GPC CONCEPTS

BEYOND THE LIMITS OF SPC

The Global Process Control (GPC) is an extension of the SPC technique (Statistical Process Control). However, its features go far beyond monitoring, since it allows the optimization of operating processes or equipment.

Many companies use the control cards of the SPC, but they meet serious difficulties when the number of mesured  characteristics (variables)  per observation becomes too important.

  • False alarms multiply: we often give up monitoring continuously all the measures when its collection is too expensive.
  • It is difficult to extract relevant information which can lead to more effective actions.

GPC CONCEPTS

The patented approach of the Global Process Control is based on multidimensional statistical models. Unlike univariate analyses of the SPC where each variable is studied individually, GPC technology is able to take into account all the variables at the same time.

This powerful approach is perfectly adapted to the reality of the operation of industrial production equipment and other complex equipment or systems.

To assess the effectiveness of the GPC, we propose you a first quick analysis of your data: the GPC Flash Audit.

GPC FUNCTIONS

GPC technology is based on a global approach of the considered system – production line, process, equipment – by proposing a set of software tools for data analysis and modeling.

The power of the exclusive multivariate models of GPC allows the tools to perform the following functions with unequaled efficiency:

TO DETECT

To analyze in order to detect and identify the causes.

  • Removal of defects and the causes of downtime.

TO IDENTIFY

To analyze in order to identify the main causes of ordinary variability.

  • Improvement of the robustness of process and product, and improvement of quality.

TO SELECT

To select relevant measures by integrating economic criteria.

  • Reduction of control costs.

TO MONITOR

To monitor a process or an equipment in real-time.

  • Reactivity on drift or incident, false alarms control, detailed information to the operator, reduction of shutdown times on incidents.

TO COLLECT

To build indicators collected from the curves.

  • Fuller exploitation of available measures.

TO OPTIMIZE

To optimize process or equipment settings.

  • Simultaneous centering of the  product characteristics on their targets, reduction of costs.

GPC ANALYSIS

As part of the study of historical data, the GPC approach allows, among other:

To automatically separate the points corresponding to the normal operation of the process (“under control” operation) to the points belonging to a disturbed operation (“out of control” operation: presence of an anomaly).

To classify out of control operating points by grouping them by type of anomaly. Each anomaly is described precisely by the software, using the process settings. A study of the most common anomalies allows process experts to identify the causes of disturbance and, most often, to permanently stop their occurence. This immediately leads to the reduction of quality defects and shutdown times on incidents.

To monitor the process in real-time when the operation under control settings and anomalies were modeled by a historical analysis. The failure detection is done early, often before the SPC control limits are reached. Furthermore, the operator’s action is triggered at the right moment, according to the identified anomaly.

To optimize the system operating point without any recourse to experimental designs that require the suspension of production. The measure of small perturbations in normal operation under control determine how to vary the control settings in order to approach a defined target (better capability, reduction of energy consumption…).

To reduce control costs with the PVA tool to select the least expensive measures, sufficient to obtain the same quality of surveillance. The GPC Curves tool can replace expensive or later measures. (laboratory measures, chemical analyzes…) by instant indicators and calculated from easily available curves (time curves, infrared spectrums, vibrations, sounds, colors…).

GPC OFFER

These solutions are offered as:

SOFTWARE IN THE CLOUD

Ergonomics software available in the Cloud.

SOFTWARE ON SITE

Real-time monitoring available on your site with GPC Guard.

GPC EXPERTISE

Consulting, support, training by GPC experts.

GPC ASSETS

These solutions represent for the industrial user, a considerable asset in a context of competition as they allow:

CONTROL OF QUALITY

REDUCTION OF COSTS

IMPROVEMENT OF PRODUCTIVITY