Brad Armstrong, vice president of sales at Advantive
Highlights:
- Many food and beverage manufacturers still rely on outdated paper-based systems for quality control, leading to increased costs, wasted effort and quality issues that put consumer safety and brand reputation at risk.
- Statistical Process Control (SPC) is a critical tool that enables real-time monitoring and automated alerts to detect and correct problems before they become severe, ensuring consistent quality and food safety.
- A modern, data-driven SPC system can increase productivity, reduce waste, improve your brand reputation, and foster a culture of continuous improvement to give you a competitive advantage in the ever-changing food and beverage industry.
In the high-stakes world of food and beverage manufacturing, quality control issues can have serious consequences. With consumer safety and brand reputation at stake, manufacturers must actively monitor and adjust processes to prevent deviations and maintain consistency.
This is easily achieved through the use of statistical process control (SPC), but surprisingly, recent studies have shown that 75% of food and beverage manufacturers Data collection and validation still relies on outdated, paper-based systems – an approach that not only puts professionals on the defensive, but also makes companies vulnerable to increased costs, wasted effort, and quality control issues.
The risks posed by poor paper-based systems are avoidable
When manufacturers use processes that rely on pen and paper, they are at high risk for information loss and inefficiencies. Documents get lost or misplaced, data entry errors are common, and entire workforces are overwhelmed with manual procedures. Not only do these challenges increase costs and significantly impact quality control, they can also lead to recalls and damaged reputations as manufacturers react to issues rather than prevent them. This can lead to inefficient workflows and inconsistent standards.
To avoid these issues and truly optimize their operations, manufacturers must take a holistic approach and use data to gain a comprehensive understanding of their operations. SPC is a critical tool in this effort, enabling companies to make meaningful process adjustments, reduce expenses, and ensure consistent quality compliance. By integrating SPC into their operations, manufacturers can gain a holistic view of their methods and better identify areas for improvement.
Leveraging the science of SPC to achieve optimal results
SPC uses real-time metrics and statistical analysis to monitor and control manufacturing processes. Data is plotted on graphs with pre-established control limits; data that falls within these limits indicates normal process variation, while points outside the limits suggest causes that need to be addressed. By identifying and investigating these variations, SPC helps to reduce waste and inefficiencies.
Additionally, the technology’s ability to enable fast, accurate corrections on the production floor is invaluable. Real-time, automated alerts and notifications enable manufacturers to resolve issues as soon as they occur, minimizing impact to production and ensuring consistent quality. This proactive approach saves time and money while increasing overall operational efficiency. SPC insights speed analysis of trends and patterns in data, allowing companies to make informed decisions to increase profitability. For example, live SPC updates can quickly identify bottlenecks in assembly workflows, while connecting checkweighers and in-line measurements can reduce overfilling and waste in filling operations.
SPC Protocol Can also be driven from a shared cloud systemestablishes a single place where process improvement teams, quality practitioners, and management can each access the information they need. This integrated approach speeds implementation, streamlines data access, and creates comprehensive reports that provide insight across the enterprise. This increased visibility enables organizations to identify key areas for strategic quality initiatives and drive meaningful change that will have a high impact.
The pace of manufacturing demands best-in-class solutions
The comprehensive view of manufacturing data that SPC provides is essential to prevent problems, increase productivity, and avoid a tarnished image. Real-time monitoring and automated alerts enable manufacturers to detect and correct issues before they escalate, ensuring only the best products reach consumers. Prioritizing food safety with traceability tools is key to maintaining consumer trust and satisfaction. Happy customers make for a stronger brand..
In an industry where quality, safety and efficiency are valued above all else, food and beverage manufacturers can’t afford to rely on outdated, paper-based systems. Without a modern statistical process control system, it can lead to over-provisioning, unnecessary usage, additional testing costs and higher defect rates. But the benefits of implementing SPC extend beyond the manufacturing floor, enhancing brand reputation and profitability and fostering a culture of continuous improvement. The results speak for themselves; it’s time to move to a modern, data-driven system.
