Quality Control: solution for the creation and tracking of machine parameters
and results
Feature: The Process Data Control and Monitoring module (PDCM) allows for the creation and tracking of machine parameters and results. For example, when running a new item with no predefined run standards, the Operator quickly and easily accesses information on similar items using the PDCM and determines how the machine should be setup to run. The definitions for different machines requiring unique settings are easily assigned without hassle or the need to make manual changes to the database. The PDCM is also used to define machine setup, establish standards, capture data during the actual run of the machine, and analyze machine performance.
• Definitions
are set up on a work center/machine basis with unique properties for
each machine. Necessary setup
information is defined and reporting and tracking information
is determined. Users are able to define sections of
information that are important as well as individual data
sets.
• Standards are the actual settings - how a job or work order should
be setup and/or reported against an item's bill of
materials (BOM). Standards are setup on an item-to-item
basis. Depending on the item's current BOM, standards
allow the User to enter data regarding how a job or work
order should be run.
• Data is gathered on how an item actually ran on a specific work
center/machine. Users can do more than refer to the
assigned standard of how they should setup and run their
work center. They can also examine how previous jobs
of
the same or similar items were previously run.
• Analysis is performed on a work center/machine allowing the User
to determine discrepancies in how items are
being run or in machine performance.
Benefits: The ProntoQCS streamlines the machine setup process by eliminating the guesswork in machine setup, providing a method for defining machine attributes and establishing standards, facilitating access to important data, eliminating research and related downtime, and reducing costs on sample runs. The PDCM is entirely Web-based and is written in the MicroSoft.net architecture running against a Sequel Server database that interfaces with any other ERP system.
Situation: Duralam, Inc. is a flexible packaging converter company with more than 30 years of industry experience. Duralam uses a vast variety of plastic packaging film and paper. Duralam prints flexographically using 8-color CI presses. Lamination, pouch-making and optional zipper reclose features are just part of Duralam's capabilities. ProntoQCS's PDCM streamlines the machine setup process, saving time and reducing costs. Recently, production on a new lid for blueberry yogurt would have been halted or postponed while important data needed to help determine run standards and machine setup was manually retrieved from file cabinets. Due to the variety of presses requiring different settings, sample runs, based on guesswork, would have tied up million-dollar presses. But raspberry yogurt lids, nearly identical, are already present in ProntoQCS's PDCM. Duralam's press operator simply used this information as a basis for the new package. This reduced the cost, avoided unnecessary running of expensive equipment, eliminated the downtime, and made easy work of the research to designate standards for the blueberry yogurt lid. Methods for defining standards, accessing and analyzing data were simple and provided Duralam more control of their production machines allowing them to quickly manufacture the new product for their customers.
Milwaukee/Chicago
W229 N1433 Westwood Dr.
Suite 101
Waukesha, WI 53186
(262) 524-5500
Boston
225 Cedar Hill St.
Suite 200
Marlborough, MA 01752
(508) 630-2398
South Florida
1100 Lee Wagener Blvd.
Suite 309
Ft. Lauderdale, FL 33315
(954) 359-8213