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How Data Collection Shapes Manufacturing Intelligence Performance
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March 1, 2012

Industry has pushed the limits of conventional manufacturing decision support. For you to reach the next level and become a top performer you need to move to the state-of-the-art methods known as Enterprise Manufacturing Intelligence (EMI). EMI lets you look deeper with greater understanding over the complete company. However, EMI depends on good data to improve your performance.

 Data collection processes directly affects first three important EMI functions - aggregation, contextualization, and analysis:

  • Aggregation:Pulling data from any source and organizing for useful analysis.
  • Contextualization:Providing the data associations that help users find what they need and meaningfully evaluate it when they do.
  • Analysis:Enabling users to analyze data throughout the plant and between plants.

Because these in turn affect the management decision making process, the quality of data collection procedures has strong implications for corporate performance and profitability. Real world user profiles demonstrate how to solve otherwise perplexing problems of managing manufacturing operations such as:

  • How to usefully organize data for different types of production such as continuous or batch processes and set the foundation for meaningful analysis.
  • How to deal with control systems and process historians including sampling strategies for real-time process parameters
  • How to aggregate time- and sample-based data so that you can combine data from control systems with data from the plant floor and the laboratory to completely understand process performance.

EMI makes it possible for management to clearly see the manufacturing enterprise with a comprehensive view that has eluded them to date. This enables the company to develop best of class manufacturing and superior business performance.

 

Best Practices in Data Collection for Successful Manufacturing Intelligence
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January 26, 2012

Robust Manufacturing Intelligence (MI) capabilities are fundamental to successful manufacturing enterprise management. And robust MI capabilities start with sound data collection practices. The analytics feeding management dashboards will work with any properly formed data that can be drawn from manufacturing databases. However, if that data is compromised, the decisions made by management based on the compromised data may be faulty and put the organization at risk.

The key to world-class, sound decision making is a solid data collection foundation. This webinar examines data collection best practices:

  • The requirements standards such as ISA 95, FDA Q10, and ISO 9001 and good manufacturing practices place upon the data collection process.
  • The business implications of poor data collection.
  • What data collection best practices should be implemented:
    • Operator workflow support
    • SOP enforcement
    • Input error reduction
    • Data integrity
  • How data collection integrates with manufacturing management systems

The end result is compliant process and testing data collection that dependably provides high-quality data to feed the analytics that informs MI. Data collection with integrity is a core requirement to make MI work while keeping auditors and customers satisfied.

 

About the Presenter:

Jeffery Cawley is VP of Industry Leadership at Northwest Analytics where among other roles, he investigates how process based analytics solve the problems imposed by modern manufacturing and testing activities, and how to employ process management methods to meet regulatory and commercial standards and good practices. In addition to his work at Northwest Analytics he has served two terms on the AOAC Statistics Committee and twelve years on the executive board of the Institute of Food Technologists Quality Assurance Division. He is a frequent speaker and writer on applying process analytics and management methods to testing and manufacturing.

Applying Process-based Analytics to Audit Results for Process Management and Improvement
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December 15, 2011

Operational audits and inspections play a critical role in assuring the effectiveness of the Food Safety Management System (FSMS).  To realize the maximum value and effectiveness for process management and improvement, key process indicators should be identified and plotted on control charts.  The control charts can then be assessed for trends, so actions can be taken before a food safety incident occurs. 

The proper linkage and operation of the FSMS components enables successful certification audits and gives confidence to Senior Management and other stakeholders that the plant has a robust food safety management system in place.  By applying process analytics such as SPC to sanitation data management can continuously monitor the FSMS performance, improve compliance and reduce risk.

 

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Your Presenter

John Surak is principal of Surak and Associates, a full service food safety and quality consulting service. He works with the food processing industry in developing food safety and quality management systems, designing and implementing process control systems, and implementing Six Sigma and business analytics systems.

Dr. Surak has more than 30 years of experience. He works with industry and governmental agencies in applying the principles of quality and food safety management. In addition, he held industrial positions including managing nutritional process and product development for Wyeth Laboratories and serving as vice president of quality and food safety for the Brooks Food Group. Dr. Surak is a professor emeritus of applied economics and statistics at Clemson University.

In addition to Dr. Surak’s industry responsibilities, he heads the USTAG to ISO’s Subcommittee 17 of Technical Committee 34. This subcommittee is responsible for managing the ISO 22000 family of standards. 

Factors for Manufacturing Analytics Success- Part 2
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October 20, 2011

Part 2 of the “Factors for Manufacturing Analytics Success” webinar series examines the underlying system and user interface design for successful data collection. The webinar will explain how to define the process and identify the information flows for each operation. This includes how to conduct a value stream analysis to understand how waste streams and process variances impact quality.

