A test plan can relate to: W a material, whereby several test plans

can be stored for a variety of recog-nised standards with different designa-tions,

W one (or several) products or pre-prod-ucts, beginning with the moulding material and including cast, core, un-machined parts, right through to the finished product. For each version of the resource plan an alternative test schedule (e.g. for the initial sampling or for trial orders) can be added. These test groups are classified by selecting which processes are to be tested.

Test plans can be added for purchasing materials, tools and equipment, but also for machinery, plant and test apparatus, even for environmental conditions andwaste disposal facilities.

The complexity of a test plan, its test values and test conditions is determined according to test groups which have been configured to meet the foundry’s require-ments for:W chemical analyses,W mechanical values (tensile and bending

test, notched bar impact test),W hardness test,W thermal treatment with the temperature

profile and the corresponding parts,W microstructure,W non-destructive tests (ultrasound, mag-

netic particle inspection, dye penetrant inspection),

W industrial radiography,W dimensional tests.

Planning System

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Product PlanningStructure | Resources Plan

Production PlanningProduction ControlTime Management

SalesWarehouse Man-

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OPTIQuality

Management

OPTI Quality Management is an effec-tive instrument for building a cost-effi cient supply chain, enabling you to pinpoint and remedy any shortfalls or errors in your workflow management and production process.

W The OPTI Quality Management pro-grams allow you to set up test planning for products throughout all the stages of manufacture, materials and processes.

W Test values, quality parameters and pro cess requirements are monitored with relation to products and processes.

QUALITY MANAGEMENT

W Complaint Management deals with internal and external errors and com-plaints. Orders can be frozen or cleared for shipping, and all processes are recorded and evaluated.

Test planning and product planning are closely related to each other. The test plan includes all target values, test instructions and parameters concerning inspection re-quirements according to recognised stand-ards, customer specifications or factory regulations. The programs “Test Plan” and “Resource Plan” have the same structure and their data are linked.

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programming in the foundry industry.

Target and actual values for moulding material tests, sieve analyses or measure-ments of any process parameters such as temperature, moisture etc. can also be recorded. The standard test values encom-pass internal limits, tolerance thresholds, target values, pressure parameters, a for-mula or an attributive evaluation by means of selection codes.

For the production messages (e.g. as de-fined by the casting report) test orders are generated for required tests according to the respective test plan. Limiting and target values are monitored for every process test-ed and the observed values recorded. These may be numerical values, attributive evalu-ations, or any available documents in the testing or process stage (images, logs).

There are a number of standard techniques for transferring test values from the testing apparatus or other systems. These include the exchange of files, database tables or online link-up of the data logging program.

If test results are recorded manually, incor-rect entries are prevented thanks to pre-set search functions for a test job, production messages etc. If mandatory tests are not carried out or fail to produce a satisfactory result, this in turn can block production confirmations and prevent clearance for shipping, or it can request approval for clearance by an authorized member of staff.

Production messages are assigned to test procedures through a combination of order number, piece number, reference number (part number or casting ID number), batch number and sample number.

OPTI Quality Management’s range of functions includes not only the administra-tion of samples and test objects but also data preparation for statistical analyses. A number of different basic messages, in particular delivery note and clearance for shipping, allow inspection certificates and test documents to be generated. Certifi-cates are printed on multi-language forms, saved as pdf documents and can be sent by email.

Error and Complaint Management is a major component of the OPTI QM module.

W It records complaints from outside the company and internal errors and anom-alies based on pre-defined error cata-logues.

W It defines which measures are to be taken, including whether it is necessary to freeze an item, a tool or parts of a batch, whereby approval for clearance is possible only by authorized staff.

W It triggers reworking orders to remedy errors.

All processes are documented and can be displayed in the form of an 8D-report.

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Hardness Test Online BHN Test MachineOverview Quality Assurance

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