This is a great question that requires that critical process parameters are actually controlled, or at least measured and monitored. There are many tools that can be used to tell if a process is in control, but it starts with measuring those parameters that are important to the process. It may seem obvious that anything that really is critical would be measured and monitored, but I continue to be amazed by stories of companies not keeping track of the variables that are critical to their products and their own success, which often can translate into significant financial losses.

I recently read an article which referenced a fermentation problem in the wine industry, with potential losses of several hundred thousand dollars. Utilizing the Six Sigma tool of DMAIC (Define, Measure, Analyze, Improve, Control), the root cause of the problem was determined to be fermentation tank temperatures out of specification.

In this particular example it turns out that tank temperatures were not being monitored, with costly consequences. In a case like this, there are solutions that can be deployed, increasing in sophistication, and cost.

1)    Measure the temperature, at the source. Typically, this would be done with a thermocouple or temperature sensor.

2)    Monitor the temperature. This typically would entail having someone check the temperature on a periodic basis, and hopefully recording the results. Alternatively, depending on the type of controller used, an alarm can be triggered if a high or low limit is reached. In today’s world, this can also result in an email or phone call automatically being made by the controller in order to generate a response.

3)    An open loop control system. Most typically, this type of system will allow a setpoint to be set, but there’s no feedback as to what the temperature actually is.

4)    A closed loop system. This is typically a system using a PID controller, which not only has a setpoint, but can drive the temperature to that setpoint. This is the most sophisticated type of control, and will typically be the most costly solution.

Which approach to take will depend on the degree of risk that you’re willing to assume and the potential adverse consequences if those critical parameters drift out of spec. The most expensive solution is not always the most cost effective, but can be depending on what those adverse consequences are. However, the entire process starts with some basic questions and analysis.

Is your process in control? If not, or you’re not even measuring critical parameters or know where to start, give us a call or send us an email. We’re here to help you succeed.