Treat Metrics such as OEE as Process Parameters

Food Processors create Key Performance Indicators (KPI) to better understand what is happening in their process. One of the most common, Overall Equipment Effectiveness (OEE),  combines measures of availability, throughput and quality to provide a more comprehensive understanding of equipment or production line performance. However, a single OEE value provides very limited manufacturing decision support. Companies often short change themselves by using OEE as an isolated value and not looking at the statistics and trends.

That is where process based analytics come to the rescue. By using SPC and treating OEE like any other process parameter, manufacturers can extract far more value from the monitoring process. With statistically-based trend analysis they can quickly identify the areas that fall short in quality, throughput or availability. 

By coupling OEE with SPC, process understanding becomes part of the manufacturing culture. Since this is a component of the Manufacturing Intelligence model, it sets companies on the path to state-of-the-art manufacturing process management and enables them to:

  • Apply SPC to automated OEE solutions – looking at a single KPI value adds little to process management capability, but using control charts and process capability analysis will enable the company to deliver world-class manufacturing;
  • Rapidly determine where improvement opportunities exist;
  • Focus oninformation, not data – data is the raw material; information provides the decision support that improves performance levels.

Our article, Combine OEE and SPC for Decision Support, discusses this manufacturing intelligence-based strategy and how to turn KPIs into effective real-time decision support.

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Integrating HACCP and SPC – Revisiting the Classic

FoodSafetyTech is now live. Rick Biros and his crew at Innovative Publishing have put together what promises to be an interesting and useful food safety/quality virtual magazine and associated conferences. John and I are contributors and in addition to new material, we are reposting early articles of ours that we think are milestones in developing the thought process for process based food safety and quality.

The first classic is a study, “Integrating HACCP and SPC” we initially published in Food Quality Magazine, May 1998 with another version published as Clemson University Cooperative Extension Service EB 152, September 1998. The line of thinking developed in this study has had a significant impact on the development of modern Food Safety Management Systems. John Surak has long been a strong proponent of the role process management in food safety management systems. This is reflected in his contributions to the ISO 22000 standard.

Visit FoodSafetyTech and give your feedback to Rick and Sangita.

 

Food Safety Webinar – How to Apply Analytics to Audits for Process Improvement

On Thursday December 15 at 11 AM PST, 2 PM PST, John Surak will present the webinr, “Applying Process-based Analytics to Audit Results for Process Management and Improvement” .

Operational audits and inspections play a critical role in assuring the effectiveness of the Food Safety Management System (FSMS). But that’s merely Step One.

Step Two and beyond involve leveraging the results from these audits to maximize value and effectiveness for process management and improvement by identifying the key process indicators, assessing them for trends, and taking action before a food-safety incident occurs. 

How to Use Audits for Process Improvement

The proper linkage and operation of the FSMS components enables successful certification audits. Additionally, it bolsters the view by Senior Management and other stakeholders that the plant has a robust food-safety management system in place.  By applying process-based analytics, management can continuously monitor the FSMS performance, improve compliance and reduce risk to the company.

The webinar will examine the data available in audits and pre-requisite program inspections and how applying analytics such as SPC can extract useful process management information. This method provides actionable feedback on the manufacturing processes and establishes a solid foundation for process management and continuous improvement. You can change audits from an unpleasant necessity to a positive contributor to your performance and bottom line.

Register now.

Can You Help With Audit Analytics Case Studies?

ISO 22000 requires the analysis of results of verification activities, and SQF and BRC require annual validation of the Food Safety Management System.  The analysis of the data for either of these two activities can be easily done using SPC. 

John Surak and I presented a poster on this topic at the IAFP annual meeting this summer (http://slidesha.re/uBnW1i  ) and John will present a webinar on the topic, “Applying Process-based Analytics to Audit Results for Process Management and Improvement” on December 15, 2011 ( http://www.nwasoft.com/resources/webinars/applying-process-based-analytics-audit-results-process-management-and-improvement ) .

We are looking for additional data which to develop case studies which demonstrate the power of SPC based analytics in conducting verification activities in the food industry. If you wish to participate in the project contact John Surak at jgsurak@yahoo.com or Jeffery Cawley at jcawley@nwasoft.com.

Process Control and the Food Safety Modernization Act

We have now had about 6 months to study the Food Safety Modernization Act (FSMA). This time has allowed some of the dust to settle. There are several more interesting parts to the act. One part includes the use of the word “verification,” which is mentioned 16 times. The big question is: How will the U.S. Food and Drug Administration (FDA) define verification for interpretation of the regulations? Verification can be defined in several ways.  The new regulations will require verification that the food safety system is working effectively. Finished product testing and environmental testing will be included in the verification process. These verification activities must be recorded, and the records must be made available to FDA upon request.

Read article in Food Safety

How to Apply Process-based Analytics to Audit Results

On August 1, John Surak and Jeff Cawley presented “Applying Process-based Analytics to Audit Results for Process Management and Improvement” at the International Association for Food Protection Annual Meeting. The Slide deck is attached

Operational audits and inspections play a critical role in assuring the effectiveness of the Food Safety Management System (FSMS).  To realize the maximum value and effectiveness for process management and improvement, key process indicators should be identified and plotted on control charts.  The control charts can then be assessed for trends, so actions can be taken before a food safety incident occurs. 

The proper linkage and operation of the FSMS components enables successful certification audits and gives confidence to Senior Management and other stakeholders that the plant has a robust food safety management system in place.  By applying process analytics such as SPC to sanitation data management can continuously monitor the FSMS performance.

Applying Process-based Analytics to Audits

Audit Analytics

audit analytics - swab sampleThe data gathered from food safety operational audits and inspections frequently goes no further than the summary report. The process information contained in this data can and should be used in continuous improvement programs.

On August 1, Dr. John Surak, Surak Associates, and Jeffery Cawley, NWA, will present “Applying Process-based Analytics to Audit Results for Process Management and Improvement” at the 2011 Annual Meeting of the International Association for Food Protection in Milwaukie, WI. The authors will be available for discussion at poster session P1-138 from 2:00 PM to 3:30 PM and 5:00 PM to 6:00 PM.

The presentation will examine how applying process analytics such as SPC to sanitation data provides more effective monitoring of the Food Safety Management System (FSMS) performance. This method also enables effective improvement of FSMS compliance capabilities.

The presentation is the latest in a series of studies on improving food safety by applying SPC and process improvement methods which began with the 1998 article, “Integrating HACCP and SPC”  and continued with such projects as ground beef purchase for the National School Lunch program (see Feast or Famine, “Food Safety in the Supply Chain“).