aspenONE^® V7 Manufacturing
and Supply Chain

Driving Higher Profitability in a Changing Global Economy

Improving Quality and Production

Business Problem #1: Batches with inconsistent cycle times are
difficult to monitor leading to poor quality.

With a complex set of manual, semi-automated, and automatic production tasks, it is often difficult to control quality and cycle times in batch operations. And even if you have the data to conduct analysis, the statistical models for monitoring and control are less reliable when there are inconsistent cycle times, making it harder to sustain overall quality.

Solution: Golden Batch Profiler normalizes
cycle time 

V7 solves this problem by allowing cycle time to be defined as a process variable in batch profiles. Now you can create process value-based profiles that are more accurate. Like other variables, cycle time can be monitored and alarmed to support efforts in driving consistent batch quality.

• Process value-based profiles
• • Time becomes a variable
   
• Consistent monitoring profiles
• • Improved analysis capability
  • More accurate profiles
   
• Process value examples:
• • Percent complete
  • Percent filled
  • Temperature, Pressure
  • Viscosity transitions
  • Any tag-based value
   

Business Benefit: Reduce costs, improve quality, reduce cycle times 

Business Problem #2: Poor product quality due to process variability

The increasing number of products and product characteristics has made it more difficult to keep the process "on target" and deliver batches right the first time. As process variability creeps in, product quality begins to suffer.

Solution: Provide work flow for Continuous Improvement with Golden Batch Profiler 

V7 addresses this problem by providing work flow to the continuous improvement process, directing operators to take action when a batch begins to go off target. You can now establish multiple statistical process control limits, while also defining alarm rules and the conditions during which alarms should be activated.

• Set multiple statistical process control limits
• Establish multiple alarm rules
• • Standard SPC rules
  • User defined rules
   

      ...and when they trigger

• Automatic notification of out-of-control conditions
• • Email, tag, command
   
• Record remediation - available for faster responses in future alarms

When an alarm condition is met, notifications are issued to selected users. And the problem is automatically logged and the user records the cause and action taken. Since alarms are associated with specific batch profiles and batches, the system keeps track of the improvements made to the process. Those records are then stored and made available for future use. By being able to continuously improve the process and directly support operations, the business sustains batch quality.

Business Benefit: Continuous improvement,
sustain quality