ProdX
Product Inspection Data Management Software
ProdX Software
Enhanced Productivity
Superior Product Quality
World Class Security
Total Process Clarity
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The 4 Cornerstones of Effective
Product Inspection Management
There is so much to think
about when considering the
effective management of a
production line in today’s
‘get more from less’ food,
beverage, pharmaceutical
and personal care
marketplaces.
All of these comments speak of Production Managers looking for something to make their lives, and the system, easier – looking for an extra dimension in their ability to monitor the product inspection process – looking for a better way to manage the resulting data needed to ensure due diligence is maintained - looking for something that has not been available to the world of integrated Product Inspection. Until now!Production Management
“How do I link together all my Process systems, my PI and use fewer operators without compromising line efficiency and product quality?”Line Operator
“If I produce more than one product on my line, how do I reduce downtime and lessen the risk to product quality that happens with regular product changeovers?”Quality Management
“I collect data manually from each machine. That way, I know I can manage due diligence, maintenance, traceability and tracking. But I could do this so much better!”Maintenance Supervisor
“I’m putting in more and more lines. Keeping them healthy, optimized and running true is a full time job. And that means I’ve got more and more devices to measure and manage. This can only work if it’s all centralized!”ProdX
Product Inspection Monitoring
now has an Extra Dimension
To understand what is important to production professionals, METTLER TOLEDO analyzed
the very latest production lines, the product inspection assets and routines, the impact of
increasing productivity, the challenges and the demands for product safety alongside
brand, reputation and consumer protection. This analysis gave us four clear cornerstones
to build ProdX on – Productivity, Product Quality, Security and Clarity.
Productivity
Return on investment is critical and it needs to start from day one – no matter what is being produced. So, where better to focus what ProdX can do for you than on productivity?Product Quality
Product Quality is designed to protect your product’s reputation, your brand, and your consumers. ProdX ensures that Quality Managers keep their Critical Control Points under complete control, giving product quality data quickly and efficiently, and access to multiple sites from a single location.Security
ProdX provides unrivalled levels of process and product security, keeping it’s eye firmly on customers’ commercial and compliance objectives.Clarity
ProdX gives your Product Inspection control complete visual clarity at every stage, providing plant managers, supervisors and line operators with the operational confidence that their products, brands and consumers are completely protected. Online visualization is ‘best-in-class’ with gapless logging of alarms, warnings and interventions.Pr
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ProdX Data Management Software
A New Dimension for Product
Inspection Management
Productivity
Always in focus!
Product Quality
Protection right to the point of use
Optimize Processes
Protect Your Brand
Maximize Profitability
ProdX centralizes product inspection device integration and enables monitoring from multiple locations. This is a massive benefit to Production Managers and Supervisors who can now monitor results and performance in real time. Online visualization of the complete production line and its health status means interventions are planned rather than reactive, keeping productivity at maximum for longer. The user-interface features color-coded machine icons that provide ‘at-a-glance’ status of device health and effectiveness - reducing time required for monitoring as well as being easy for operators, maintenance, and line supervisors to see and understand. With fewer people to run more devices and production lines, less time is spent on individual devices, ProdX helps to deliver the uptime needed to meet demanding production schedules with quick product changeovers to increase production and improve OEE results. The Product Quality dimension also consolidates online accept/reject traceability and transparency of information through standardized reporting including the ability to filter data for fast, complete and consistent results across all sites, areas, product lines and devices. The ProdX dashboard provides critical early warning of key Product Quality indicators such as non-conforming raw materials from suppliers or upstream processes, fillers and process tolerance, worn or broken processing equipment and machinery maintenance requests. All of which will have a negative impact on overall product quality standards.Security
Knowledge is the key
Clarity
Right through the process
ProdX is a centralized product management platform where process parameters are consistently and accurately deployed across all devices, production lines and locations. With ProdX, changes to product set-ups can be securely implemented simultaneously on multiple Product Inspection devices with less reliance on line operators for data entry and product set-up maintenance. This reduces human error and keeps production line performance data secure. It also monitors for non-conformance or legislative variation in different geographic markets. When due diligence is the challenge, documented evidence is available at any time along with proof of regular performance validation. Safety has never been more transparent. Every piece of data, reporting and critical performance measurement is designed to be as transparent as possible to meet customer and industry requirements. Standardized reports meet the specification for due diligence, at a process, device, product, alarm or operator level. And if there are issues, ProdX will see right through them. QA/QC analysis has never been more important when achieving compliance, while traceability and archiving for product liability protection helps reduce complex administrative processes. And where could this be more valuable than with Maintenance? ProdX gives remote monitoring of rejects and events. Maintenance becomes pro-active; seeing and acting upon warnings and changes to machine settings, monitoring frequency of PVR and other events at machine intervention and identifying poor tolerance devices.Pr
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Document your Production
Control Your Equipment
Critical Control Points are under your full control protecting the
consumer and your reputation. ProdX inspects your dashboard,
guaranteeing that your checkweighers, metal detectors and
x-ray devices work properly and longer every day.
