Process IQ in Commercial Clean Green Energy

Eradicate Paper - Enhance Quality & Build Efficiency

Transform production & eradicate paper build & quality sheets with a ‘Digital Twin’ of your processes.

Process IQ in Commercial Clean Green Energy

Eradicate Paper - Enhance Quality & Build Efficiency

We interviewed one of our customers in the commercial green energy industry and here’s what they had to say.

Paper travellers are the norm whether its process instructions or quality sheets for data capture. Created in Word or Excel, routed around the relevant departments for sign off and then printed. These critical documents form part a manufacturing / production order pack and are issued to the shop floor.

Large binders are put together where printed updates are applied and the revision history is kept up to date for compliance. When a production order runs, the manufacturing order reference is applied to the traveller paperwork (build sheets & quality data capture sheets) and the operators follow the build sheets (Or more likely reference them when changes have been applied to the process) and they write in the quality data on the paper.

 

The quality data sheets are then be scanned for record keeping purposes, but the data is flat, other than to read from the paper once you have spent hours problem solving.  

The data is a record in time, not searchable, not reportable, chartable and there has been, understandably as it’s paper a lack of systemised quality control or validation in the process for say upper or lower limits.

The problem with using paper for production & quality processes.

Process, quality & inspection are all impacted with the use of paper.
Large binders containing updates per production run are scanned for quality & record keeping but with no data extraction.

Troubleshooting is very challenging & time consuming & you can often spend hours, and not surprising when you can have 100’s of data sheets with quality and inspection data to sift through. For high value, high complexity configured to order products electronic build and data capture brings many advantages, a number of which are highlighted below.

Unfortunately there is a hesitancy to invest.

Paperless quality and work instructions Integrated to ERP and MES
Synchronous motor and motor controller of electric vehicle
Digital traceability enables efficient problem solving

Why ProcessIQ for Commercial Clean Green Energy Manufacturers?

Integrated build and quality processes

Embedded in your build process or dedicated operations to quality, ProcessIQ provides highly flexible configuration to ensure your operators are building to spec. If something is out of specification the system will stop the job from progressing and any remedial activity can be triaged integrated withing the workflow of production.

Enhanced Quality Control

Reduce defects and maintain consistency with automated inspections, compliance tracking, and predictive quality monitoring.

Digital Traceability

Once you start collecting quality data electronically the world becomes a better place. Data is at your fingertips to query and problem solving becomes a great deal easier than sifting through paper binders.

Electronic Build History Records for quality and your customers

Another great benefit of moving to electronic data for the shop floor is the ability to create outputs that evidence the process was adhered to and provides digital records for quality and customers.

Data Insights with charts & trends

Once you establish an integrated build and quality process the data collected provides a significant amount of insight from the shop floor. Using industry standard tools such as Microsoft PowerBI your organisation can develop critical reports for areas of interest such as first pass yield, planned vs actual and unit quality reports.

System and Process Integration with ERP

Connect with existing systems, IoT devices, and automation tools to create an optimized production environment.

Sustainability & Waste Reduction

Minimize waste and enhance sustainability efforts with data-driven insights to improve resource efficiency.

Benefits of ProcessIQ in the Commercial Clean Green Energy Sector

Highly Configurable Production Workflows

Streamline manufacturing processes, reduce inefficiencies, and improve production speed to meet demand.

Integrated Quality Control & Compliance

Ensure consistent product quality with automated out of spec detection, compliance tracking and quality reporting.

Standardised Work Instructions

Provide clear, step-by-step digital guidance to operators, reducing errors and accelerating training and onboarding.

Streamline Production Operations

Integrate with ERP and MES systems to synchronize data and processes, reducing waste, and preventing production delays.

What our customer say

Georg Fischer

“We have 800+ SKUs which are subject to frequent changes. As we have customers across all regions, we have to adhere to certain localised or legislative requirements. Yet, about 20 SKUs represent 80% of our revenue, but we also have a vast number of low volume products to produce. This adds complexity to our production lines.“Additionally, some products require complex production processes, so ProcessIQ is extremely helpful for the production cells. It provides a very specific method sheet and documentation to support the build,” explained Nick.“ProcessIQ eliminates wasted time. Anyone can use the tool, so we are not relying entirely on engineering to make updates. You simply revise, following a document control workflow and share directly.

Read the Georg Fischer Case study

Georg Fischer – https://www.georgfischer.com/en.html

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