Improving Quality Control with SPC

The fully automated SPC scale system displays the real-time process, and prompts the operator to action when necessary. Samples are now added in a cumulative fashion, rather than being weighed one by one. The operator adds a sample then adds additional samples as prompted by the computer; samples are never removed from the scale during this process. This eliminates the error of weighing a sample more than once, as well as any confusion or falsification of results. The scale then calculates the statistical data required for evaluation and stores this in a password-protected memory file for collection by the quality control manager. The statistical data may be sent wirelessly to a spreadsheet, printed on a label to accompany the sampled product, or simply viewed on the scale interface. The flow diagram in Figure 2 details the improved and streamlined automated SPC process.

In addition, manufacturing companies can also utilize various connectivity and software options that can integrate filling machines to automated SPC scale systems. This means that product fill volumes based on statistical trends calculated by the SPC scale system can be easily adjusted via an automated system. Quality Control Managers and Plant Managers can also connect all SPC scale systems in a production factory to a central control computer, which provides easy access to real-time data.

Conclusion

Upgrading outdated manual SPC methods is the first step to improve overall quality, efficiency, traceability, and profitability. Integration of a new automated SPC scale system into any manufacturing environment will have several advantages over the old manual method. Sample weight results can now be automatically recorded and evaluated without manual data manipulation, and all results are completely traceable, conforming to current Good Manufacturing Practices (cGMPs). In addition, the automated SPC scale system may be directly integrated into production filling machines with automatic adjustment of fill volumes. And overall, the automated SPC scale system streamlines production sampling analysis to better utilize production employees and work hours.

Quality control managers and plant managers should carefully evaluate current production sample analysis methods, and take a hard look at how these measurements are translated into improved production line efficiency. It is now time for companies to step into the 21st century and upgrade to a fully automatic SPC weighing system.

Ryan Titmas is product manager, Industrial Scales for Sartorius Corporation (Edgewood, N.Y.). He can be reached at 800-635-2906, ext. 8307, or [email protected].