IFT2005-Using SPC Methods to Trigger Preventative Maintenance
15
Using SPC methods to trigger preventative maintenance and prevent CCP violations Jeffery L. Cawley Northwest Analytical, Inc. July 20, 2005 93 – Integrating Preventative Maintenance Into HACCP
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Transcript of IFT2005-Using SPC Methods to Trigger Preventative Maintenance
Using SPC methods to trigger
preventative maintenance
and
prevent CCP violations
Jeffery L. Cawley
Northwest Analytical, Inc.
July 20, 2005
93 – Integrating Preventative Maintenance Into HACCP
Process Management & Predictive Maintenance
• Event Driven vs. Scheduled Maintenance
– Economics
– Effectiveness
• Inspection vs. Process Management
– Inspection is never 100% effective
– Insensitive to process drift
– Triggers only when critical value exceeded
• Information Rich & Intelligent Manufacturing
SPC Contribution
• SPC appropriate whether measuring pathogen levels,
shaft load, bearing wear, etc.
• SPC differentiates signals from noise
• Observed CCP violations too late for current production
• SPC and process management model more sensitive to
equipment and process deterioration than inspection
• SPC enables dynamic, “intelligent” system response
Stable – Control Chart
Capable – Process Capability Report
SPC Enables HACCP Success
• Stable Process
• Capable Process
• Timely Alerts
www.nwasoft.com/press/mag_haccp.htm
SPC Enables HACCP Success - Butterball Case Study
www.nwasoft.com/press/mag_haccp.htm
Process Management Results
• Process management vs. inspection model
• SPC gives more sensitive alarms in addition to critical values
– Control limits
– Rule violations
• Capability/stability relation to process management
– Headroom indication
– Better planning & decision making
• Fix it before it’s broke – predictive maintenance
• Problem prevention mode
• Automated systems
• Analysis – increase system knowledge & appropriate response
• Performance monitoring -optimize maintenance timing
International SEMATECH e-Diagnostic Levels
Can We Learn From
Other Industries?
www.geindustrial.com/products/documents/eDiagnosticsGECiscoWhitePaper.pdf
Level 0 – Access & Remote Collaboration
Level 1 – Collection & Control
Level 2 – Analysis
Level 3
Prediction
International SEMATECH e-Diagnostic Levels
www.geindustrial.com/products/documents/eDiagnosticsGECiscoWhitePaper.pdf
Level 0 – Access & Remote Collaboration
Level 1 – Collection & Control
Level 2 – Analysis
Level 3
Prediction
Inspection vs. Process Management
www.geindustrial.com/products/documents/eDiagnosticsGECiscoWhitePaper.pdf
SPC – Predictive Maintenance
• How to use data
• How to make decisions
• How to intelligently trigger maintenance
• How to prevent process disruptions
SPC Enables Predictive Maintenance:
SPC & Predictive Maintenance – Universal Application
SPC & Predictive Maintenance Enable HACCP Success
• Less disruptive, more productive
• Stability
• High capability
• Result – safer product at less cost
Northwest Analytical, Inc.111 SW 5th Ave., Suite 800
Portland, OR 97204
503-224-7727
www.nwasoft.com
