Spectrum > Process Control
Process Control
Process and manufacturing industries face numerous challenges, ranging from challenges with procuring the right quality of raw material at the right price, to producing finished products to the desired standard of quality and at the right cost.
The transitional manufacturing process entails various quality checks and procedures to ensure consistent product quality and cost efficiency. In manufacturing, some failures – product errors or defects – are inevitable; others are not.
Through testing and statistical analysis, producers can minimize failures by diagnosing the causes of manufacturing problems, and also by predicting the problems and preventing them from happening. How effectively problems and variations can be monitored and controlled during different manufacturing phases is dependent on the tools that you choose.
Spectrum is industry standard software designed to monitor and analyze manufacturing processes through the timely measurement of critical quality and performance attributes of every process (from raw materials through work-in-progress and packaging to the finished good). The aim of the solution, just like the aim of the companies that use it, is to ensure a final product quality, to achieve cost efficiency, optimization, and full regulatory compliance.
The concept of the solution is to provide effective controls across a plant’s complex set of independent units and lines, to manage compliance and quality on lowest cost.
Across large manufacturing installations, where a complex set of different plants, departments and manufacturing lines need to operate together, Spectrum allows all functions to see a single set of data on quality. For example, plant engineers can see scheduled sample testing as soon as it has been performed in the lab, and they can respond immediately.
Spectrum’s core focus is total quality and compliance at each phase of manufacturing, and the implementation of Spectrum helps our clients:
- Produce consistent product quality to reduce cost and improve customer satisfaction
- Easily bring innovative products and increase throughput.
- Decrease manufacturing cost, increase revenue, and improve margins.
- Optimize resources and maximize plant performance and utilization.
- Plan and control their manufacturing performance to align strategy and execution.
- Continuously improve their manufacturing process.
The detailed definition of plants with their units and sample points is maintained in the system.
Multiple schedules for sampling and testing can be maintained in Spectrum Process. These schedules can be on the basis of hour(s), day(s), week(s), month(s) etc. These schedules also include a schedule for holidays and other special days.
Testing protocols (Tests & Limits) for a group of sample can be defined into Spectrum Process – samples received for testing follow the rules defined within its groups.
Multiple methods to conduct a test can be established, allowing the user to perform every test as per the requirements, keeping the results together under one particular test.
In addition to the passing limit, Spectrum Process supports action/target and other limits to facilitate test result monitoring and behaviour monitoring. These limits can also be defined on individual sample point level.
Simple and complex result calculating formulae can be defined into Spectrum Process, making it easy for the user to calculate final results from raw data. In addition to the final results, Spectrum Process maintains the original raw data to facilitate further analysis and decision making. Spectrum Process also manages repeat test results, providing a full history of tests and results on every sample.
Work list assignment in Spectrum Process helps in the time and resource management of a lab by distributing the testing work load to different analysts on individual test level at the time of sample receipt.
Raw data and test results can be transferred directly through “instruments interfacing” or entered manually into Spectrum. Spectrum Process provides a fast and convenient approach to enter results into your system.
In addition to results obtained through analysis, Spectrum Process can be interfaced directly to plant equipment to obtain real-time data directly without requiring any human interaction. This enables a user to obtain chemical as well as physical attributes of any sample at any particular point.
Spectrum Process provides a wide variety of data outputs, ranging from simple listings, to analytical reports and decision making reports. It also generates historical data to monitor trend analysis, sample behaviours, analyst performance and compilation of periodic reviews.
Spectrum Process has a comprehensive reporting and analysis tool set to provide different views of the data through graphical presentations, trend analysis and real-time reporting.
The dashboard facility in Spectrum Process provides senior management with a comprehensive view of all the relevant operational performance of plant(s) at a glance to support key decision-making.
Spectrum Process has an integrated SPC tool to facilitate understanding of the processes involved in manufacturing and product development. |
