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InfinityQS helps the bottling industry’s biggest companies transform quality performance across the enterprise with our cloud-native, SPC-powered quality intelligence platform, Enact®. But this software provides more than traditional statistical process control—it delivers visibility across your enterprise and visual analytics for operational insights into your processes. This all leads to actionable information that can help you truly transform your bottling operations.

Enact empowers users to make data-driven decisions in real time thanks to centralized data and actionable intelligence. By fully taking advantage of these two capabilities, the quality intelligence platform can help you with compliance, analysis, and prioritization.

Content provide by InfinityQS

 

Data Centralization for Bottlers 

Throughout your bottling operations, you can collect data manually or through semi-automatic or fully automated means. With Enact, all your quality data is standardized and stored in a centralized data repository in the cloud. From this secure location, anyone who has been given access can see it—line supervisors, plant managers, operations directors, and plant floor operators. With this kind data, your team will have instantaneous access to the valuable information they need to maintain and continuously improve your manufacturing processes. Even during these difficult times, Enact customers have anywhere, anytime access to the data that drives their production facilities.

Let’s look at some examples that demonstrate the powerful capabilities that centralized data unlocks.


Example 1: Centralized Data and Compliance

The importance—and power—of centralized quality and operational data lies in aggregation. When you aggregate data, you “roll it up” together and summarize it in a way that makes sense to you. Summarizing your data enables you to see your operations from a bird’s-eye view, which makes it possible to ask meaningful quality and process questions and discover issues that your quality experts can address.

In the example, you can see that there are three packaging lines in this bottling plant.


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On packaging line number one, there are 138 checks. Using Enact’s dashboard, it’s possible to see what checks were performed. By clicking the plus sign on the Pareto chart in the compliance dashboard, you can easily and quickly drill down.


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Of the 138 checks, 108 were for net weights, 30 for pre-op checks, and so on. The shift on which they occurred is also visible.


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Next let's look at actions users can take when they see this rolled-up data. Pictured below is a compliance tile.


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The tile contains all the data rolled up for the packaging department. There have been 155 checks. Six were missed—about 4%—and 149 were completed. Of those 149, 13 were late checks and 136 were on time. The result is a total aggregated packaging department on-time performance of almost 88%.

The insights don’t stop at this summary level, though. Users can drill down into the data to see each of the three packaging lines that make up the packaging department. Quickly, you can see that packaging line number two has only (about) 77% on-time performance. Clearly, this is an opportunity for the packaging department supervisor to speak with packaging line number 2 about performing their checks and improving this rate.

The Pareto chart and the compliance tile in this example are great tools for supervisory oversight and provide data for higher-level views. If a user wants to look at performance for a single plant across all operations, Enact will show data for all the product codes rolled up and aggregated across all the production lines. From this high-level overview, just like in the zoomed-in product-specific view, tools help you analyze all the elements of production.


Example 2: Analytics

For beverage bottlers, a few of the most common measurements are brix, net volume, and torque. Most manufacturers are familiar with Box-and-Whisker plots, but for this example, the focus is on the percent-out-of-specification (%OOS) column on the far-right side of our dashboard.


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4,009 net volume checks have been performed in the specified timeframe; about 8% of those checks were outside specifications. Net volume stands out compared to brix and torque as an area that requires attention. To drill down into this data, Enact users simply click the plus sign to see net volume performance on those filling lines.


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This column provides valuable information to the user, showing that filling line 1 clearly has an issue. The line in question is more than 17% out of specification. The Box-and-Whisker plot provides the specifics for this data point, showing both underfills and overfills (both upper and lower spec limits lie outside the predetermined boundaries).


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By clicking the plus sign for filling line 1, Enact users can see a display of individual product codes for the line. This shows users which specific product codes are causing the problem. %OOS, displayed in the farthest right column, shows that the 375-milliliter product is about 28% out of spec. Users now know the specific product that is being underfilled.

Using Enact’s data and intelligence, users have just discovered the following production performance insights:

  • Filling line 1 is the biggest issue in the plant. 
  • The 375-milliliter product run on this production line is underfilling.
  • The half-liter product code is overfilling on more than a third of all checks.

