Manufacturers can use process control technology to keep their processes functioning within specified limitations and to set restrictions that are more exact in order to maximise revenue, assure quality, and emphasise safety.
Simply, process control is the science of keeping a certain process output within a specified range. The ratio of one ingredient to any other, the material temperature, how effectively ingredients will be mixed, and also the pressure under which all the materials are held, all have an impact on the ultimate product’s quality.
Process control systems are also crucial when we decide to source from China we need to implement the concept of process control on the product where they are being manufactured in any Chinese manufacturing industry.
Process control enables automation
For mass production, process control is widely employed. It allows for industrial processes automation due to its precision. A small team of operators can control even the most complicated processes from a certain central control room with the right knowledge and technology.
It is crucial to distinguish between process control and automation. Instead, the two collaborate to achieve maximum efficiency. Plant operators must manually examine outputs without automation to find the appropriate settings to employ with production equipment.
Data is collected and stored using automated sensors, and thereby allowing better decision-making.
It is a common process
Process control is a highly popular approach used across a range of disciplines since it encompasses so many instruments. Anything that measures or that controls the variables listed below might be considered a process control application.
When used in a proper manner, process control can ensure safety?
Manipulation of chemicals to create a product is a difficult and often dangerous task. Even minor modifications can result in significant differences in the final product. As an example, improper boiler pressure could disrupt the flow of air and exhaust gases, putting worker’s safety and product quality at risk.
To generate the required product with the least amount of energy and raw materials proportions, flow, turbulence, temperature, and many other parameters must be managed carefully and consistently.
Process control can be energy efficient
Factory managers can use process control to oversee production, and measure how any plant is performing, and make informed decisions based on that information.
By changing in reaction to this data, a strategy may be put in place to ensure that equipment is utilised to give the best output at the lowest feasible cost. This maintains quality consistency, using less energy in the process of avoiding defective product manufacture.
What will inspectors check during QC checks?
When you source from China then while manufacturing in China it is important to carry out the necessary quality inspection.
Quality control inspectors check to see if the product meets the customer’s specifications, which could include questions like:
- Whether the colour is the same as the original sample?
- Are the dimensions on the drawing within the tolerance?
- Are they within the allowable deviations?
Inspectors also check to see if all of a batch of 100 sample pieces are within the range of the same quality. Even if a few of them are incorrect, it is preferable that they all remain incorrect by a similar amount, as this indicates that there is a system fault that is reasonably easy to repair and detect.
However, if the deviations are randomly all over the place, and some items are fantastic and others are dreadful, there is something more serious at hand and it could be a reflection of the total incapacity of the factory to establish well-defined production controls.
Under such circumstances, it can be a good idea to figure out what is wrong, try to remedy it, and then hunt for another factory if the problem persists.
What will happen when any problem is found during inspections?
When issues are discovered, factories are ordered to rework the whole products that have been already produced, as well as to make absolutely sure that the problem does not spread further down the line.
Reworking a bad batch can always be costly and time-consuming, causing delivery to be delayed. When any company comes across such situations when performing quality control inspection for any clients, they determine the best course of action based on the circumstances.
If we are aware of the application of that particular product and know fully well that the deviations is not going to actually hurt it, then we can probably let the bad batch go, but we should surely put a plan in place to fix the problem for the subsequent batches.
Take, for example, a bathroom water tap. One side of the tap is visible, while the other is hidden behind the sink or against the wall. In case there is a flaw on the side that will go into the wall or sink, we will most likely reject the batch, but please notify the factory and the client.
Most clients will agree that we made the right option because the flaw has no impact on the use of the product and is unlikely to be seen by the final user.
However, because it is still a problem that has to be addressed, it will be addressed in the next batch. As a result, it will all depend on the application and circumstance.
To sum up, quality control checks are required for every production cycle, whether it is the first or the hundredth. This will help your firm maintain consistency and attract repeat consumers.
It is now being used across several industries
Process control enables efficient and effective production systems regardless of where it is applied. As a result, it’s employed in a wide range of industrial procedures. Process control is used in a variety of industries including:
- Pulp and paper
- Power generation
- Oil and gas
- Heat treatment
- Food and diary
When we source from China, it will be extremely necessary to implement a certain industrial control process so that the problem can be found at the manufacturer’s end and the end customer should never get any defective or rejected product.
Usually, it becomes the responsibility of the sourcing agent in China to ensure that proper industrial process control has been ensured at the manufacturing plant.