Monitoring Multi-Recipe Batch Manufacturing Performance

Overview:

Quality and consistency are key factors in determining business success. Manufacturing products that satisfy product quality and consistency specifications first time result in increased productivity and lower overall manufacturing costs. Approaches to achieving consistently high quality production and enhanced manufacturing performance include Statistical Process Control (SPC) and Six Sigma with increasing attention now being paid to Multivariate Statistical Process Control methodologies (MSPC) or perhaps better termed “Process Performance Monitoring”. In today’s process manufacturing environment, a number of issues arise which can challenge the application of MSPC based process performance monitoring technologies. For example, most applications of MSPC have tended to focus upon the manufacture of a single product, i.e. one grade, one recipe, etc. with separate models being developed to monitor individual product types. However, with process manufacturing trends being influenced by customer demands and the drive for product diversification, there has been an increase in flexible manufacturing. Thus with many companies now producing a wide variety of products, there is a real need for process models which allow a range of products, grades or recipes to be monitored using a single process representation. Three industrial case studies are presented to demonstrate the application of the multi-group performance monitoring approaches.

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Author: Julian Morris, Elaine Martin, WBF

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