What Is a Process Control System?
A process control system is a system that streamlines the process control operations in the manufacturing industry.
It refers to a process control system that manages “processes,” which systematically categorize each operation at a manufacturing site, and keeps track of the progress. Processes are operations such as receiving, inspection, processing, and shipping in the manufacturing industry.
The purpose of a process control system is to ensure that products are delivered on time and that each process of manufacturing is planned and operated efficiently. The system is also indispensable for production control because it has functions such as inventory control, worker management, and quality control.
Uses of Process Control Systems
Process control systems are widely used in all areas of production. They are used not only in manufacturing but also, in some cases, in software development, in terms of managing the software development process.
In larger manufacturing sites, process control systems are generally operated as part of a higher-level production control system, rather than as a stand-alone system. In small factories or software development sites, it is used by setting up a process for each product and displaying it on a Gantt chart to grasp progress and manage delivery dates.
Some sites create and operate their own process control system using Excel, so small factories and software development sites operate with the minimum functions of a process control system.
Principle of Process Control Systems
The typical process of a control system works by following three steps:
1. Process Setup
For each product, the sequence of processes is clarified, and the materials, parts, machinery, equipment, personnel, working hours, and deliverables for each process are set. Since this includes not only in-house production processes but also all processes outsourced to subcontractors, it is also necessary to identify whether the process is outsourced or in-house.
2. Process Planning
Based on the quantity of products to be manufactured, the delivery date, and the working hours of each process, a schedule for each process is established and put into a Gantt chart. A Gantt chart is a diagram in which the contents of each process are described on the vertical axis in the order of processes and the schedule bar on the horizontal axis, so that the flow of the entire process can be visually confirmed.
The process plan clarifies the work to be performed in each process and also specifies the assignment of workers. If an inspection is required before the deliverables are transferred to the next process, the inspection is also considered as one of the processes, and the procedures and pass/fail criteria are specified.
3. Process Progress Management
Record the status of work in the field and constantly check the progress. At this time, visualization of the plan and actual results, such as a Gantt chart, makes it easier to grasp the progress.
A process plan is not something that can be established only once. After the plan is executed, the actual results are evaluated, and if there are areas for improvement, they can be fed back into the next work plan, leading to further streamlining of the work process, which can also be used for on-site improvements.
Other Information on Process Control Systems
Functions of Process Control Systems
The basic functions of a process control system are schedule management and progress management. Other functions include inventory control, worker management, and quality control, and they are operated in various combinations depending on the product, manufacturing type, and scale of production.
Inventory Control System
Inventory control systems are used in production control systems to grasp and control the amount of product inventory in real time at the distribution site. Inventory control systems are also used for inventory counts to determine the cause of the difference between the actual number of items and the number of items in the data.
Worker Management System
A worker management system is a system that manages the entry and exit of workers and manages the assignment of workers. The system can view information on the working conditions and health status of assigned workers, which is useful for utilizing human resources that are important for production management.
Quality Control System
A quality control system is a system used by a company to improve the quality of its products and services. Each company has different goals for quality control, and quality control systems are used to achieve those goals.