quality control system concrete advice pty ltd melbourne, australia web site :

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

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.)


Concrete Advice Pty. Ltd. Concrete Advice Pty. Ltd. Where are we? Where are we?

We are Here

Melbourne

SydneyPerth

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


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?


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


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


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


ENTER DETAILS OF CLIENTS, ENTER DETAILS OF CLIENTS, PROJECTS,TESTERS, PLANT, SUPPLIERPROJECTS,TESTERS, PLANT, SUPPLIER


Batch Plant Data InterfaceBatch Plant Data Interface


Batch Plant Data Error GraphBatch Plant Data Error Graph


Batch Plant Error Data GraphBatch Plant Error Data Graph


Material Data EntryMaterial Data Entry


TIMELINE GRADING VARIATIONTIMELINE GRADING VARIATION


GRADING DISTRIBUTIONGRADING DISTRIBUTION


TEST DATA ENTRYTEST DATA ENTRY


TEST DATA ENTRY SET UPTEST DATA ENTRY SET UP


SPECIMEN DATA ENTRYSPECIMEN DATA ENTRY


ALTERNATIVE SPECIMEN ENTRYALTERNATIVE SPECIMEN ENTRY


““FULL SCREEN” VIEWFULL SCREEN” VIEW


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


DATA SELECTION SCREEN FOR ANALYSISDATA SELECTION SCREEN FOR ANALYSIS


Multigrade Statistical Data 1Multigrade Statistical Data 1


Multigrade, Multivarible CusumMultigrade, Multivarible Cusum


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


Example of automatically prepared reportExample of automatically prepared report


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


CUMULATIVE BATCHING ERROR OVER PERIODCUMULATIVE BATCHING ERROR OVER PERIOD


CONCRETE QUANTITY PER TRUCKCONCRETE QUANTITY PER TRUCK


AVERAGE PRODUCTION RATE OVER DAYAVERAGE PRODUCTION RATE OVER DAY


AVAILABLE GRAPH TYPESAVAILABLE GRAPH TYPES


ACI acceptance criteria 1ACI acceptance criteria 1


ACI acceptance criteria 2ACI acceptance criteria 2


TESTER STATS 1TESTER STATS 1


TESTER STATS 2TESTER STATS 2


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


MIXTABLE WORKING SCREENMIXTABLE WORKING SCREEN


GENERATED TABLE OF MIXESGENERATED TABLE OF MIXES


GRAPHS OF DATA USED TO GENERATE TABLEGRAPHS OF DATA USED TO GENERATE TABLE


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


• Three benefits are seen:

• sales benefit of higher prestige

• technical assistance with problems

• economic benefit from assistance with mix design, materials selection etc



• 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!



• 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



MIXTABLE INPUTMIXTABLE INPUT


BATCHING SEQUENCEBATCHING SEQUENCE


MIX CODE INTERPRETATIONMIX CODE INTERPRETATION


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


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


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.


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


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


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


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


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),


Current CONAD ClientsCurrent CONAD Clients• Other clients with CONAD on trial

• APASCO (Mexico)• • DUFFERIN(Canada)

• Pioneer (Philippines)

• Partek (Finland)


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


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


CONAD - Materials ControlCONAD - Materials Control

• Material Entry

• Material Reports

• Edit Plant Material Costs


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


CONAD - In-situ Early AgeCONAD - In-situ Early Age

• Temperature Monitoring

• Equivalent Age / Actual Age Relationship

• In-situ Strength Vs Actual Strength


CONAD - In-situ Early AgeCONAD - In-situ Early Age


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


CONAD - Mix ControlCONAD - Mix Control

• Cement Margins / Benchmark

• Mix Design Alternatives– Auto-mix– One mix fine tune, trial mix– Quick mix– Mix tables


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


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

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