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!
AA CONCRETE SUPPLIERSAA CONCRETE SUPPLIERS
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
• 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
AA CONCRETE SUPPLIERSAA CONCRETE SUPPLIERS
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
MIXTABLE INPUTMIXTABLE INPUT
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
BATCHING SEQUENCEBATCHING SEQUENCE
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
MIX CODE INTERPRETATIONMIX CODE INTERPRETATION
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Features and BenefitsCONAD - Features and Benefits
• MANAGEMENTMANAGEMENT– 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Features and BenefitsCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Features and BenefitsCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Features and BenefitsCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Features and BenefitsCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Features and BenefitsCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Features and BenefitsCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Current CONAD ClientsCurrent 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
Current CONAD ClientsCurrent CONAD Clients• Other clients with CONAD on trial
• APASCO (Mexico)• • DUFFERIN(Canada)
• Pioneer (Philippines)
• Partek (Finland)
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Test Result EntryCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Batch Plant DataCONAD - Batch Plant Data
• Batch Variation ProcessingBatch Variation Processing
• Batch Variation Quantity/Cost AnalysisBatch Variation Quantity/Cost Analysis
• Production AnalysisProduction Analysis
• Grading VariationGrading Variation
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Materials ControlCONAD - Materials Control
• Material Entry
• Material Reports
• Edit Plant Material Costs
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Combined AnalysisCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - In-situ Early AgeCONAD - In-situ Early Age
• Temperature Monitoring
• Equivalent Age / Actual Age Relationship
• In-situ Strength Vs Actual Strength
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - In-situ Early AgeCONAD - In-situ Early Age
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - InternationallyCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Mix ControlCONAD - Mix Control
• Cement Margins / Benchmark
• Mix Design Alternatives– Auto-mix– One mix fine tune, trial mix– Quick mix– Mix tables
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - Maintaining MixesCONAD - 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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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
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Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000Concrete Advice Pty. Ltd. ALKON Presentation Jan 2000
CONAD - SummaryCONAD - 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