Enact provides users with a large amount of operational data in a single chart. This is actionable intelligence for operations teams because they can adjust their problem areas with it. And the insights are all derived from centralized data.


Example 3: Data Prioritization

Systems that provide only data can overwhelm users. Enact helps to prioritize production information through a suite of powerful but easy-to-use tools: bubble charts, stream grading, and the site summary.

Bubble Charts

The bubble chart tool rolls up data across multiple features and multiple locations in an easy-to-interpret, visually appealing format.

Manufacturers need to know that data is collected on time and that the processes and products being measured are performing to standards. Enact bubble charts provide a single view to assess yield and on-time checks in one view.


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Bubble charts are not new; they’re just new to manufacturing quality software. Like the scatter plot, a bubble chart is primarily used to show relationships between two numeric variables. However, the bubble chart adds even more functionality. Combining different-sized bubbles and time-based animation with the x and y axis plotting on a standard scatter plot provides four dimensions of data that can be incredibly valuable.

When manufacturing leaders can apply visual meaning to huge data sets, it’s easier for them to make intelligent, efficient business decisions. By looking at those large data sets in a visual context, supervisors and managers can isolate patterns of interest and process behaviors over time. This, of course, is very useful for making sure your organization’s data are collected on time, and that the values are believable and reflect true process and product yields.


Example 3: Stream Grading

Stream grading is another feature unique to Enact. Stream grading provides a way to roll up and interpret performance across products, processes, and sites—again, in an easy-to-interpret, visual format. With stream grading users can:

  • quickly assess which sites offer immediate improvement opportunities
  • measure process yield
  • measure site potential

Stream grading allows users to “interrogate” their quality data—dig deeper into it than ever before—though an elegant, efficient tool that helps prioritize production efforts.

The Enact Stream Grading white paper provides a detailed breakdown of how this powerful tool helps quality professionals take their manufacturing processes to the next level. Here, we’ll focus on the Site Summary feature of stream grading.

In the example site summary below, there are overviews of multiple sites with a breakout of the four most important features: brix, caffeine, net volume, and wall thickness.


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The site summary view shows users the graded performance for each of these features at each plant. Steam grading uses the following criteria:

  • Stream potential is a measure of process yield that works by assuming perfect centering on the target using the current level of variability. It tells you how well you could be doing. This component is graded as A, B, or C.
  • Stream performance is a measure of how much a process yield is suffering because it is not performing up to its potential—for example, when it’s not centered on its target. This component is graded as 1, 2, or 3.

The nine different grades available from this matrix are shown below:


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This chart shows the good (green), the bad (red), and all points in between. With Enact, users can learn how to increase green results and minimize red.

Looking back at the first site summary image above, we can see which sites have clear opportunities for improvement. For instance, London has no green.

From this high-level view, the actionable information that Enact provides to the user is that across all products and all plants, efforts should be focused on London.


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The Site Summary also displays data from a feature standpoint. Net volume shows the most red and yellow of any of the columns—an opportunity for improvement.

Another high-priority area is where the most red is displayed: caffeine in London.

With just a few clicks, we’ve seen how Enact provides high-level, aggregate information that doesn’t require statistical expertise to act on. Any user can call up a Site Summary, see the color-coded table, and make the same analysis shown here. Instead of spending time and resources manually collecting and aggregating data, the Enact Quality Intelligence platform does this work for you automatically so that companies can focus on meaningful process improvements.


Leverage the Transformative Power of the Cloud

Enact’s real-time data collection, real-time notifications, and centralized data combine to make it a system that moves beyond traditional SPC. The incredible visibility across your enterprise that Enact offers helps you gain operational insights into your processes, enable actionable information, and better determine which improvements to implement across your manufacturing operations. 

Through the power of the cloud, you can truly transform your bottling business.

Manufacturers across all industries are accelerating their digital transformation efforts. InfinityQS can help. Connect with us online to learn more about the power of quality in the cloud — or contact your local Enact channel partner.