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Elements of a SuccessfulPlant Data Collection System
Jeffery L. CawleyNorthwest Analytical, Inc.
39-2
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NWA Northwest Analytical, Inc.
Process & Product Quality ControlData Collection
SPC Analysis & ReportingIntegration with Manufacturing and EnterpriseManagement Information Systems
Booth 2274
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Process Data Collection
Realtime Control Systems
Plant Floor Data Collection
Laboratory
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Data Collection Modes
On-Line
Control Systems - HMI/SCADA
In-line sensors Automated operation
APC capability
Data local log file orto historian for SPC & CPI
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Data Collection Modes
At-Line Plant Floor Teststation
Sampling from process
Manual to Semi-Automated Operation
Alarming capability
Data local file to QIS
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Data Collection Modes
Off-Line
Laboratory
Sample process to final product Manual to Semi-Automated operation
Process feedback ,finished goods CofA
Data local file to LIMS
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Data Collection Success
Workflow
Non-intrusive
SOP Data Handling Integrity
Standards Conformance
Data Integration with Enterprise Systems
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Data Collection Success
Cawleys First Law
Whats Easy Gets Done
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Real-time Enterprise
Process Management
Reduced Data
Collection Overhead Data Management &
Accessibility
Continuous Process
Improvement (CPI)
Improve ROI &Profitability
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Real-time SPC
APC - SPC
Productive Use of
SCADA Data CPI
Feed Enterprise-wide Process
Management
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HMI
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SPC & APCPhilosophy Minimize variability by detecting &
removing process upsetsMinimize variability by adjusting processto counteract process upsets
Application Expect process stability Expect continuous process drift
Deployment
1. Level2. Target3. Function4. Cost - deployment5. Cost - action6. Focus
StrategicQuality CharacteristicsDetect DisturbancesSmallLargePeople & Methods
TacticalProcess parametersMonitor setpointsLargeSmallEquipment
Results Process improvement Process optimization
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At-line Data Collection
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Workstation vs SCADA Roles
Testing Samples
Chemical/Physical Properties ofGrab Sample
Fill Weight / Portion Control
Technician Interface
Workflow Control SOPEnforcement
Alarming
Plant Floor Data Collection
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Steps to Consider:
Test Station Data Collection
Define the target process
Understand data collectionrequirements
Hardware/networking requirements
Decide on features to use Design interface, Configure Devices
Test and install
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Define the target process
Follow process control and improvement techniques
to determine your target process for improvement
Determine the scope of the project
Define the boundaries i.e., Line 14, retail pack only
Understand your objective i.e. Reduce product giveaway by 20% through net weight
SPC methods for retail products produced on line 14
Select key measurement(s)
What are the variables that need to be controlled to achieveyour objective? Net weight, temperature, line speed, etc.
State your objective.
i.e. Reduce product giveaway by 20% through net weight
SPC methods
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Understand data collection requirements
What measurements are required? Key measurements that measure the process: Weight,
temperature, line speed, etc.
Which descriptive variables are needed?
Date, time, shift, line, machine ID, operator, product ID,etc.
Adequate descriptive variables are necessary forproper analysis of the data
How will data be collected?
Keyboard, serial device, barcode
What is the sample plan?
Sample size and frequency
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Plant Floor Data Collection
Improve Plant Floor Data Collection
Reduce Workflow Interruption
Link At-line Testing with Enterprise Enable CPI Programs
Operational & Economic Gains
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Pr
ocess
SupplyChain
QualityManager
Production
VPOperations
PlantManagerAnalytics
HMISCADA
MES
LIMS
QIS
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Enterprise Process Quality
CPI
Within Enterprise Reporting
Multi-Location, Complex Organizations
Benchmarking Best Practices
Supply Chain Quality Reporting
Contractually Required Deliverables
Vender Certification
Bid Requirement
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Northwest Analytical, Inc.
111 SW 5th Ave., Suite 800
Portland, OR 97204
USA
1-503-224-7727www.nwasoft.com
Booth #2274
