Blog post written by Senior MES Engineer Mayuri Dahibhate
Imagine if you could capture the specifications of your ideal product run (the best/golden batch of your product) and recreate it consistently throughout your entire production.
Imagine the amount of time, money, raw material, rework you could save by reducing product waste, scraps, overruns to an absolute minimum. This could also help the company in saving annually by virtually eliminating quality-related product runs. I want to show you how using the Proficy Plant Applications Quality module can allow you achieve all of this and so much more.
Quality module allows the operators to capture the quality data with the help of dedicated screens/displays in Proficy. This data is further classified and summarized in context of production events. Quality module also allows you to apply product specifications to the captured data. This gives the ability to raise alarms when any key process indicator goes out of specification and can be corrected before it turns into a bigger problem. If an entire run is flawed, this module allows to you isolate exactly which products have been impacted in order to reduce waste. KPIs (Key Process Indicators) can be calculated using this quality information, then information can be further analyzed in the form of Proficy reports that can be created according to the customers’ needs.
As a result, Proficy Quality module not only greatly increases the quality of the product and production process but also significantly reduces the cost of achieving those gains and helps to get better, safer products out faster and more efficiently than ever before.
This infographic illustrates a typical Quality Management Process in Proficy:
Interested in implementing Proficy Quality Module?
Proficy Quality Module typically consists of following components (but can be altered based on site’s needs):
The operator manually enters or selects most of the Quality information. Automatic data transfer from measurement tools is possible, but interfaces must be developed. The checks are automatically inserted on the Quality Attribute or Quality Variable displays. The operator can navigate to any display from the Quality view. The quality operator follows existing work processes and logs everything into Proficy even if something is not correct. For example, if the metal detector fails, it is repaired/restored according to normal procedures. The failure reason and repair are recorded in Proficy.
Columns automatically appear on the display according to a set time period. Operator then follows work process and logs Quality information in Proficy.
Each Proficy variable is equivalent to a Quality attribute at the plant. The entered data is stored in these quality variables and is passed to the database for storage and reporting. If there are any rule violations or out of specification limits for any variables, an alarm appears in the panel at the bottom of the display.
The quality data is further processed by SQL stored procedures and can be used to create reports based on defined KPIs (Key Process Indicators)
Implementing Quality Management Overview
Configuration Steps for Quality Management
- Build up the physical layout of the plant’s production lines and units
- Determine which process variables to capture and summarize on each unit
- Determine which manually entered variables to capture
- Establish any calculations combining or summarizing other variables
- Build up products and specifications
- Attach products to units
- Configure a production event on each unit
- Configure a product change event on each unit
- Establish rules for disposition / routing
- Establish rules for alarming
- Establish inspection plans / testing frequencies for manual entries
- Build Quality Management displays
- Configure security on variables and displays.
This is a baseline for getting ready to implement the Proficy Quality Module at any site, so the site should be aware of these prerequisites before taking the decision of implementing Proficy Quality.
This is a high-level introduction to Quality module of GE Proficy Plant Applications which can help save money and resources while minimizing waste. For a detailed walk through, please contact us and we will be happy to provide more information.
This post uses information from GE’s open source materials on Proficy Plant Applications.
Image sources: Proficy logos are taken from the GE Digital website and other images are taken from free image sources on the web. Infographic created by Mayuri Dahibhate of E Technologies Group.