Our experiences with industrial companies of every size have shown that both the processes and the product quality provide a big lever for optimisations. Our product IPN – inPROC is specifically designed to the needs of these areas. Therefore, it supports you perfectly in reaching operational excellence in your production.
Deviations from the desired product quality and the need for re-work in your production processes are minimized by our product. This unlocks a huge cost saving potential for your company. Our product records measurements and parameters from your production processes in order to predict deviations in product quality. It then triggers the necessary recalibration work before the event to prevent it from occurring.
For many companies quality control is still something they do on a random basis. For continuous production processes in a closed system it is mostly performed on the final product. This bears the risk of producing a big amount of spoilage until its detection. Our product offers you online quality monitoring and the possibility to perform root cause analysis of when and how the quality deviations were triggered.
In order to optimise your production processes and plants it is important to identify the drivers of the problems. To know which process and parameter is the cause of a problem allows the specific and cost effective optimisation of your production. Therefore, our product provides you with in-depth analysis of the problem drivers which help your employees to optimise the processes.
The requirements of the new energy efficiency laws constitute a big challenge for producing companies. IPN – inPROC enables you to predict the energy consumption of your machines and to decrease the amount of energy wasted by machine faults.
In order to optimise the energy consumption of your machines and production processes our product provides a detailed analysis of every monitored machine both in real time and historically.
In the glass manufacturing process (e.g. wine glasses or optics) the quality of the final product depends on a variety of process steps. It starts with the melting process followed by several grinding and washing steps. Quality controls are performed after some of the process steps in order to guarantee the quality of the final product. In case of quality deviations the batch is rejected or re-work has to be performed and the cause of the deviation has to be analysed. For the company this means a loss of production due to the rejected Batch, the cause analysis and the necessary recalibration work.
Our product allows the prediction of future quality deviations and its cause. This enables our customer to act and correct the cause before the quality deviation occurs. Furthermore, it automatically identifies and integrates new drivers of quality deviations into its predictive models. The utilisation of our product helps to optimise productivity by reducing spoilage production and to increase customer satisfaction as it reduces delivery delays and increases overall product quality.
Imagine the different grinding machines of a glass manufacturer. The quality of the grinding strongly depends on the quality of the blank, the preceding process steps, the state of the grinding disc, etc. Our product monitors the whole production process and automatically informs the technicians about expected future quality deviations and its cause. This might be an increased wear of a preceding grinding disc due to a deviation in the blanks volume and hardness. The technician in charge can recalibrate the blank’s parameters and replace the grinding disc even before a single glass has to be rejected.
For paper machines it is extremely important to run without any interruption and that failures in the production process are reduced to a minimum. The optimal production setup of these machines depends on a diversity of variables which are not apparent at first sight (e.g. humidity, surrounding temperature, etc.). As long as these variables are not perfectly balanced, deviations in product quality like too high paper porosity are very likely to occur. Spoilage production due to paper porosity is measured on the final product which means that tons of reject are still in the machine. Furthermore, the root cause of this deviation is unknown until an ex-post analysis is performed so an early detection is not possible.
Our product offers an efficient yet very quick remedy as it provides a prediction of the quality deviations as well as a root cause analysis of the deviation. Based on the results of the analysis a manufacturer can optimise the relevant parameters as well as the overall machine setup in order to prevent this problem from occurrence. Furthermore, the Manufacturer receives the necessary information to optimise the machine’s overall construction of the machine.
Further information/Paper: AKIDA 2014 – Statistische Methoden für die Industrie
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