Additionally, Charlie Gifford will discuss how to select and measure the appropriate parameters to deliver the data needed to understand and control the process. He will show how create a successful system by taking steps to:

  • Define and maintain consistent data formats
  • Maintain consistent variable naming across databases
  • Design and implement data collection that delivers high quality data
  • Design for compliance with industry standards and best practices

The webinar will provide a road map on how to deliver, role-specific reporting and analytics to everyone in operations and management. The final system will provide actionable feedback on both the measurement and manufacturing processes, thereby establishing a solid foundation for process management and continuous improvement.

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Your presenter:

Charlie Gifford, President and Chief Manufacturing Consultant
21stCentury Manufacturing Solutions LLC
Hailey, ID

Mr. Gifford is an international independent consultant for optimizing manufacturing and supply chain systems. He chairs the ISA-95 Best Practices Working Group which produces public methods for aligning Continuous Improvement and Manufacturing Operations Manufacturing systems to optimize manufacturing work processes. He is the author of four books, most recently, When Worlds Collide in Manufacturing Operations: ISA-95 Best Practices Book 2.0.

Factors for Manufacturing Analytics Success
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September 29, 2011

Real-time process assessment and informed decision making require the same solid foundation of good database setup and maintenance.

NWA presents a two part webinar series that explains how to set up and maintain your databases and data-collection systems to support enterprise-wide manufacturing intelligence and more successful management decision making.

Webinar 1 - Organizing Data to Enable Enterprise-wide Manufacturing Intelligence

Thursday September 29, 2011, 11 AM PDT, 2PM EDT

Successful enterprise-wide manufacturing information and analytics systems require a consistent organization of data that can accommodate expansion and changes. Most enterprises end up patching together manufacturing and business databasesbased on the needs of different applications.  Thesedifferences make it difficult to create useful reports, apply effective analytics, and adapt to changing conditions.

This webinar examines how to analyze data structure needs, design them to fit best practices, and produce a robust data structure that supports current and future manufacturinganalytics requirements.

View Recorded Webinar 

Webinar 2 - Designing Data Collection for Consistency that Improves Process Management

Thursday October 20, 2011, 11 AM PDT, 2PM EDT

Webinar 2 examines the underlying system and user interface design of plant floor data collection and speaks to how a full featured user interface contributes to quality system success.

Your presenter:

Charlie Gifford, President and Chief Manufacturing Consultant
21stCentury Manufacturing Solutions LLC
Hailey, ID

Mr. Gifford is an international independent consultant for optimizing manufacturing and supply chain systems. He chairs the ISA-95 Best Practices Working Group which produces public methods for aligning Continuous Improvement and Manufacturing Operations Manufacturing systems to optimize manufacturing work processes. He is the author of four books, most recently, When Worlds Collide in Manufacturing Operations: ISA-95 Best Practices Book 2.0. http://bit.ly/pL2pfN

 

Finding the ROI in Your Quality System
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August 11, 2011

Whether you are producing cooking oil, baby oil or motor oil, one matter is constant, if you are trying to implement a quality system, you are competing with other projects for finite corporate resources. One of the most effective ways to compete for those resources and demonstrate project success is to be able to quantitatively demonstrate Return On Investment (ROI).

On August 11, Louis Halvorsen, CTO, Northwest Analytics, will explain how to develop the ROI of quality systems and provide example case studies. He will present:

  • How to choose the project justifications that best meet your commercial requirements and to improve your bottom line.
  • What are common ROI targets and how may they be adapted to your plant requirements.
  • How to quantify ROI.

Quality systems and operations typically deliver substantial cost benefits and rapid returns. Properly done, ROI modeling will not only enable you to obtain the necessary resources to develop your projects, but will also provide an ongoing basis to justify the quality management operations.  

Mr. Halvorsen will present two case studies which illustrate how to set up data collection and analysis to successfully demonstrate ROI and provide for continuing reporting.

  • An assembly process where management must determine which defects are most amenable to process improvement and will provide the greatest return for the effort.
  •  A food processor facing product giveaway by overfilling. How can the processor improve the filling performance and calculate the ROI of the effort?

Applying SPC to your production process is one of the quickest ways to realize a return from your quality system. SPC-based process improvements reduce variation and make further improvements possible.

Improving Packaging Line Performance with OEE and SPC
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June 23, 2011

Overall Equipment Efficiency (OEE) is a widely recognized Key Performance Indicator (KPI) that provides a high level indication of operational performance.  OEE incorporates measures of machine or system availability, throughput and quality into a KPI that can be monitored for alarming and analyzed with process based analytics such as SPC.

