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Road map for process control |
J. G. SURAK, Dept. of Applied Economics & Statistics, Clemson Univ., 224 Barre Hall, Clemson, SC 29634-0313 Process control is a manufacturing strategy that relies on the following: Collecting data on the status of the process, analyzing the data to develop knowledge on the process status, then converting the knowledge into appropriate actions. The two primary actions are either adjust the process or improve the process. Process control can be subdivided into either automated process control or statistical process control. Automated process control is used when there is a rapid natural deterioration of the process and it is possible to use an automated feedback system to make rapid and proper adjustments. Statistical process control is used when the process shows unpredictable variation, when the process shows a slow deterioration, or when it is inefficient to use an automated feedback and adjustment system. The process control system must be linked to a continuous improvement system. Often when food processors implement a process control system, the actual results are less than the predicted results. There may be only marginal gains in efficiency or in improved product quality. Some of these issues can be attributed to a lack of a plan to achieve the objectives. This plan needs to have goals, objectives and a timetable. In addition, it must address personnel, hardware and software needs. Failure of a process control system to meet the intended objectives can be attributed to several other reoccurring factors: Poor planning of the implementation process Lack of linking process control to continuous improvement Lack of management commitment Lack of committing time, training, and other resources to achieve desired results Poor use of consulting resources. Most times, implementing a plan will not go as expected. Food processing companies that have successfully implemented process control linked to continuous improvement, show flexibility and the tenacity to readily identify appropriate solutions to solve the implementation problems. This seminar provides a road map that will allow a company to implement an effective process control strategy that is linked to continuous improvement.
Session 6, The roadmap for process control
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