Online monitoring of checkweighers from METTLER TOLEDO Hi-Speed and metal detectors and x-ray inspection systems from METTLER TOLEDO Safeline turns your product inspection equipment into a networked monitoring system, increasing production transparency and maximizing device uptime. • Networked monitoring stations give you online access to all inspection results while the production runs • Color coded pictograms for fast situation recognition • Gapless logging of alarms, warnings and activities • Online accept/reject tracing • System controlled performance validation (PVR) management • Centralized product specification management and fast device set-up at product change • Device grouping for quick changeover of entire production lines • Comprehensive set of standardized reports for fast documentation of production data • Centralized SQL database with collected inspection results • Collection of all individual package values (100% option)
Primary Online Monitoring
If you select a production line in the scope tree and Charts is selected in the view, the detail view will display the selected production line. The header area shows the names of the site, area, and production line. • An expandable pane is displayed for each device • The order in which the devices appear is defined in the production line configuration by means of position numbersMonitoring Events
Select the scope (e.g. a device) and then the events list view. The events for this scope and for the period defined are now called up from the database and displayed in the list. The events are differentiated according to their severity (alarms, warnings, and activities) • Activities check box: Including events such as product parameters changed, device stopped, product changed, etc • Warnings check box: Warnings inform the user of changes that will require intervention soon, such as performance test is due • Alarms check box: Indicating critical status. The user must respond to these immediately, e.g. the rejects container is full and needs to be emptied immediatelyHistorical Data
Instead of current data, the list can display data from the past. Activate the Historical data check box and use the date/time fields to specify the period you wish to display data in the list. Click ‘Search’ to load the relevant data from the database.The Rejects Monitoring allows you to track all products which have been rejected from each device, production line, area, or site. Accurate accounting of all non-conforming product is an important element in a robust quality program.
1. See Rejects by site, area, line, or device 2. Choose live data or historical information 3. Time, date, Product ID, & inspection performed 4. Workstation ID & reject type 5. Checkweigher net weight & reject zone classification 6. Metal Detector phase & amplitude results 7. X-ray system file location for each rejected product 1 2 3 4 5 6 7
The Events Monitoring screen enhances overall system productivity by allowing you to stay ahead of your inspection processes through monitoring the various activities, warnings, and alarms that occur on each device.
1. See Events by site, area, line, or device 2. View Alarms, Warnings, or Activities 3. Choose live data or historical information 4. Type of Event with, Product ID, time & date stamp 5. Device type & name, inspection sequence 6. Event type is logged & displayed 7. Before & after event data shown 1 2 3 4 5 6 7
User management is a key ingredient to ensuring a safe and secure system. The User Management Screen provides a convenient and flexible method of user administration or you can use the Windows Active Directory Service feature and leave user administration up to your IT Department!
1. User view for easy administration 2. Enable Windows Active Directory Service for IT user administration 3. User ID, Name, & contact information 4. User language preference 5. Job roles or profiles that are assigned to the user 6. Password management 7. Make the user ‘active’ or “inactive” if they are no longer an authorized user 8. Number of failed logins that are allowed prior to eliminating user access 1 3 4 5 2 6 7 8
Quick at-a-glance monitoring of your product inspection assets is key to ensuring maximum uptime and that yield targets are attained. The Main Monitoring Screen delivers a wealth of real time information to give you the pro-active management needed in today's do more with less
production environment! 1. Easy to select the line which will be monitored 2. Toggle between Charts, Events, & Rejects Monitoring Screen 3. Large device status icon monitors PackML state. Green = Good 4. When a ‘Warning’ even occurs the device status icon changes from Green to Amber 5. ‘Alarm’ state changes the icon to bright red for immediate attention 6. Data table displays current production data & package set-up information for the device 7. Enhanced checkweigher graph shows mean value, standard deviation & range by hour 8. Accepts and Rejects by hour are graphed to provide yield indication 1 2 3 4 6 8 5 7
Clarity
Security
Security
• No manual and error prone data handling • Maximum protection of investment and continuous maintenance by METTLER TOLEDO • Comprehensive set of standardized reports for fast documentation of production data • Extensive user security and tracking, use your Windows Active Directory for user name and password management • Centralized SQL database with collected inspection resultsProductivity
• Faster product changeovers for more production uptime • Data transparency for production yield results, & trend processes throughout the production cycle • Helps customers achieve goals accurately and efficientlyClarity
• Long-term program visibility and viability • High customer satisfaction • Continuous monitoring including logging of errors helps users to plan maintenance schedules • Performance Verification Reports for increased device reliability, lineProduct Quality
• Frequency of ‘non-conformances’ separates in-tune from out of control processes! • Added control point even when only deploying a single inspection device for expensive, high value products • Consistent, centralized productMettler-Toledo Hi-Speed 5 Barr Road Ithaca, NY 14850 Telephone 607-257-6000 Toll Free 800-836-0836 Fax 607-257-5232 E-mail [email protected] Mettler-Toledo Safeline 6005 Benjamin Road Tampa, FL 33634 Telephone 813-889-9500 Toll Free 800-447-4439 Fax 813-881-0840 E-mail [email protected] Subject to technical changes ©03/2011 Mettler-Toledo Product Inspection Printed in USA MCG MarCom Greifensee