On June 23, 2011, Wendy Armel and Dan Engelhard of Stone Technologies will discuss how to effectively apply OEE to packaging operations in food, beverage, and consumer goods production. They will discuss:

  • What is the OEE KPI and how is it applied to packaging operations. How can active use of OEE support compliance with regulations such as the Food Safety Modernization Act and industry standards such as GFSI?
  • How to serve the needs of OEE users in Operations, Maintenance and Quality.
  • How to incorporate process based analytics such as SPC to alert operations to production problems and provide manufacturing intelligence and decision support for efficient operation and continuous improvement. 

About Wendy Armel and Dan Engelhard

Wendy Armel is Senior MES Engineer at Stone Technologies. Wendy is project engineer for MES projects and leads design, software development and start-up for OEE and Downtime systems. She has extensive experience in food, beverage, consumer goods and packaging industrial applications.

Dan Engelhard is Director of Business Development and Marketing at Stone Technologies. For twenty years, Dan has focused on Manufacturing Execution Systems (MES), PLC/HMI systems in addition to other real-time integration applications. His experience includes business development, project and business management, and supply chain enterprise to manufacturing integration.

Stone Technologies an information (Manufacturing Execution System –MES / Manufacturing Operation Management-MOM) & control systems integrator.  Stone Technologies provides industrial automation services including process control and MES/MOM consulting, design, software development, and commissioning. Control Engineering and Packaging Digest named Stone Technologies the 2010 System Integrator of the Year.

The Impact of New Regulations and Standards on Packaging Traceability
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April 28, 2011

Consumer, commercial and regulatory concerns require an effective track and trace system for all food products. On April 28, David Miller, President, Operations Technologies, presented an overall view of the requirements and solutions for food packaging traceability.

Supply-chain traceability links the physical flow of products with the flow of information about them. All items must be uniquely identified and the information made available to all supply-chain partners. Successful traceability depends on the design and production of packaging coupled with effective data collection and reporting systems. Mr. Miller discussed:

  • Industry standards such as GS1 Global Trade Item Number (GTIN) and mpXML
  • Impact of new regulations including the Food Safety Modernization Act (FSMA)
  • Technology overview
    • Labeling
    • Data collection
    • Data management and exchange including internet based systems
  • Operational implications and capital and operating costs including consumables
Food Safety Audits – A Business Advantage Not a Burden
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March 29, 2011

Major food retailers require food processors to certify their food-safety-management systems under Global Food Safety Initiative recognized audits. This has, in turn, led food processors to make additional demands of their supply chain, including packaging vendors, to demonstrate viable audited HACCP programs.

Meeting the customer’s food-safety-audit requirements gives packaging suppliers a competitive advantage and unique market opportunity.

Allen Sayler discussed standard food-safety audits in general and SQF in particular as they pertain to plastic and paperboard food-container manufacturing including:

  • GFSI – Concept for the Future
  • HACCP – Applicability to the Food Packaging Industry
  • SQF
    • The Whys for the Food Packaging Industry
    • Technical Implementation Details for the Food Packaging Industry
  • Food Safety Due Diligence for the Food Packaging Industry
Increase Food Safety, Reduce Risk, and Achieve Operational Effectiveness and Compliance
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February 8, 2011

Deborah Kacera, Industry Solutions Director for Pilgrim Software, addressed how following the process requirements of the GFSI schemes yields analytics that foster growth and compliance while supporting:

  • Management Reviews
  • Supplier Performance Inputs and Ratings
  • Decision-making based on predictive, actionable intelligence
  • Feedback into your Food Product Design and HACCP Plans
Process Improvement with GFSI Compliant Management Systems
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January 11, 2011

Dr. Tatiana Lorca discussed the Global Food Safety Initiative and how their benchmark and recognition process drives improvement and cost efficiency.

Topics presented:

  • What is the Global Food Safety Initiative (GFSI)?
  • How the benchmark and recognition process drives improvement and cost efficiency across the food supply chain
  • How the GFSI requirements incorporate the principles of the Plan-Do-Check-Act cycle into the recognized programs and thus help drive improvement within a certified business
  • Four of the most widely used food safety management systems (SQF, BRC, FSSC and IFS) and their requirements highlighted from a process improvement perspective
Building a Corporate Food Safety Culture
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December 16, 2010

Building a culture for food safety starts with top management developing a strong commitment for food safety. In this webinar, John G. Surak focused on using the elements of ISO 22000 to accomplish the following:

  • Linking the food safety management system to the corporate business system
  • Linking the quality policy to the corporate culture
  • Developing effective food safety objectives
  • Increasing the effectiveness of management review
Comprehensive Strategies to Protect Your Brand
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November 9, 2010

Dr. David Acheson began the series with his insights into the food industry regulatory and commercial landscape. In his talk he:

  • Discussed the current pressures and challenges facing the food industry
  • Defined the changes from a regulatory and congressional perspective
  • Discussed the status and implications of pending US food safety legislation
  • Provided insights into future trends
  • Presented a forward looking strategy for brand protection.