STATpaq System OverviewSPC QA Main Page
The total Sigma Line Process Monitoring System:
- Recipe building
- Lot and batch tracking/genealogy
- SPC/QA checks
- Contaminant Detection (X-ray/Metal Det.) and data collection from those machines
- Yield Management
- Pack Out/Giveaway tracking system
All networked, traceable, paperless, and in real-time.
RECIPE BUILDING/LOT-BATCH TRACKING/INGREDIENT TRACEABILITY.
With our "ProBatch" recipe system we can receive a plant floor recipe order, batch ingredients to that order, pull and place the ingredients for that recipe, create a batch/lot code or assign an existing one, then associate all quality checks down the processing line to that order. This assures product quality, maximizes yield, and improves traceability. STATpaq SE FDA-approved for traceability and electronic signature capture.
REPLACE YOUR CLIPBOARD and HAND-WRITTEN DATA!
Everyone would like to get rid of the cabinets full of paper their data resides in now. Even if you’re eventually getting the data into electronic form, you’re probably writing it down first and transferring the data later. This takes time and inevitably results in data gaps and errors. Cut out these intermediate steps by using our networked STAT SPC system and tables. Weights and other tests (temperature, dimensions, defects, etc.) are entered directly into our touchscreen computers or networked scales. All of this data is instantly transferred through your network to the InfinityQS database. The data is automatically charted and tested for adverse trends and alarm conditions. In the event of a worrisome trend or alarm, the user is prompted for a corrective action and a distribution list is alerted via e-mail. You can even publish reports automatically to your intranet web page.
This operation is designed to be very easy for operators, with one touchscreen pushbutton navigation to almost any test that needs to be taken.
One example: When it comes time to test a five-piece sample for weight, a window automatically opens up on the computer screen and prompts the operator to begin. He/She then places the first sample on the scale and the weight is automatically sent to the computer upon stability. The other four samples are placed on the scale in rapid succession, and as soon as the fifth weight is sent, the data is saved to the database and a control chart is updated. If there are no alarms, the operator can go about other business until the next prompt to take data. In this case, there are no buttons to push, no calculations to key in, no numbers to write down. The sampling process is stripped down to its most efficient form.
COLLECT DATA THAT IS BEING GENERATED BY YOUR CHECKWEIGHERS and/or METAL DETECTORS.
Production floor weights come from two sources: 1: from “static” scales tied to our computers or 2: from your in-motion and in-line checkweighers. Typically the data from the checkweighers is used protect against underfills using a reject mechanism, but nothing significant is ever done with it beyond that. You may be able to walk out to each checkweigher and pull up totals such as number of rejects, average weight, etc. You might even be able to copy these totals to a USB flash storage device. But with the STATpaq system, you can view total weight produced, average weight, total accepted/rejected weight, weight range and so much more, in REAL-TIME from anywhere on your network. These production totals can be sorted by product, by line, by shift, by operator, or any combination of pertinent data labels. Plus, customizable alarms rules can alert you of a problematic trend BEFORE you reject a large amount of product and are forced into the re-work mode.
We have also developed a ”two-way” interface for certain machines. This means that you can add a new product or change spec limits, tare weights, etc., from anywhere on your network. You no longer have to go to each machine to make such changes.
NETWORK OUR ANRITSU XRAY MACHINES!
We are authorized nationwide OEM for Anritsu X-ray machines. Anritsu is the largest supplier of X-ray machines to food industries worldwide ( www.detectionperfection.com). These machines can be used to detect both minute contaminants and packaging mistakes. We provide the ability to monitor reject totals by type, including stored images, from anywhere on your network.
Anritsu has recently introduced and AMI certified IP69k X-ray machine that is perfect for the food industries. This rugged machine can detect down to millimeters of stainless and even partially calcified bones!
COOKER, FRYER, OVEN and FREEZER DATA- ALL COLLECTED AND REPORTED IN REAL TIME.
Production lines have all sorts of machines that contribute to the manufacture of your product. Most of those machines generate data constantly. Our STATpaq system can MONITORS THESE MACHINES and ALARM when they stray from pre-set boundaries. Like all data in our system, these charts and alarms can be viewed from any desktop workstation or Sigma Industrial computer on your network- as soon as an event happens. If any of your machines don’t have a serial or Ethernet port or PLC-based controls, we can equip your personnel with handheld computers to monitor and periodically enter key parameters. The data is then sent wirelessly to our system, where the same charts and alarms are updated in real time.
TRACK BOX WEIGHTS, PIECE COUNTS, AND GIVEAWAY in DOLLARS on our N.T.E.P.-APPROVED PACK-OUT SCALE.
Our SM series Stop-Motion scales are one-of-a-kind systems, developed to meet the strict requirements of both Tyson Foods and Sysco. They weigh the pack-out boxes, print and apply the label per your specification, and reject any erroneous weights or misplaced labels. In addition, the weight of each weighment is recorded, classified, and appended to running, real-time totals. These totals and any calculated giveaway can be charted and viewed in both pounds (or other units) AND in ACTUAL DOLLARS. Reports can be developed to show these totals by shift, by day, by week, etc., giving you tools to help maximize your profitability.
We offer systems that are completely Allen-Bradley enabled for those companies that have standardized on that brand.
DATA REPORTING in THE MANAGERS OFFICE.
Most of the discussion so far has concentrated on the gathering of data by one method or another. But the whole purpose of this data gathering is to give managers the tools to run their plants more profitably. There are numerous tools in our system to help you achieve this. First, real-time data access and alarm notification lets you immediately become involved when, and only when, you need to be. You can make changes before you’ve produced a warehouse full of product you can’t sell or must rework. Second, you can have instantaneous reports based on process performance indicators, unusual events, corrective actions, etc., all sorted by line, by product, and by shift. You can even use our system to track Overall Equipment Effectiveness (OEE) to determine such things as which products run best on which lines or with which personnel crews. Third, before you ship a product, you can rest assured that the product is in compliance. This might be compliance with regulatory requirements such as HACCP, or it might be compliance with your customer’s specifications, ensuring that no product is rejected or charged back. Finally, you can streamline the whole process of information delivery. Once you’ve standardized the data tables, charts, and analyses you want, you can process and distribute a report with only a few clicks of a mouse. Or even with NO clicks, for that matter. Using the built-in web publisher, you can schedule automatic, periodic reports to be published to a web page on your company’s intranet site. Other managers can view the data at any time, from virtually anywhere, simply by opening a web browser.
FINAL PIECE CHECK, BAG FILLS, AND BAG COUNT STATISTICS ARE ALSO GATHERED.
At the end of your production line, we take final SPC checks of your packaged product. Typical tests here are bag weights, piece counts, and individual piece weights. Also possible are attribute-type checks such as piece defects, proper packaging/labeling, legibility of barcodes or ink-jet lot codes, etc. All these checks can be related back to all other quality control and production parameter data collected during the current run.