Challenge:
A key process is out of control.  Delays in quality test results were hampering good control.

Solution:
Process Intellect with on-line quality and product performance prediction.

 

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The Methods
BioComp engineers came on site and familiarized themselves with the process.  Flows of materials, process control points and information in and out of the process were identified, much like a mass and energy balance.  Data was collected on these attributes from the local process and quality management systems.  This data was modeled extensively using BioComp's iUnderstand to demonstrate the feasibility of predicting quality on-line.

Results
The iUnderstand analysis identified that there was not only a lag in quality results, but also a two-hour lag in the process.  These lags were potentially contributing to untimely process adjustments by the operators.  A Process Intellect system has been installed to manage and report estimated quality parameters to operators within seconds rather than 30 minutes to an hour.