| Revolutionary
knowledge based engineering solution for the process industry!
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WSL has launched the Process
Audit to increase capacity utilisation, decrease process waste,
enhance quality of end product along with the several critical
analysis by highly interactive knowledge based software. |
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NEED
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In the
present scenario of globalisation of almost all the industries,competitiveness
becomes very critical. Among the various industries, process
industries are very critical for their manufacturing processes.
The majority of manufacturing process are batch type, however
in certain industries viz.; oil & petrochemicals these
are continuous process. In the recent past some of the conventional
batch processes are being converted to continuous process
for various advantages of their continuous operations. Thus
the process industry is a dynamic industry with changes
occurring continuously in the process used.
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| Apart from the major shift which is likely to occur from
batch to continuous process to more & more processes,
there has already been introduction of instrumentation in
controlling of the process. The automation has already set
in almost all types of process industries. The automation
has been used for process control and quality control In
spite of automation in the control, there is no solution
for the analysis, modification, rectification and changes
in the process parameters, which are required due to various
reasons of changes in the inputs and such other parameters.
These operations are presently done manually. WSL identified
these lacunae and undertook detailed study, and has now
designed solution for the same.
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P
R O D U C T - P R O C E S S A U D I T |
Process
Audit is WSL’s unique software solution for all types of process
industries, which enables every process industry to analyse,
monitor, control and guide simple/complex manufacturing processes
Process audit is a customised process knowledge bank for the
concerned industry, which analyses the process technologies
and equipment’s along with the ideal process parameters and
variables in the process. It is not only a decision making
system, but virtually controls the actual process to achieve
the rated production and optimum quality of the end product
at minimum losses and optimum process time.
This
software solution will be useful in optimisation of the manufacturing
processes from batch to batch with minimum or no variation
in yield or quality of the product. The software will also
store the historic data of the earlier batch, which could
be used as reference for the future operations. In short,
Process Audit is virtual process knowledge bank, which will
not only take intelligent decisions, but also automatically
control and give signals for manual control at all the process
stage in order to achieve optimum resource utilization. The
use of this software will also help in reduction of process
and energy losses.
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WSL’s pioneering efforts in addition will
also enable process industry to reduce work strength in maintenance
and control, which enhances overall efficiency and profitability.
Process Audit is a customised software solution for the process
industry. The software solution will be able to predict the
result of the production batch in advance once the raw material
data is feed to the software. Thus the software offers a real
time study and analysis of production based on the raw material
data which may vary from batch to batch. Process Audit not
only controls the process, but also takes feedback from every
individual process stage to provide knowledgeable analysis
to management for changes in production and R&D activities.
It analyses the end product based on interval parameters as
well as the parameters, which effects the process externally.
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D E S I G N
M E T H O D O L O G Y
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WSL’s team of professionals having experience
from the process industry will interact with the technical
team/consultants of the company to collect the process data
to understand the process used and create a methodological
process knowledge bank. All the variables and the governing
conditions in the process will be studied in detail along
with the present process flow and equipment. Thereafter the
data will be transferred to our software department for developing
right process technology software solution. The time to prepare
the solution depends on the complexity of the concern process.
The existing control system can be integrated with process
audit software with minimum cost and thus will offer an integrated
control system for the entire process.
The solution will be
implemented on the site for the satisfactory working of the
system. After the system is installed & operational, then
the same could be modified as per the changes made in the
process by the company in future.
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| O P E R A
T I O N |
Once Process Audit is implemented by the company for a
particular manufacturing process, then the same will work on
the following guidelines: |
| Compares ideal raw materials with actual input raw materials
and suggests whether to accept the raw material, alter/modify
production process at required stages or not. This minimises
the human decision in altering the process parameters from batch
to batch. |
Provide following analysis of the process
with respect to the following criterion.
| Capacity analysis |
| Time analysis |
| Energy
analysis |
| Wastage
analysis |
| Bottleneck
analysis |
| Cost
analysis |
Quality
analysis
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| Provides immediate cost analysis for the altered production
process from batch to batch due to variation in raw material.
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If
user decides to proceed with the production with the raw material,
the software automatically controls and alters all the process
parameters through the instrumentation system.
It provides complete process analysis by comparing end
product with standard one and suggests the action to be taken
for achieving the same. |
Process Audit estimates chain reaction in several chemicals
and provides optimum operating levels and controls the process.
Thus Process Audit predicts
the result of the process by analysing the input data that is
provided and gives corrective measures to be taken in order
to obtain the desired product as per the standard quality. |
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| A
P P L I C A T I O N |
Process Audit could be a useful process technology software
solution for numerous process industries such as:
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| Chemical process Industry: Batch or Continuous manufacturing
organic and inorganic chemicals.
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| Bulk Drug industries
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| Cement plants
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| Metallurgical process industries
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| Food and dairy industries
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| Sugar and distilleries
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| Dyes and Pigment industries
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| Oil and petrochemical industries |
| Resins and Polymers
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| Pesticides
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| Fertilisers
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| A
D V A N T A G E S |
Quality
assurance and effective quality control. |
| Can
increase optimum capacity utilisation |
| Minimises
the process losses |
| Optimises
the process time |
| Minimises
the chances for human errors |
| Preventive
maintenance by giving messages in advance |
| Reduces
the strain on process management |
| Saves
energy |
| Provides
production cost analysis. |
| Process
Online alarms |
| Strong
on-line help |
| Stores
historical process data batchwise |
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| I
N S T R U M E N T A T I O N
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Either existing or new instrumentation euipments as per
process requirements.
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