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93 Integrating Preventative Maintenance Into HACCP

Using SPC methods to trigger

preventative maintenance

and

prevent CCP violations

Jeffery L. Cawley

Northwest Analytical, Inc.

July 20, 2005

Process Management & Predictive Maintenance

Event Driven vs. Scheduled Maintenance

Economics

Effectiveness

Inspection vs. Process Management

Inspection is never 100% effective

Insensitive to process drift

Triggers only when critical value exceeded

Information Rich & Intelligent Manufacturing

SPC Contribution

SPC appropriate whether measuring pathogen levels, shaft load, bearing wear, etc.

SPC differentiates signals from noise

Observed CCP violations too late for current production

SPC and process management model more sensitive to equipment and process deterioration than inspection

• SPC enables dynamic, “intelligent” system response

Stable Control Chart

Stable – Control Chart

Capable Process Capability Report

Capable – Process Capability Report

SPC Enables HACCP Success

SPC Enables HACCP Success • Stable Process • Capable Process • Timely Alerts www.nwasoft.com/press/mag_haccp.htm

Stable Process Capable Process

Timely Alerts

www.nwasoft.com/press/mag_haccp.htm

SPC Enables HACCP Success - Butterball Case Study

SPC Enables HACCP Success - Butterball Case Study www.nwasoft.com/press/mag_haccp.htm

www.nwasoft.com/press/mag_haccp.htm

Process Management Results

Process management vs. inspection model

SPC gives more sensitive alarms in addition to critical values

Control limits

Rule violations

Capability/stability relation to process management

Headroom indication

Better planning & decision making

• Fix it before it’s broke – predictive maintenance

International SEMATECH e-Diagnostic Levels

International SEMATECH e-Diagnostic Levels Can We Learn From Other Industries? • Problem prevention mode • Automated

Can We Learn From

Other Industries?

Problem prevention mode

Automated systems

Analysis increase system knowledge & appropriate

response

Performance monitoring - optimize maintenance timing

www.geindustrial.com/products/documents/eDiagnosticsGECiscoWhitePaper.pdf

International SEMATECH e-Diagnostic Levels

Level 3 Prediction
Level 3
Prediction
Level 2 – Analysis
Level 2 – Analysis
Level 1 – Collection & Control
Level 1 – Collection & Control
Level 0 – Access & Remote Collaboration
Level 0 – Access & Remote Collaboration

www.geindustrial.com/products/documents/eDiagnosticsGECiscoWhitePaper.pdf

Inspection vs. Process Management

Level 3 Prediction
Level 3
Prediction
Level 2 – Analysis
Level 2 – Analysis
Level 1 – Collection & Control
Level 1 – Collection & Control
Level 0 – Access & Remote Collaboration
Level 0 – Access & Remote Collaboration

www.geindustrial.com/products/documents/eDiagnosticsGECiscoWhitePaper.pdf

SPC Predictive Maintenance

SPC Enables Predictive Maintenance:

How to use data

How to make decisions

How to intelligently trigger maintenance

How to prevent process disruptions

SPC & Predictive Maintenance Universal Application

SPC & Predictive Maintenance – Universal Application

SPC & Predictive Maintenance Enable HACCP Success

Less disruptive, more productive

Stability

High capability

Result safer product at less cost

Northwest Analytical, Inc.

111 SW 5 th Ave., Suite 800 Portland, OR 97204

503-224-7727

jcawley@nwasoft.com

www.nwasoft.com